Concrete Weight Coating

PETRONAS CARIGALI SDN BHD

PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT

(CONTRACT NO. CHO/2012/D316/1000) TABLE OF CONTENT 1

PROJECT INTRODUCTION ............................................................................................................ 5

1.1

SCOPE OF DOCUMENT ....................................................................................................................... 7

1.2

DEFINITION ......................................................................................................................................... 7

1.3

ABBREVIATION ................................................................................................................................... 7

2

REFERENCES ................................................................................................................................ 8

2.1

PROJECT DOCUMENTS ....................................................................................................................... 8

2.2

COMPANY STANDARDS ...................................................................................................................... 8

2.3

CODES AND STANDARDS .................................................................................................................... 8

2.4

SYSTEM OF UNITS ............................................................................................................................... 9

3

GENERAL REQUIREMENTS ......................................................................................................... 10

4

CONCRETE COATING MATERIALS .............................................................................................. 11

4.1

CEMENT ............................................................................................................................................ 11

4.2

AGGREGATES .................................................................................................................................... 11

4.3

WATER .............................................................................................................................................. 12

4.4

ADDITIVES ......................................................................................................................................... 12

4.5

REINFORCING STEEL ......................................................................................................................... 12

4.6

WELDED STEEL WIRE MESH.............................................................................................................. 13

4.7

STEEL CAGE TYPE .............................................................................................................................. 13

5

RECEIPT, HANDLING AND STORAGE OF BARE PIPES ................................................................... 14

6

CONCRETE COATING APPLICATION ........................................................................................... 15

6.1

VISUAL AND HOLIDAY INSPECTION OF 3‐LAYER PE COATED PIPES ................................................. 15

6.2

PLACEMENT OF REINFORCEMENT STEEL ......................................................................................... 15

7

APPLICATION OF COATING MATERIALS ..................................................................................... 16

7.1

PREPARATION OF THE CUTBACK AREA ............................................................................................ 16

7.2

FINISHING OPERATIONS WITHIN CONCRETE COATING PLANT ........................................................ 16

7.3

CURING ............................................................................................................................................. 17

7.3.1

WATER CURING ............................................................................................................................... 17

7.3.2

STEAM CURING ................................................................................................................................ 18

7.3.3

CURING BY SEALING COMPOUNDS ................................................................................................. 18

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(CONTRACT NO. CHO/2012/D316/1000) 7.3.4

CURING UNDER POLYETHYLENE WRAPPING ................................................................................... 18

7.3.5

FOG CURING .................................................................................................................................... 19

8

INSPECTION AND TESTING ........................................................................................................ 20

8.1

STACKING OF 3‐LAYER PE COATED PIPES ......................................................................................... 21

8.2

CONTROL, IDENTIFICATION AND SEGREGATION OF 3‐LAYER PE COATED PIPES ............................. 22

8.3

DELIVERY AND STORAGE OF CONCRETE COATING RAW MATERIALS .............................................. 22

8.4

TEST TO BE PERFORMED ON CONCRETE COATING MATERIAL UPON RECEIPT ............................... 23

8.4.1

SIEVE ANALYSIS AND CLEANLINESS CONTROL OF AGGREGATES .................................................... 23

8.4.2

STEEL REINFORCEMENT WIRES DIMENSIONAL CONTROL .............................................................. 23

8.4.3

MIXING WATER CHEMICAL ANALYSIS ............................................................................................. 23

8.5

VERIFICATION OF CALIBRATION OF THE TEST INSTRUMENTS ......................................................... 24

8.5.1

HOLIDAY DETECTOR ........................................................................................................................ 24

8.5.2

PIPE WEIGHING SCALES ................................................................................................................... 24

8.6

VISUAL AND HOLIDAY INSPECTION OF THE 3‐LAYER PE COATED PIPES .......................................... 24

8.7

CONCRETE COATING MIX CONTROL ................................................................................................ 25

8.8

CONCRETE COATING MIX TEMPERATURE MEASUREMENT ............................................................. 25

8.9

WATER‐CEMENT RATIO CHECK ........................................................................................................ 25

8.10

REINFORCING WIRE POSITION CONTROL ......................................................................................... 26

8.11

CONCRETE COATING APPLICATION CONTROL ................................................................................. 26

8.12

MEASUREMENT OF EXTERNAL DIAMETER OF APPLIED CONCRETE ................................................. 26

8.13

CUTBACK CONTROL .......................................................................................................................... 27

8.14

WEIGHING OF FRESHLY CONCRETE COATED PIPE............................................................................ 27

8.15

CALCULATION OF NEGATIVE BUOYANCY ......................................................................................... 27

8.16

VISUAL INSPECTION OF APPLIED CONCRETE .................................................................................... 28

8.16.1

SURFACE FALL‐OUTS (SPALLING) OF FRESHLY CONCRETE COATED PIPES ...................................... 29

8.16.2

CONCRETE COATING DAMAGES ON FRESH AND HARDENED CONCRETE ....................................... 29

8.16.3

CRACKS ............................................................................................................................................ 29

8.17

ELECTRICAL RESISTANCE BETWEEN STEEL REINFORCEMENT AND THE PIPE ................................... 30

8.18

CONTROL OF CURING PROCESS ....................................................................................................... 30

8.19

CONTROL OF STACKING OF PIPES DURING THE CURING PROCESS .................................................. 30

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(CONTRACT NO. CHO/2012/D316/1000) 8.20

CONTROL OF MARKING ON CONCRETE COATED PIPES ................................................................... 30

8.21

CONTROL OF MARKING ON CONCRETE COATING REPAIR ............................................................... 31

8.22

DETERMINATION OF FACTOR ALPHA IN THE FORMULA FOR CALCULATION OF NEGATIVE BUOYANCY ....................................................................................................................................... 31

8.23

COMPRESSION STRENGTH TEST CUBES ........................................................................................... 31

8.24

COMPRESSION STRENGTH CORE SAMPLES ...................................................................................... 32

8.25

DETERMINATION OF THE TIME FOR STACKING OF PIPES IN MORE THAN ONE LAYER ................... 33

8.26

WATER ABSORBTION TEST ............................................................................................................... 34

8.27

ADHESION BETWEEN THE 3‐LAYER PE COATING AND CONCRETE COATING ................................... 34

8.28

IMPACT TESTING .............................................................................................................................. 35

8.29

STACKING OF CURED CONCRETE COATED PIPES.............................................................................. 36

8.30

LOAD OUT INSPECTIONS .................................................................................................................. 37

9

3‐LAYER PE COATING REPAIR .................................................................................................... 38

10

CONCRETE COATING REPAIR AND STRIPPING OF CONCRETE COATED PIPES .............................. 40

11

PIPE MARKING .......................................................................................................................... 42

12

STORAGE, HANDLING AND TRANSPORTATION OF CONCRETE COATED PIPES ............................ 43

13

DOCUMENTATION .................................................................................................................... 45

13.1

GENERAL REQUIREMENTS ................................................................................................................ 45

13.2

TECHNICAL DOCUMENTATION TO BE SUBMITTED DURING THE BIDDING PHASE .......................... 45

13.3

TECHNICAL DOCUMENTS TO BE SUBMITTED AFTER AWARD OF THE CONTRACT TO SUBCONTRACTOR ............................................................................................................................ 46

13.4

FINAL TECHNICAL DOCUMENTATION .............................................................................................. 47

13.5

CONTENT OF PARTICULAR TECHNICAL DOCUMENTS ...................................................................... 48

13.5.1

CONCRETE COATING APPLICATION PROCEDURE ............................................................................ 48

13.5.2

INSPECTION AND TEST PLAN ........................................................................................................... 49

13.5.3

DAILY PRODUCTION REPORT ........................................................................................................... 49

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(CONTRACT NO. CHO/2012/D316/1000)

1

PROJECT INTRODUCTION

NC3 and NC8 are gas fields located in Block SK 316, approximately 180km North of Bintulu, Sarawak with water depth ranging approx. between 70m – 105m. NC8 field is located approximately 7km South East on NC3 field. The nearby riser facility E11RC is located approximately 80 km South West of NC3. The existing trunk line connecting E11RC to shore TL 6 is available and provisioned for in this gas field development. The locations of NC3, NC8 and nearby facilities are illustrated in Figure 1‐1 below.

Figure 1‐1 Location of Project Gas from NC3 and NC8 fields are the main feed gas supplier into the PETRONAS LNG Complex Train 9 near Bintulu which is expected to be ready for start‐up in December 2015.The scope demarcation between upstream and downstream facilities is as described below in Figure 1‐2.

Figure 1‐2 Upstream and Downstream Scope Demarcation

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(CONTRACT NO. CHO/2012/D316/1000) The development of NC3 and NC8 fields is envisaged to be in complex‐type configuration. NC3 will become a hub comprising of a Central Processing Platform (CPP) with living quarters and a bridge‐linked Wellhead Platform (WHP). Another WHP is to be installed at NC8; it will be tied‐back to NC3 via an inter‐field subsea pipeline. Though compression may not be required at the beginning of production, the need for gas compression is anticipated after approximately four (4) years. Hence the provision for future compression facilities and mercury removal facilities shall be considered as part of this FEED work for the NC3 CPP.

Figure 1‐3 Overall Development Concept A new subsea pipeline connecting NC3 and E11RC will be installed to deliver the processed gas and the spiked dehydrated condensate. Due to incompatibility of this gas quality with the existing gas supply at the riser, a dedicated manifold at E11RC may be required to accommodate this tie‐in. This is to ensure that the gas from NC3 and NC8 fields do not contaminate the entire network to shore. As such, modification will be required to convert the existing TL 6 to be dedicated for gas from NC3 and NC8. The future trunk line (TL 7) may be required in the future should TL 6 no longer be fit for service. The processed gas and dehydrated condensate will be separated at onshore receiving facilities prior to being introduced into LNG Plant Train 9.

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1.1 SCOPE OF DOCUMENT The purpose of this document is to define the minimum requirements for concrete weight coating to be used for the following offshore rigid pipeline in the SK316 Development Project:  32” Offshore pipeline from NC3 WHP to E11RC Platform  32” Offshore pipeline from E11RC Platform to Onshore Beach Valve Location  20” Offshore pipeline from NC8 WHP to NC3 WHP (Diameter to be confirmed) 1.2 DEFINITION COMPANY

PETRONAS Carigali Sdn Bhd

CONTRACTOR

SAIPEM

SUBCONTRACTOR

Party selected by COMPANY/CONTRACTOR responsible for application of the concrete weight coating on PROJECT pipes in accordance with this specification and other contractual documents

MANUFACTURER

Supplier of the raw materials or inspection and testing equipment required to perform the work

PROJECT

FEED for SK316 Facilities ‐ Development of the NC3 and NC8 Gas Fields

1.3

ABBREVIATION

FBE

Fusion Bonded Epoxy

N/A

Not Applicable

No.

Number

OD

Outside diameter (external pipe diameter)

PQT

Pre‐Qualification Test

3LPE

3‐Layer Polyethylene

3LPP

3‐Layer Polypropylene

CWC

Concrete Weight Coating

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2

REFERENCES

Unless otherwise stated, the latest issue of the below listed PTS COMPANY Specifications, Codes, Standards and Regulations shall apply. Equivalent alternatives may be offered; these shall be identified and mutually agreed on. 2.1

PROJECT DOCUMENTS

DOCUMENT

NAME

/1/ 05‐SSPL‐BOD‐U‐0001

Pipeline And Riser Design Basis

/2/ TBC

Input for Pipeline Study

/3/ 05‐GEN‐BOD‐B‐0001

Process Design Basis

/4/ 05‐SSPL‐REP‐U‐0001

Steady State Pipeline Simulation Report

/5/ 05‐GEN‐BOD‐Z‐0002

Corrosion Study Memorandum

/6/ 05‐SSPL‐REP‐U‐0002

Pipeline Transient Analysis Report

/7/ 05‐SSPL‐REP‐U‐0003

Pipeline Route Selection Report

2.2

COMPANY STANDARDS

DOCUMENT

NAME

/8/ 31.40.00.20

Pipeline & Riser Engineering

/9/ 31.40.30.30

Concrete coating of linepipe

2.3

CODES AND STANDARDS

DOCUMENT

NAME

/10/ ISO 21809‐1

Petroleum and Natural Gas Industries ‐ External Coatings for Buried or Submerged Pipelines Used in Pipeline Transportation Systems ‐ Part 1: Polyolefin Coatings (3‐Layer PE and 3‐Layer PP).

/11/ BS EN 10288

Steel Tubes and Fittings for Onshore and Offshore Pipelines ‐ External Two Layer Extruded Polyethylene Based Coatings

/12/ ASTM C 150

Standard Specification for Portland cement

/13/ ASTM C 33

Standard Specification for Concrete Aggregates

/14/ ASTM A 810‐01

Standard Specification for Zinc‐Coated (Galvanized) Steel Pipe Winding Mesh

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/15/ ASTM A 615 M

Standard Specification for Deformed and Plain Carbon Steel Bars for Concrete Reinforcement

/16/ ASTM 185‐01

Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete

/17/ ASTM A 82‐01

Standard Specification for Steel Wire, Plain, for Concrete Reinforcement

/18/ ASTM C 309‐98 A

Standard Specification for Liquid Membrane‐ Forming Compounds for Curing Concrete

/19/ ASTM C 171

Standard Specification for Sheet Materials for Curing Concrete

/20/ ASTM C 39/C39 M‐01

Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

/21/ ASTM C 617‐98

Standard Practice for Capping Cylindrical Concrete Specimens

/22/ BS EN 197‐1

Cement ‐ Part 1: Composition, Specifications and Conformity Criteria for Common Cements

/23/ 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

/24/ BS 4482

Cold Reduced Steel Wire for the Reinforcement of Concrete Products‐ Specification

/25/ BS 4483

Steel Fabric for the Reinforcement of Concrete ‐ Specification

/26/ BS EN 12390‐2

Testing Hardened Concrete ‐ Part 2: Making and Curing Specimens for Strength Tests

/27/ BS EN 12390‐3

Testing Hardened Concrete ‐ Part 3: Compressive Strength of test Specimens

2.4

SYSTEM OF UNITS

The International Unit System (SI) shall be utilized throughout the project, unless otherwise highlighted. Any conversion shall be provided in parenthesis where applicable.

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3

GENERAL REQUIREMENTS

For testing purposes specified in this Specification, the production shift shall be considered of maximum 12 hours depending on the SUBCONTRACTOR’s internal organization. In case SUBCONTRACTOR intends to work more than 12 hours per day, COMPANY/CONTRACTOR shall consider that the work is performed in more than one shift and the relevant testing frequency shall be respected as per this Specification. All SUBCONTRACTOR’s documents shall comply with the limitations of this Specification. SUBCONTRACTOR shall promptly inform COMPANY/CONTRACTOR of any need to make changes to these documents, which shall have to be specifically accepted by COMPANY, who has the right to require additional testing without additional costs. Any technical deviations to this Specification shall be obtained by SUBCONTRACTOR only through a concession request format. In any case it is not allowed to insert any deviation from this Specification in any SUBCONTRACTOR’s document prior that this deviation has not been previously presented separately to COMPANY/CONTRACTOR and approved in written by COMPANY/CONTRACTOR. Concession requests require COMPANY’s review and approval prior to implementation of the proposed changes. Pipes coated by implementing the technical changes prior to the COMPANY’s approval shall be rejected. Prior to the commencement of the production and during the production, COMPANY shall reserve the right to perform audits in the SUBCONTRACTOR’s facilities. COMPANY and COMPANY’s representatives shall be permitted by SUBCONTRACTOR the unlimited access to all SUBCONTRACTOR’s facilities related to the SUBCONTRACTOR’s scope of work for the PROJECT starting from the moment the work has been awarded to SUBCONTRACTOR until SUBCONTRACTOR has completed all of the obligations related to his scope of work in the PROJECT. It is mandatory requirement for SUBCONTRACTOR’s coating facilities that all of the inspection activities according to the action points specified in inspection and test plans can be performed by inspectors from all involved Parties in safe manner for all personnel involved in these activities. In case the inspection activities cannot be safely performed for all persons involved in inspection (CONTRACTOR, SUBCONTRACTOR’s, COMPANY’s and Third Party’s personnel), SUBCONTRACTOR shall stop all of the activities at that particular inspection point and shall organize the work space in a manner that all activities can be performed in safe manner. All costs due to such stoppages shall be borne only by SUBCONTRACTOR.

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4

CONCRETE COATING MATERIALS

The concrete coating applied on line pipes shall have the following nominal dry and cured concrete density of 3044 kg/m3. 4.1 CEMENT Unless otherwise specified in the Purchase Order, all cement used for the preparation of the concrete shall be “Portland Cement” conforming to the requirements of one of the following standards depending on the availability at the location where the concrete coating application shall be carried out: 

ASTM C 150 Type II and V;



MS 522 standard;



BS EN 197‐1 standard.

All batches of cement shall be supplied to SUBCONTRACTOR with test certificate stating the compliance either with the ASTM C 150 (Type II and V) or BS 12 or EN 197‐1 standard which shall then SUBCONTRACTOR submit to COMPANY for review prior to its use. The certificates must be presented to COMPANY’s review to verify that also the following mandatory requirements are met: 

that the content of alkali is < 0.6 %;



that the content of tri‐calcium aluminate C3A is < 8 %.

Cement that has hardened, partially set or lumpy will be rejected and shall be removed from the work site. Reground and graded cement shall not be used. Cement not meeting any single of above mentioned requirements shall not be used in the PROJECT. Cement shall be stored in covered areas or covered by plastic sheeting. 4.2

AGGREGATES

The sand shall be of the silica type. Clayey and schistose sands shall not be used. Sand shall be stored in a manner to avoid contamination from soil or other foreign matter. Heavy aggregates shall be made of crushed granite, or any other aggregate approved by the COMPANY/CONTRACTOR. Aggregates shall not be made from chalky or decomposed stone. In case high density concrete is required, SUBCONTRACTOR may add iron ore to the concrete coating mix. All aggregates shall be certified according to ASTM C 33 standard with exception of grading. SUBCONTRACTOR shall propose the grading of aggregates in the concrete mix which shall be confirmed during the Pre‐Qualification Test. However it is mandatory that all aggregates shall be of the size that 100% of their quantity will be able to pass 10 mm sieves. All aggregates shall be washed and shall be free from injurious amounts of salts, alkali, organic impurities or deleterious substances such as oxides of lead and zinc that may affect the strength of the concrete.

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(CONTRACT NO. CHO/2012/D316/1000) Sampling and testing for cleanliness of aggregates shall be carried out for each delivery of each aggregate in accordance with ASTM C 33 standard and other standards referred in the ASTM C 33 standard. During production the grading and cleanliness shall be checked at least once every three days from each stockpile and each new consignment for cleanliness and grading. The grading shall be as per the nominal values and tolerances specified by SUBCONTRACTOR and verified during the PQT. The test for cleanliness shall mean visual inspection for presence of any foreign material in tested sample beside the tested aggregate itself (wood, shells, or any other similar contaminant). SUBCONTRACTOR shall be responsible for proper storage of aggregates and all costs related to the COMPANY’s rejection of contaminated aggregate shall be borne by SUBCONTRACTOR. Different types of aggregates shall be stored separately in bins or well prepared areas, i.e. cobbled, paved or well compacted areas allowing adequate drainage of materials. 4.3 WATER Water used in concrete coating mix shall be fresh and shall comply with Appendix A of BS EN 1008. Water shall be of potable quality and obtained from a public supply where possible. Water shall not be taken from a spring, well, lake or similar source unless test indicate its suitability. During the bidding stage of the PROJECT the SUBCONTRACTOR shall present the certificate for the mixing water used in the coating plant and the SUBCONTRACTOR shall provide the guaranty that the same water shall be used during entire SUBCONTRACTOR’s work in the PROJECT. 4.4 ADDITIVES Additives containing chlorides shall not be used in the concrete mix. The total quantity of chlorides within the concrete mix, calculated as free CaCl2, shall not exceed 0.4% of the weight of the cement. Water reducing agents for concrete may be used in the concrete mix. Air entraining agents shall not be used in the concrete mix. 4.5 REINFORCING STEEL The reinforcing steel may be used in the following forms: 

welded steel wire mesh (type WW‐C or type WW‐N as per the ASTM A 810‐01 standard);



steel cage type.

Chicken wire mesh and steel poultry netting are not allowed as the reinforcement material. The diameter of the reinforcing steel shall be selected in a manner that all of the following requirements are met: 

the minimum circumferential reinforcement shall be 0.5% of the longitudinal cross sectional area of the concrete coating;



the minimum longitudinal reinforcement shall be 0.08% of the transverse cross‐sectional area of the concrete coating;

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(CONTRACT NO. CHO/2012/D316/1000) 

minimum diameter of the reinforcing wire for the welded steel wire mesh shall be 1.6 mm;



minimum diameter for the reinforcing wire in the cage type shall be 3 mm.

4.6 WELDED STEEL WIRE MESH The welded steel wire mesh shall be galvanized. The only approved type of the reinforcing steel wire mesh are Type WW‐C and Type WW‐N as per the ASTM A 810‐01 standard. The physical and chemical properties of the wire and wire mesh shall be in accordance with the ASTM A 641 and ASTM A 810‐01 standard. 4.7 STEEL CAGE TYPE The reinforcement shall be in the form of spirally wound cages having a continuous hoop wire with a number of straight longitudinal bars evenly spaced around the spiral and welded at each wire intersection. Alternatively, the continuous hoop wire may be replaced by single circumferential hoops. The material used shall ben hard drawn wire to BS 4482 or ASTM A 615 M (deformed), or to COMPANY/CONTRACTOR‐ approved equivalent standard. The welding of materials shall result in a steel fabric in accordance with BS 4483 or ASTM A 185. The diameter of the circumferential and longitudinal bars shall be calculated from the required percentage of reinforcing, with a minimum diameter of 3 mm. The spacing of the longitudinal bars shall be between 50 and 250 mm but not less than four longitudinal bars at approximately equal spacing shall be provided. The circumferential hoop spacing shall not be more than 100 mm. Cages shall have two hoops spaced 50 mm apart at each pipe end. The physical and chemical properties of the reinforcing wire and of the wire mesh shall be in accordance with the ASTM A 82‐01 (or ASTM A 615 M) and ASTM A 185‐01 standard.

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5

RECEIPT, HANDLING AND STORAGE OF BARE PIPES

Pipes coated only with 3‐layer polyethylene shall be handled, stored and transported in a manner that the pipe steel and pipe coating shall not be damaged. All foreign substances such as excessive dirt, debris of coating materials or any other foreign objects shall be removed from internal pipe surface before stacking of pipes or application of concrete coating. Coated pipes can be handled using slings, lifting hooks padded with soft material with suitable spreader bars, forklifts having lifting forks padded with soft material, front loaders padded with soft material and vacuum lifting. Chains or wire ropes or any other device that may damage the pipe steel or pipe coating shall not be used. When more than one pipe is lifted, separate slings or hooks shall be used for each pipe. Pipes shall be picked up from the stacking point and at no time shall be dragged or rolled. Coated line pipe shall not be subjected to jar or impact and all pipe supports shall be padded. Pipe supports shall be spaced to avoid bending of line pipes. The coated line pipes shall always be stacked to avoid surface contact with the ground. The pipes shall be stacked on approved supports which shall be free of any material that could potentially damage the applied coating. The stacking height of 3LPE/3LPP coated line pipes shall be limited to avoid damage of the coated line pipes due to the weight of other ones. The maximum number of stacking layers for the coated line pipes shall be calculated by SUBCONTRACTOR and relevant calculation showing calculation steps and results shall be submitted to COMPANY/CONTRACTOR for review and approval however, for safety reasons the maximum height of any stack shall be 3 m. In case SUBCONTRACTOR does not provide any calculation note related to stacking of coated pipes acceptable for COMPANY/CONTRACTOR, the coated pipes shall be stacked in maximum 4 rows. The stacks of coated pipes shall be separated for each of the following combinations: 

pipe nominal OD x pipe nominal wall thickness.

The line pipes shall be stacked at a slight angle to allow drainage of any rainwater. The coated pipes shall not be stacked below and near electrical lines or near any facility which may increase residual magnetism in the pipes (at all times it shall be kept the minimum distance of 30 m between the stored pipes and any electrical cable measured from the vertical projection to the ground of the nearest electrical cable). In case it is detected disbondment of the 3‐layer PE coating from the pipe at the coating edges when the coated pipes are stacked either before or during the load out operation, that particular pipe shall be rejected and the 3‐layer PE shall be stripped and re‐applied at SUBCONTRACTOR’s cost.

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6 6.1

CONCRETE COATING APPLICATION VISUAL AND HOLIDAY INSPECTION OF 3‐LAYER PE COATED PIPES

Prior to placement of the steel reinforcement and/or application of concrete coating, the entire factory applied anticorrosion coating of the pipe shall be visually inspected. Any foreign matter shall be removed from the surface of the anticorrosion coating and each detected coating damage shall be repaired according to the approved procedure prior to the commencement of the concrete coating application. Then, the entire coated surface of the pipes shall be inspected using a holiday detector at a voltage of minimum 25 kV. The holiday detector shall be equipped with a visual and an acoustic signalling device clearly audible in the prevailing working conditions. All damages detected by the holiday detector shall be repaired. 6.2

PLACEMENT OF REINFORCEMENT STEEL

For concrete thickness up to 50 mm, one wrap of reinforcing shall be used. For thicknesses of more than 50 mm, two layers should be considered. Additional layers may be necessary for concrete thicknesses in excess of 120 mm, but this would then require further COMPANY/CONTRACTOR’s approval, so the number of steel reinforcing layers shall be as follows: 

concrete coating thickness up to 50 mm  1 layer;



concrete coating thickness from 51 mm up to 100 mm  2 layers;



concrete coating thickness from 101 mm up to 140 mm  3 layers.

According to SUBCONTRACTOR’s discretion, SUBCONTRACTOR may apply also the combination of the reinforcing steel cage and reinforcing steel welded wire mesh but the above mentioned number of reinforcing layers vs. concrete coating thickness and the requirements for percentage of reinforcing steel in concrete coating cross sectional areas must be respected. During the application of the reinforcing steel, at all times, the following requirements must be met: 

minimum 15 mm distance between the reinforcing steel and the factory applied anticorrosion pipe coating;



minimum 10 mm distance between the reinforcing steel and the outer surface of applied concrete coating;



minimum 10 mm distance between two layers of reinforcing steel.

In case the reinforcing steel welded wire mesh is used, the longitudinal overlap of the wire mesh shall be minimum 25 mm. In case the cage type of reinforcement is used, the steel reinforcement shall terminate: 

10 mm – 30 mm from the end of concrete coating. Page 15 of 50

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7

APPLICATION OF COATING MATERIALS

It will be the SUBCONTRACTOR’s decision to apply the concrete coating using impingement method or compression coat method (extrusion), however only the application method used during the successfully passed and completed pre‐qualification test shall be used. Prior to the application of the concrete coating, the temperature of the concrete coating mix shall be within the range between +5°C and +35°C. In case the temperature of the concrete coating mix is less than +5°C, the concrete coating shall not be performed until SUBCONTRACTOR manages to heat the entire concrete mix up to +5°C. In case the temperature of the concrete coating mix is higher than +35°C, the mixing water shall be cooled with ice or a suitable cooling system shall be provided for the mixing water in order to obtain the concrete mix temperature of maximum +35°C. The free water/cement ration shall not exceed 0.45 by weight. The concrete coating application method shall be such that the coating time for each pipe does not exceed 30 minutes (starting from the moment that the water was added to the concrete mix and the concrete coating application started on that particular pipe up to the completion of application of concrete coating on the same pipe) otherwise the concrete coating on that pipe shall be rejected. Use of reclaimed/rebound material might be allowed providing it is demonstrated that it does not have any detrimental effect on the final concrete product. Secondary mixing of the reclaimed material with freshly batched concrete must follow immediately and must produce a homogeneous cohesive mixture. The amount of recycled material used shall not exceed 10% of the total mix by weight. If a break of this operation, for whatever reason, exceeds 30 minutes any reclaimed material not previously added to the mix shall be discarded and removed from the coating area. 7.1

PREPARATION OF THE CUTBACK AREA

The concrete coating shall be removed at both pipe ends taking care not to damage pipe steel or factory applied anticorrosion coating. The length of such prepared concrete coating cutback shall be 380 mm (‐ 0 mm / + 20 mm). The cutback shall be square with respect to pipe axis. 7.2

FINISHING OPERATIONS WITHIN CONCRETE COATING PLANT

Surface fallouts (spalling) shall be filled by guniting. The repair mix shall be similar in composition to the original mix. The repair shall be carried out in accordance with approved procedure within 30 minutes after application of the original concrete coating mix. Surface damage on concrete coating shall not be considered as a defect if all of the following conditions have been met: 

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damage is not extended to more than 20% of the nominal concrete coating thickness;



damaged area is less than 1000 cm2 (0.1 m2).

In case the total area of fall‐outs (spalling) is more than 20% of the concrete surface, the concrete coating shall be removed from that particular pipe. The cutback area and internal pipe surface shall be completely free from any residual concrete coating material and from any materials detrimental to the welding, NDT and field joint coating operations which shall be performed by pipe laying CONTRACTOR during the pipe laying operations. Finally, each pipe end shall be protected with end cap and the exposed steel and the first 100 mm of 3‐ layer PE coating shall be wrapped with polyethylene sheet that does not contain any adhesive and which shall be firmly tightened around this pipe location. 7.3

CURING

Immediately after completion of the application of concrete coating operations, the concrete coated pipe passing all online inspections and tests shall be transferred to the curing area. During the curing period, the pipes shall be stacked in a single layer. Curing shall be performed either by using water curing, steam curing, curing by sealing compounds or by polyethylene wrapping. The exposed surfaces of the concrete coating shall be protected during the curing period from any adverse effects of sunshine, drying winds, rain or running water. The curing process shall continue until a minimum compressive strength of 14 MPa has been achieved when the compression strength test is performed on core samples after which the concrete coated pipe can be lifted, transported and stacked in more than one layer up to the maximum allowed number of stacking layers. In case the period when the pipe reaches minimum 14 MPa of compression strength on core samples has not been determined by practical tests, the pipes shall remain stacked in a single layer for minimum seven days. Locations where the core samples shall be taken from the pipe for this purpose shall be selected by COMPANY/CONTRACTOR. 7.3.1

WATER CURING

Water curing shall consist of wetting and moistening the concrete coating, starting not later than 6 hours after completion of concrete coating application. The concrete coating shall be kept continuously moist by intermittent spraying for a period of at least 7 days. The interval between spraying shall not be more than 24 hours. At the ambient temperatures below +4°C, suitable precautions shall be taken to prevent damage due to freezing.

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(CONTRACT NO. CHO/2012/D316/1000) 7.3.2

STEAM CURING

If the curing process involves steam or warm high‐humidity air, then it shall be demonstrated that the process will have no deleterious effects on the concrete. Under no circumstances shall the pipe wall be allowed to reach a temperature that would cause any damage to the anticorrosion coating. Curing by steam shall not start sooner than 3 hours after completion of the concrete coating application completion. Concrete coated pipes shall be enclosed in plastic or similar cover suitable to maintain steam circulation. Steam circulation shall start at the ambient temperature and shall be controlled to give a temperature gradient of approximately 10°C/hour up to the maximum steel or coating temperature of +60°C. The pipes shall be held under steam curing for at least 6 hours and then allowed to cool for a similar period. SUBCONTRACTOR shall demonstrate during the pre‐qualification test that the curing time used is sufficient to meet the specified concrete strength levels. 7.3.3

CURING BY SEALING COMPOUNDS

Sealing compounds shall meet requirements of ASTM C 309 – 98A standard. The material shall be stored, prepared and applied in accordance with instructions supplied by the MANUFACTURER of sealing compounds. The compound shall be non‐toxic and non‐flammable and shall not react with any constituent of the concrete, reinforcement, protective coating or pipe steel. Unless otherwise specified by the compound MANUFACTURER’s instructions, membrane sealing compounds shall be sprayed over the complete concrete surface within 6 hours after completion of the concrete application and shall remain for a minimum of 7 days. The materials shall not be applied at temperatures less than +4°C. 7.3.4

CURING UNDER POLYETHYLENE WRAPPING

Wrapping in polyethylene film shall be done during the application of concrete coating. A light spray of water shall be applied before applying the plastic film. The polyethylene film shall have a minimum thickness of 0.2 mm and the overlap of the sheet shall not be less than 25% of the sheet width. The polyethylene film shall be in accordance with ASTM C 171 standard. The interface between the concrete and the bare steel at the pipe ends shall also be protected in order to achieve an air‐tight seal. The polyethylene wrapping shall remain on the pipe for minimum seven days but it shall be removed prior to final load out of the pipe.

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(CONTRACT NO. CHO/2012/D316/1000) 7.3.5

FOG CURING

Fresh concrete coating is continuously moistened by mist released from fogging tips and covered with tarpaulin sheets to provide a “closed” environment for curing. “Atomized” mist, with high “wet‐ability” is introduced gradually building to a “closed” high humidity, near saturation ambience to facilitate proper curing environment. The continuous introduction of “atomized” fog/mist into tarpaulin shall be continued for one shift before the pipe is removed/subject to further handling.

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8

INSPECTION AND TESTING

The Pre‐Qualification Test shall be performed on five fully concrete coated pipes and shall be completed before the start of actual production in the PROJECT. The combination of pipe material vs. pipe external diameter vs. pipe wall thickness vs. concrete coating thickness selected for Pre‐Qualification Test shall be agreed between SUBCONTRACTOR and COMPANY/CONTRACTOR. It is mandatory that all five concrete coated pipes are concrete coated in a sequence without any stoppage of the concrete coating plant in order to allow performance of the off‐line PQT tests. In case this requirement is not met, the PQT shall be repeated. All of the inspections and tests listed in this document shall be addressed in the inspection and test plan. Defects or anomalies detected during coating process shall start immediate corrective actions from the SUBCONTRACTOR. All line pipes to be submitted to the inspections and tests shall be selected in agreement with the COMPANY/CONTRACTOR’s Inspector. In the event that a production line pipe fails to meet the acceptance criteria for the tests listed in the table the test can be repeated only should the failure be caused either by improper use of the testing equipment or by error in the testing procedure. The following inspections and tests shall be carried out: Inspection/Test Inspection of the 3‐layer PE coated pipes during the receipt Visual inspection of the stacking of the 3‐layer PE coated pipes Inspections of the concrete coating materials during their receipt

Reference Section 6 Section 8.2 Section 8.1

Before the start of the PQT.

Production Before the start of production. Periodically.

Before the start of the PQT. Mixing water certificate to be delivered before the start of the PQT. Before the start of the PQT.

Once per day.

Each PQT pipe.

Each pipe.

Section 8.7

Before the start of the PQT.

Once per week.

Concrete coating mix temperature check

Section 8.8

Once.

Water – cement ratio check

Section 8.9

Once.

When the ambient temperature is within the range from +10°C up to +25°C, the test shall not be carried out. In case the ambient temperature is outside the above mentioned range the concrete coating mix temperature shall be measured at the beginning of each working shift and then every 4 hours. First working shift of each working day.

Verification of calibration of the holiday detector and the concrete coated pipes weighing scale Visual and holiday inspection of 3‐layer PE coated pipes immediately before application of concrete coating Concrete coating mix control (verification of calibration of the concrete coating mixing plant)

Section 8.3 Section 8.4.1 Section 8.4.2 Section 8.4.3 Section 8.5 Section 8.5.1 Section 8.5.2 Section 8.6

PQT Before the start of the PQT.

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(CONTRACT NO. CHO/2012/D316/1000) Inspection/Test Verification of the correct positioning of the concrete coating steel reinforcement

Reference Section 8.10

PQT First two PQT pipes.

Concrete coating application control Measurement of external diameter of applied concrete coating Cutback control Weighing of freshly concrete coated pipe Calculation of negative buoyancy Visual inspection of applied concrete Measurement of the electrical resistance between the steel reinforcement and the pipe

Section 8.11 Section 8.12

Each PQT pipe. Each PQT pipe.

Section 8.13 Section 8.14 Section 8.15 Section 8.16 Section 8.17

Each pipe. Each pipe. Each pipe. Each pipe. Reinforcing steel wire mesh: each PQT pipe. Steel cage: On the pipes where the test for verification of the correct positioning of the concrete coating steel reinforcement has been performed.

Control of the curing process and control of stacking of concrete coated pipes during the curing process Control of marking on concrete coated pipes


Each PQT pipe. Each PQT pipe. Each PQT pipe. Each PQT pipe. Reinforcing steel wire mesh: each PQT pipe. Steel cage: On the pipes where the test for verification of the correct positioning of the concrete coating steel reinforcement has been performed. Each PQT pipe.

Section 8.20

Each PQT pipe.

Each pipe.

Control of the concrete coating repair Control of the concrete coating repair


Each PQT pipe. Each PQT pipe.

Determination of factor α in the formula for calculation of negative buoyancy (performance of this test is not mandatory) Compression strength test cubes

Section 8.22

Two PQT pipes not submitted to the water absorption test. Each PQT pipe.

Each pipe. Each pipe on which the concrete coating has been repaired. N/A.

Compression strength test on core samples

Section 8.24

Determination of the time for stacking of pipes in more than one layer (performance of this test is not mandatory) Water absorption test

Section 8.25

Three PQT pipes.

Section 8.26

Two PQT pipes.

Section 8.27

One test.

One pipe coated each day during the first three production days. In case all tests had acceptable results the test shall be performed once per shift. week N/A.

Section 8.28 Section 8.29 Section 8.30

When Requested N/A N/A

When Requested one per week Each pipe. Each pipe.

Adhesion between the 3‐layer PE coating and concrete coating Impact testing Stacking of cured CWC pipes Load out inspections

8.1

Section 8.23

Each PQT pipe.

Production One pipe concrete coated at the beginning and on one pipe concrete coated in the middle of each working shift. Each pipe. Each pipe.

Periodically.

4 cubes from first pipe at the beginning of each working shift and then every 25 pipes. 2 x 3 cores from first pipe at the beginning of each working shift and then every 15 pipes. N/A.

STACKING OF 3‐LAYER PE COATED PIPES

Periodical visual inspection shall be performed in the area dedicated for stacking of the pipes coated with 3‐layer PE awaiting the application of concrete coating in order to verify that these pipes have been stacked in a maximum allowed number of layers and that they have been stacked on approved supports. In case of non‐conformance with relevant requirements SUBCONTRACTOR shall inform COMPANY/CONTRACTOR who will bring further decisions and COMPANY/CONTRACTOR’s decision shall be binding.

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(CONTRACT NO. CHO/2012/D316/1000) 8.2

CONTROL, IDENTIFICATION AND SEGREGATION OF 3‐LAYER PE COATED PIPES

The 3‐layer PE coated pipes shall be visually inspected for bevel damages, dents, gauges, flat ends and coating damages. Also the content of agreed pipe marking required at this stage of work shall be verified on the pipe. In case bevel damages, significant corrosion, dents, gouges, lamination or flat ends have been detected on bare pipe portion at the cutback area, the pipe shall be marked with coloured tape, segregated if practical to do so, and brought to COMPANY/CONTRACTOR’s attention who will instruct SUBCONTRACTOR about actions to be taken on this pipe. In case the coating damage has been detected, damaged area shall be marked and coloured tape shall be put around that pipe which shall remain on the pipe until the coating repair has been completed and approved by COMPANY/CONTRACTOR. In case oil, grease or any similar contamination has been detected at the cutback area, the contamination shall be removed with fresh water and detergent, solvent or any other suitable method. In case the missing or incorrect pipe marking has been detected, the pipe shall be marked with coloured tape, segregated if practical to do so and brought to the COMPANY/CONTRACTOR’s attention who will instruct SUBCONTRACTOR about the actions to be taken on that pipe. 8.3

DELIVERY AND STORAGE OF CONCRETE COATING RAW MATERIALS

At each delivery of the coating raw materials, the received documentation shall be reviewed against the received material packages and against the Purchase Order documents in order to verify that the received documents and materials conform to the requirements specified in the purchase order. In case of any non‐conformance, it shall be the SUBCONTRACTOR’s responsibility to resolve this issue with the supplier of the non‐conforming material. However, the batch of the material delivered in SUBCONTRACTOR’s premises non‐conforming to the requirements of this specification, shall not be used in the PROJECT. Periodically, a visual inspection shall be performed in order to verify that the coating materials have been stored in conditions as recommended by the material MANUFACTURER. The cement shall be stored in proper waterproof silos. The aggregates can be stacked in stockpiles at the open on clean site, free from the possibility of contamination. The galvanized wire mesh may be stored at the open clean site free from possibility of contamination but the wires used for manufacturing of steel cage must be stored in closed storage facility in dry place. The polyethylene wrapping that shall be used for curing of concrete coated pipes may be stored outside in clean site but it must be covered with appropriate sheeting to avoid exposure to the rain and raised from the ground to avoid flooding. Page 22 of 50

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(CONTRACT NO. CHO/2012/D316/1000) COMPANY/CONTRACTOR reserves the right to reject the use of improperly stored material in the PROJECT. 8.4 8.4.1

TEST TO BE PERFORMED ON CONCRETE COATING MATERIAL UPON RECEIPT SIEVE ANALYSIS AND CLEANLINESS CONTROL OF AGGREGATES

The grading and cleanliness of aggregates shall be checked from each stockpile for cleanliness and grading. The grading shall be as per the nominal values and tolerances specified by SUBCONTRACTOR and verified during the PQT. The test for cleanliness shall mean visual inspection for presence of any foreign material in tested sample beside the tested aggregate itself (wood, shells, or any other similar contaminant). In case of test failure, the test shall be repeated on doubled number of samples taken from the same batch. In case of repeated failure, the affected batch of supplied material shall not be used in the PROJECT or it shall be cleaned from all contamination as per COMPANY/CONTRACTOR’s satisfaction. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, tested material, material supplier, material batch number if applicable, acceptance criteria, test results, remarks. 8.4.2

STEEL REINFORCEMENT WIRES DIMENSIONAL CONTROL

For each batch of received reinforcing steel some of the received rolls of wire mesh and/or the wires for cage type reinforcement shall be checked by measuring the diameter of longitudinal and stay wires with a calliper. The measured value shall correspond to the minimum value provided by the reinforcing steel MANUFACTURER required to meet the requirements for reinforcing steel in concrete coating in this specification (minimum tolerance specified first by relevant standard and if this value cannot be found in the standard then the minimum tolerance value can be specified by the MANUFACTURER). In case of test failure, the test shall be repeated on doubled number of samples taken from the same batch. In case of repeated failure, the affected batch of supplied material shall not be used in the PROJECT. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, tested material, material supplier, material batch number if applicable, acceptance criteria, test results, remarks. 8.4.3

MIXING WATER CHEMICAL ANALYSIS

Water used in concrete coating mix shall be fresh and shall comply with Appendix A of BS EN 1008. During the bidding stage of the PROJECT the SUBCONTRACTOR shall present the certificate for the mixing water used in the coating plant and the SUBCONTRACTOR shall provide the written guaranty that the same water shall be used during entire SUBCONTRACTOR’s work in the PROJECT.

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(CONTRACT NO. CHO/2012/D316/1000) In case the above mentioned requirement is not met, the chemical analysis of mixing water shall be completed and the certificate submitted to COMPANY/CONTRACTOR two weeks before the commencement of the Pre‐Qualification Test otherwise SUBCONTRACTOR shall not be allowed to start the performance of the pre‐qualification test. In case the quality of mixing water does not meet the requirements of this specification, the concrete coating plant shall not be qualified for the work. 8.5

VERIFICATION OF CALIBRATION OF THE TEST INSTRUMENTS

The verification of calibration shall be verified for the holiday detector and pipe weighing scales each working day while the calibration of other testing equipment shall not be verified but the Third Party’s calibration certificates shall be used. The instruments whose accuracy is not meeting the relevant acceptance criteria for each particular instrument shall not be used in the PROJECT until the instrument’s accuracy is brought back within acceptable limits. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, testing equipment, testing equipment serial number, acceptance criteria, test results, remarks. 8.5.1

HOLIDAY DETECTOR

The voltage of the holiday detector shall be compared with the voltage of the certified calibration high voltage instrument recommended by the MANUFACTURER of the holiday inspection equipment for this purpose. The holiday detector shall be considered acceptable when the voltage of the holiday detector when checked with the high voltage calibration instrument set at 25.0 kV shows the values within the range from 25.0 kV to 25.5 kV. 8.5.2

PIPE WEIGHING SCALES

The verification of calibration of the weighing scales which shall be used for determination of the weight of freshly concrete coated pipes shall be performed by weighing of the minimum 11.5 m long minimum 10” diameter pipe having known and certified weight. The weighing bridge shall be considered acceptable for use when the measured value of the known weight is within the range: 

Nominal weight of the pipe having known and certified weight ± 0.3%.shift.

8.6

VISUAL AND HOLIDAY INSPECTION OF THE 3‐LAYER PE COATED PIPES

Prior to the commencement of application of the concrete coating, the 3‐layer PE coated pipes shall be submitted to the visual inspection and holiday inspection at 25 kV. The pipes shall have no major steel defects and the pipe coating shall be without visible defects. There shall be no holidays detected after holiday inspection at 25 kV.

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(CONTRACT NO. CHO/2012/D316/1000) The 3‐layer PE coating shall be repaired in accordance with the SUBCONTRACTOR’s coating repair procedure approved by COMPANY/CONTRACTOR. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity only in case any not conformance occurred. 8.7

CONCRETE COATING MIX CONTROL

Prior to the commencement of the pre‐qualification test and during the production once per week, SUBCONTRACTOR shall perform the verification that their batching plant provides the composition of the concrete coating mix within the tolerances selected by the SUBCONTRACTOR himself. Production shall not start if the batching plant is not properly calibrated. Within the concrete coating application procedure, SUBCONTRACTOR shall describe in details the verification of calibration of batching plant for determination of percentage of each component in the concrete coating mix. 8.8

CONCRETE COATING MIX TEMPERATURE MEASUREMENT

When the ambient air temperature is less than +10°C and it is higher than +25°C, SUBCONTRACTOR shall measure the temperature of the concrete coating mix at the beginning of each working shift and then every 4 hours. Approximately 3 ‐ 10 kg of concrete mix shall be taken at the end of the belt located after exit of the mixer and put into the bucket or any other suitable container. Then, the immersion probe of the digital thermometer shall be immersed in the fresh concrete mix and the temperature shall be read from the display of the instrument. In case the temperature of the concrete coating mix is less than +5°C, the concrete coating shall not be performed until SUBCONTRACTOR manage to heat the entire concrete mix up to +5°C. In case the temperature of the concrete coating mix is higher than +35°C, the mixing water shall be cooled with ice or a suitable cooling system shall be provided for the mixing water in order to obtain the concrete mix temperature of maximum +35°C. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, acceptance criteria, test results, remarks. 8.9

WATER‐CEMENT RATIO CHECK

The free water / cement ratio shall be checked at the beginning of the first working shift of each working day. The water to cement ratio shall not exceed 0.45 by weight. In case the acceptance criterion is not met, the concrete coating operations shall not start it has been verified that the water/cement ratio is within acceptable limits.

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(CONTRACT NO. CHO/2012/D316/1000) Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, acceptance criteria, test results, remarks. 8.10 REINFORCING WIRE POSITION CONTROL On one pipe concrete coated at the beginning and on one pipe concrete coated in the middle of each working shift, the proper positioning of the reinforcing steel wire mesh shall be verified by opening a window of approximate dimensions 200 mm x 75 mm penetrating down to the anticorrosion pipe coating while the concrete coating is still fresh. During this visual inspection it shall be verified that the requirements specified in Section 8.2 of this specification have been met. Only in case the cage type steel reinforcement is used by SUBCONTRACTOR, during this test it shall be tested also the electrical resistance between the bottom layer of the reinforcing steel and the pipe end. One electrode of the ohmmeter shall be in the contact with the bottom layer of the reinforcing steel of the cage and another electrode shall be in the contact with bare pipe end at the cutback area. The minimum measured resistance shall be 1 000 Ohm. In case the acceptance criteria have not been met, the testing shall continue until it is determined on two consecutive pipes concrete coated before and on two consecutive pipes concrete coated after the test failure, that these tests are successfully passed. The pipes not passing any single of these tests shall have the concrete coating removed. 8.11 CONCRETE COATING APPLICATION CONTROL During the application of the concrete coating the following verifications shall be carried out on each pipe: 

that the concrete has been applied reasonably uniformly throughout the entire pipe length and that it has been applied without any major irregularities;



that the spalling is repaired on the freshly concrete coating pipe maximum 30 minutes after adding the water in the concrete coating mix in the concrete batching plant;



when the reinforcing steel in the form of wire mesh is used that the polyethylene wrapping has been applied immediately after the concrete application with minimum overlap of 25 % of the sheet width.

Pipes not meeting acceptance criteria shall have the concrete coating removed. 8.12 MEASUREMENT OF EXTERNAL DIAMETER OF APPLIED CONCRETE The external circumference/diameter of applied concrete shall be measured on each concrete coated pipe using a flexible measuring tape at five equidistant points along the pipe length. The measurements shall not be taken at first 400 mm from the ends of applied concrete coating. The average of five measurements for external diameter of applied coating shall than be inserted in the formula for calculation of negative buoyancy.

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(CONTRACT NO. CHO/2012/D316/1000) Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, pipe sequence number, pipe number, pipe external diameter, pipe wall thickness, pipe nominal concrete coating thickness, test results, remarks. 8.13 CUTBACK CONTROL The cutback length shall be measured on each concrete coated pipe end. The average of two measurements shall be inserted in the formula for calculation of negative buoyancy. The edges of concrete coating at the cutback area shall be perpendicular with respect to the pipe axis and entire concrete coating cutback area shall be free of residual concrete coating and from any materials detrimental to the welding, NDT and field joint coating operations which shall be performed by the pipe laying CONTRACTOR during the pipe laying operations. The concrete coating cutback length shall be 380 (‐ 0 mm / +20 mm). In case the acceptance criteria have not been met, the pipe shall be quarantined until the remedial work is taken which shall result in acceptable concrete coating cutback. Relevant inspection report specifying cutback lengths shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, pipe sequence number, pipe number, pipe external diameter, pipe wall thickness, pipe nominal concrete coating thickness, acceptance criteria, result of each cutback length measurement, remarks. 8.14 WEIGHING OF FRESHLY CONCRETE COATED PIPE Each freshly concrete coated pipe shall be placed on a weighing scale where its weight shall be measured. The result shall be displayed and when the pipe weight has stabilized. The result of measurement shall be inserted in the formula for calculation of negative buoyancy. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, pipe sequence number, pipe number, pipe external diameter, pipe wall thickness, pipe nominal concrete coating thickness, test results, remarks. 8.15 CALCULATION OF NEGATIVE BUOYANCY The negative buoyancy shall be calculated on each pipe as follows:

NB

= negative buoyancy [kg/m];

Wbp

= weight of bare pipe, information supplied from the pipe MANUFACTURER [kg];

W3LPE/3LPP

= weight of applied 3‐layer PE/3‐layer PP not including mass of bare pipe, calculated using either nominal or average 3‐layer PE or other external anticorrosion coating thickness [kg];

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L

= length of the line pipe taken the data from pipe MANUFACTURER [m];

CB3LPE/3LPP

= average of two measurements of the 3‐layer HDPE/3‐layer PP cutback length; theoretical average is also allowed for this purpose [m];

CBCWC

= average of two actually taken measurements of the concrete coating cutback length on which the length has been measured [m];

α

= factor of change in the weight of concrete coating from wet and fresh to dry and cured; unless otherwise demonstrated during the PQT, the factor α = 0.99 [non dimensional value];

WCWC

= weight of the pipe coated with fresh concrete, measurement taken immediately after application of concrete coating [kg];

DCWC

= external diameter of the concrete coated pipe obtained by average of five measurements of the concrete coating circumference as per this specification divided by π [m];

ρW

= density of seawater.

The acceptance criteria for negative buoyancy for each combination of pipe external diameter vs. pipe wall thickness vs. concrete coating thickness shall be provided by COMPANY/CONTRACTOR in due time. Only unless otherwise communicated by COMPANY/CONTRACTOR the following tolerances shall apply: 

per working shift: nominal value of negative buoyancy (‐0% / +4.5%);



per single concrete coated pipe: nominal value of negative buoyancy (‐0% / +10%).

Each pipe not meeting acceptance criteria have the concrete coating removed. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, pipe sequence number, pipe number, pipe external diameter, pipe wall thickness, pipe nominal concrete coating thickness, acceptance criteria, test results, remarks. 8.16 VISUAL INSPECTION OF APPLIED CONCRETE Each freshly concrete coated pipe shall be visually inspected for defects. Surface damage on concrete coating shall not be considered as a defect if all of the following conditions have been met: 

damage is not exposing reinforcing steel;



damage is not extended to more than 20% of the nominal concrete coating thickness;



damaged area is less than 1000 cm2 (0.1 m2).

Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. Page 28 of 50

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(CONTRACT NO. CHO/2012/D316/1000) The report shall contain the following items: date, shift, pipe sequence number, pipe number, pipe external diameter, pipe wall thickness, pipe nominal concrete coating thickness, test results, remarks. The following shall be considered during visual inspection of concrete coated pipes. 8.16.1 SURFACE FALL‐OUTS (SPALLING) OF FRESHLY CONCRETE COATED PIPES In case the spalling occurs, it shall be repaired only if the maximum 20% of the concrete coating surface is affected by it. The spalling shall be repaired in production line within 30 minutes after application of the original concrete coating mix or in case this time is exceeded by guniting using the concrete composition similar to the original concrete coating mix applied on the pipe. After repair the pipe shall be reweighed for calculation of negative buoyancy. 8.16.2 CONCRETE COATING DAMAGES ON FRESH AND HARDENED CONCRETE Damages caused by taking of core samples for compression strength test shall be repaired unless the anticorrosion pipe coating has been damaged. In case the anticorrosion coating has been damaged during the core sampling process, the concrete coating shall be removed from that pipe. In case reinforcing steel has been only cut but not removed from the pipe, the concrete coating can be repaired and the reinforcing steel shall be positioned properly during the repair. However, if any portion of reinforcing steel has been removed from the pipe, the concrete coating shall be removed from that pipe. Concrete coating damages resulting also in damage of the 3‐layer PE coating shall have the concrete coating removed. Considering above mentioned limitations, repair of concrete coating damages is allowed when the concrete coating has been damaged or it has been removed from the pipe for repair purposes up to maximum 20% of the concrete coating surface (not of the concrete coating volume. 8.16.3 CRACKS Circumferential surface cracking of the concrete not exposing reinforcing steel having a crack width less than 5 mm shall not be considered as a defect. Circumferential annular cracking visible at pipe ends is generally not acceptable and all pipes having such cracks in total circumferential length greater than 200 mm shall have the concrete coating removed. All cracks penetrating down to the 3‐layer PE coating shall not be acceptable and such pipe shall have the concrete coating removed. Longitudinal surface cracks less than 250 mm in length and having a width of 8 mm or less shall not be considered as a defect but holes of 10 mm nominal diameter shall be drilled at the crack tips to prevent propagation of the crack. The bottom of these holes shall be 7‐10 mm from the anticorrosion coating. Longitudinal cracks having a length from 250 mm up to 1000 mm shall be repaired by chiselling out the crack to a width of at least 25 mm throughout its length taking care not to damage anticorrosion coating.

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(CONTRACT NO. CHO/2012/D316/1000) The prepared area shall be undercut to form an adequate key for repair material. Then the concrete repair material shall be inserted into the prepared void until the void is completely filled. Then the repair material shall be smoothed with the adjacent concrete coating. Longitudinal cracks having a length over 1000 mm shall not be acceptable and such pipe shall have the concrete coating removed. 8.17 ELECTRICAL RESISTANCE BETWEEN STEEL REINFORCEMENT AND THE PIPE When the steel reinforcement in a form of wire mesh is used by SUBCONTRACTOR, the electrical resistance between the reinforcing steel and the pipe end shall be carried out by placing one electrode of the ohmmeter connected to the protruding reinforcing steel at the concrete coating cutback and by placing another electrode on bare pipe end at the cutback area. The minimum measured resistance shall be 1 000 Ohm. This test shall be performed on each pipe. All of the pipes not meeting acceptance criterion shall have the concrete coating removed. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, pipe sequence number, pipe number, pipe external diameter, pipe wall thickness, pipe nominal concrete coating thickness, acceptance criteria, test results, remarks. 8.18 CONTROL OF CURING PROCESS Periodically it shall be verified the conditions of curing process in order to verify that the curing process meets the requirements specified in Section 8.6 of this Specification. All pipes not being cured in accordance with PROJECT documents shall be quarantined and submitted to COMPANY/CONTRACTOR’s decision who reserves the right to reject the concrete coating on these pipes or in case to avoid concrete coating removal to ask additional testing without any extra cost borne by COMPANY/CONTRACTOR. 8.19 CONTROL OF STACKING OF PIPES DURING THE CURING PROCESS Periodical inspection of pipes stacked in curing area shall be carried out in order to verify that the pipes has been stacked in a single layer and on approved supports. All pipes not conforming to the PROJECT Specification shall be marked with coloured tape and COMPANY/CONTRACTOR shall inform the SUBCONTRACTOR about the actions to be taken on non‐ conforming pipes. 8.20 CONTROL OF MARKING ON CONCRETE COATED PIPES The marking applied on concrete coated pipe shall be checked in order to verify that the marking and its content meet the requirements specified by COMPANY/CONTRACTOR and that it has been applied in accordance with agreed procedure.

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(CONTRACT NO. CHO/2012/D316/1000) 8.21 CONTROL OF MARKING ON CONCRETE COATING REPAIR When the repair of concrete coating has been allowed, it shall be verified that the concrete coating repair material approved by COMPANY/CONTRACTOR has been used, that the repair material completely filled damaged area and that it has been reasonably smoothed with the adjacent previously applied concrete coating. Pipes not conforming to the requirements of this Specification related to the repair of concrete coating shall have the concrete coating removed unless repair cannot be redone in accordance with this Specification. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, pipe number, pipe external diameter, pipe wall thickness, pipe nominal concrete coating thickness, description of coating damages found on the pipe, test results, remarks. 8.22 DETERMINATION OF FACTOR ALPHA IN THE FORMULA FOR CALCULATION OF NEGATIVE BUOYANCY This test shall be performed only during the pre‐qualification test in order to verify the difference in the weight between freshly concrete coated pipe and dry and cured concrete coated pipe in order to calculate negative buoyancy more precisely. In case this test is not performed the factor α shall remain 0.99. During the pre‐qualification test it shall be verified the difference between the weight of the concrete coated pipe after minimum 7 days passed after the application of concrete coating and the weight of concrete coated pipe having freshly applied concrete coating. This verification shall be performed on minimum two PQT pipes not submitted to the water absorption test by weighing of the pipes immediately after application of concrete coating and at least 7 days after application of concrete coating as follows: Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. 8.23 COMPRESSION STRENGTH TEST CUBES The cubes shall be taken at a frequency of one sample for every 25 pipe joints coated, up to a maximum of three times per work shift. A minimum of 4 cubes (100 x 100 x 100 mm) from each sample shall be taken. Two cubes shall be tested at 7 days age and the remaining cubes at 28 days age. The test cubes shall be made, cured and tested according to BS EN 12390‐2 and BS EN 12390‐3, or ASTM C 39. The test cubes shall be tested for density and compressive strength, to indicate the consistency of the concrete. The minimum compressive strength shall be expressed as equivalent core strength.

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(CONTRACT NO. CHO/2012/D316/1000) 8.24 COMPRESSION STRENGTH CORE SAMPLES The compression strength on core samples shall be performed on the first concrete coated pipe at the beginning of each working shift and then every 15 concrete coated pipes passing online tests; 2 sets of 3 core specimen shall be removed by pipes using a diamond cutter to ensure that the cut is perpendicular to the pipe surface. Core samples shall be taken within four days of concrete application and stored in a curing tank until test performance. The diameter of the core sample shall be between 35 mm and 44 mm and when trimmed for testing, the ratio core sample diameter / core sample length shall be approximately 1:1. In case the capping of core sample must be performed, the maximum height of applied capping at any point shall be 8 mm as per the Table 1 of the ASTM C 617‐98 standard. Three core samples shall be taken approximately 500 mm from the edge of concrete coating from pipe lead end, three core samples shall be taken from the centre of the pipe and three core samples shall be taken approximately 500 mm from the edge of concrete coating from the pipe tail end. In case of cage reinforcement type the core sample shall be taken in a manner that there is no reinforcing steel included in core sample. One core sample taken from the pipe lead end, one core sample taken from the centre of the pipe and one core sample taken from the pipe tail end shall be submitted to the compression strength test 7 days after application of concrete coating (first set of core samples). The same shall be done also for compression strength test 28 days after application of concrete coating on that pipe (second set of core samples). Remaining set of core samples shall be spare core samples in case relevant core sample does not pass the test and the spare core sample shall be retested instead (for example, in case of test failure of core sample on pipe lead end, the spare core sample taken from the pipe lead end shall be tested). Only in case when the reinforcing steel in the form of welded wire mesh is used and the reinforcing steel is included in core sample and this cannot be avoided, SUBCONTRACTOR may use the following number of spare core samples due to the negative influence of reinforcing steel in core sample on test results: 

from 40 mm to 45 mm nominal concrete thickness: 10 cores taken from the pipe lead end, 10 cores from the centre of the pipe and 10 cores from the pipe tail end;



for nominal concrete coating thickness above 45 mm: 5 cores taken from the pipe lead end, 5 cores from the centre of the pipe and 5 cores from the pipe tail end.

When cage type of reinforcing steel is used, only one spare core sample for each location is allowed (pipe lead end, centre of the pipe and pipe tail end). For acceptance or rejection of the pipe, only the 28 days test result shall be considered while the 7 days test shall be performed only for information.

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(CONTRACT NO. CHO/2012/D316/1000) The test performance shall be in accordance with the ASTM C39/C39M‐01 standard with exception of requirements contradicting this standard specified in this Specification. In case the acceptance criteria valid for 28 days test have been achieved after 7 days, the 28 days test shall not be performed on that pipe. The following acceptance criteria shall apply for 28 day test: 

minimum value for individual core: 32 MPa;



minimum average value of three cores (one taken at the pipe lead end, one taken at the centre of the pipe and on taken at the pipe tail end): 35 MPa.

In case of test failure on first set of core samples and on allowed number of spare samples the following remedial actions shall be performed: 

all of the pipes concrete coated between the previous successful compression strength test before the test failure and after the following successful compression strength test performed on the pipe coated after the pipe on which the test failure occurred shall be quarantined;



then, the compression strength test shall be performed on two pipes concrete coated immediately before and on two pipes concrete coated immediately after the pipe on which the test failure occurred. In case of test failure on any single of these test pipes, all of the quarantined pipes shall be either submitted to the compression strength test until acceptable test results have been found on three consecutive pipes concrete coated before and on three consecutive pipes concrete coated after the test failure, otherwise the quarantined pipes shall have the concrete coating removed;



the pipes not meeting acceptance criteria shall have the concrete coating removed.

Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, pipe sequence number, pipe number, pipe external diameter, pipe wall thickness, pipe nominal concrete coating thickness, acceptance criteria, test results, remarks. 8.25 DETERMINATION OF THE TIME FOR STACKING OF PIPES IN MORE THAN ONE LAYER SUBCONTRACTOR shall take core samples from three different pipes (three cores taken per each pipe as described in previous paragraph) and submit them to the compression strength test considering core sampling and compression strength testing requirements specified in previous paragraph. Then SUBCONTRACTOR shall decide how much time shall pass from the completion of application concrete coating on test pipe and testing of core sample. However, the time allowed for stacking of pipes in more than one layer shall be considered as the time when each single tested core sample achieved the minimum compression strength of 14 MPa. In case this test is not performed, the pipes shall remain stacked in a single layer for minimum seven days. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. Page 33 of 50

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(CONTRACT NO. CHO/2012/D316/1000) 8.26 WATER ABSORBTION TEST The water absorption test shall be performed on one pipe coated each day during the first three production days. In case all tests had acceptable results the test shall be performed once per week. The test shall be performed as follows: 

freshly concrete coated pipe selected for the water absorption test shall be placed in the curing area together with other pipes but it shall be marked as a test pipe and it shall remain in the curing area for minimum seven days after which the pipe can be submitted to the water absorption test;



immediately prior to the performance of the water absorption test, the test pipe shall be weighed on the weighing scale and the result of measurement shall be recorded and used in the formula for water absorption (W1);



immediately after weighing the pipe shall be completely immersed either in seawater or in the fresh water as per the SUBCONTRACTOR’s discretion and left constantly immersed for minimum 24 hours;



after immersion of minimum 24 hours, the pipe shall be weighed again on the weighing scale (W2);



the water absorption shall be calculated as follows:

Maximum allowed value of the water absorption test shall be 5%. In case of test failure all of the pipes coated between the previous successful water absorption test and the next successful water absorption test performed after the test on which the water absorption test failure occurred shall be quarantined. The pipe on which the test failure occurred shall have the concrete coating removed. Then, two pipes selected from the quarantined pipes shall be submitted to the water absorption test and in case of test failure on any of these test pipes all quarantined pipes shall be submitted to COMPANY/CONTRACTOR’s decision who deserves the right to ask for additional testing or to reject all quarantined pipes without any additional costs borne by COMPANY/CONTRACTOR. Relevant inspection report shall be prepared by SUBCONTRACTOR related to this inspection activity. The report shall contain the following items: date, shift, pipe sequence number, pipe number, pipe external diameter, pipe wall thickness, pipe nominal concrete coating thickness, acceptance criteria, test results, remarks. 8.27 ADHESION BETWEEN THE 3‐LAYER PE COATING AND CONCRETE COATING During the Pre‐Qualification Test, on one concrete coated PROJECT pipe (minimum 1 m length of the 3‐ layer PE and concrete coated pipe piece is allowed for this purpose), the adhesion test (push‐off test) shall be performed in order to determine the shear strength between the external anticorrosion coating of line pipes and concrete coating. The test shall be performed in accordance with agreed procedure.

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(CONTRACT NO. CHO/2012/D316/1000) The minimum value of the shear strength between the external anticorrosion coating of line pipes and concrete coating shall be 0.5 MPa. SUBCONTRACTOR shall prepare a report related to this test activity. 8.28 IMPACT TESTING Impact testing may be required to demonstrate suitability for use in offshore applications where fishing activities occur. Impact testing shall be carried out on qualification test pipes selected by the COMPANY/CONTRACTOR and on one concrete coated pipe per week or at the COMPANY/CONTRACTOR's discretion until the COMPANY/CONTRACTOR is satisfied that the concrete coating procedures produce a consistent product with acceptable impact resistance. The impact testing equipment and procedure are detailed below. The exact details of the test rig shall be submitted to the COMPANY/CONTRACTOR for approval and shall include details of safety measures to be taken to avoid injury to personnel. Pipes subject to impact testing shall be scrapped and not repaired or incorporated in the pipeline. The impact test rig is designed to simulate impact by the trawl beam shoes of typical fishing trawl equipment as used in e.g. the North Sea. It shall consist of a steel framework on which a heavy cylindrical impact 'hammer' is suspended. The hammer shall be supported in the horizontal position by two sets of wire ropes attached to the supporting framework. The impact hammer shall be designed to simulate the mass and momentum of a 2.68 tonne trawl board travelling at 7 knots over the seabed. The 'hammer' shall be 300 mm long, have a 10 mm radius tip, and be connected to a plate perpendicular to the pipe axis as shown in (Figure 3). The mass of the hammer shall be 2.68 tonne with the capability of reducing the mass to 1.84 tonne. The vertical drop of the hammer shall be 660 mm giving a velocity on impact of 3.60 mls (7 knots). Note: The above‐indicated values are based on specific North Sea trawling equipment, for other areas different values may be applicable. The concrete coated test pipe shall be rigidly supported from the rear over its full length by moist sand. The pipe shall be held rigidly at its ends by wooden cradles and wedges to prevent movement of the pipe under impact. The point of impact on the concrete shall be at the 3 o'clock position. The pipe shall be supported so that impact of the concrete is made when the hammer is at the lowest point in its swing. Testing shall be carried out in three ways: 1.

90° to pipe axis at one location (2.68 t)

2.

90° to pipe axis at five locations each 300 mm apart (2.68 t)

3.

60° to pipe axis at one location (1.84 t).

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(CONTRACT NO. CHO/2012/D316/1000) For all tests, recording of impact locations shall include: a) photograph after each blow; b) diagram(s) of crack patterns and spa lied areas including dimensions of major cracks (length and width); c) dimensional changes, if any, of the pipe; detected by visual internal inspection and subsequent external measurement. The concrete area covering crack arrestors shall be impacted during qualification tests, for information purposes. Test 1 The test pipe shall be supported with a minimum of 2 m concrete section either side of the section under test. Impact blows shall be directed on the same location and the condition of the concrete recorded after each blow, until the anti‐corrosion coating is exposed. The anti‐corrosion coating shall not be visible and the steel pipe wall shall not be indented or damaged after 5 blows. Spalling shall not occur over an axial distance greater than 300 mm each side of the points of impact, after 5 blows. Test 2 The test pipe or rig shall be moved along at least 2 m and then a single blow shall be directed on five locations, each 300 mm apart. The condition of the concrete shall be recorded after each blow. Any spalling shall not extend from one impact location to another. Test 3 The test pipe or rig shall be moved along at least another 2 m and the pipe impacted in the 60° position to the line of motion of the hammer. Five impact blows shall be directed on the same location and the condition of the concrete recorded after each blow. The anti‐corrosion coating shall not be visible after five blows. 8.29 STACKING OF CURED CONCRETE COATED PIPES Periodical inspection shall be performed in storage area to verify that the requirements specified in Section 12 of this specification are met. All pipes not conforming to the PROJECT Specification shall be marked with coloured tape and COMPANY/CONTRACTOR shall inform the SUBCONTRACTOR about the actions to be taken on non‐ conforming pipes.

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(CONTRACT NO. CHO/2012/D316/1000) 8.30 LOAD OUT INSPECTIONS The following inspections shall be performed on each concrete coated pipe during the load out operation (pipes not conforming to the requirements of PROJECT specifications for external coating and concrete coating shall not be accepted for load out): 

check of pipe marking;



visual inspection of 3‐layer PE coating at the concrete coating cutback area and



verification that 3‐layer PE coating did not disbond from the pipe at the edges;



visual inspection for the presence and integrity of end caps and polyethylene sheeting



protecting the 3‐layer PE coating cutback;



visual inspection of concrete coating;



check of residual magnetism on both pipe ends (only when requested by COMPANY/CONTRACTOR).

Inspection report shall be prepared only for non‐conforming pipes quarantined during the load out inspection.

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9

3‐LAYER PE COATING REPAIR

3‐layer PE coating damages and the relevant external coating repair are not allowed at the cutback area where the external coating has been bevelled (at the coating angle). All coating damages located on the area 100 mm measured from the coating edge after cutback preparation towards centre point of the pipe on both sides of the pipe can be repaired only if the repair material is perfectly smoothed with adjacent factory applied coating. Acceptance of coating repair at this area shall be done only according to the COMPANY/CONTRACTOR’s discretion (this request is inserted due to the positioning of the support for welding/NDT equipment and for application of heat shrink sleeves as the field joint coating material). Defects reducing the coating thickness below the minimum allowed total coating thickness or exposing the primer or bare steel are not allowed when they occur before the completion of the visual inspection of the pipe at the relevant inspection point within the coating plant. All such line pipes shall be rejected, stripped, cleaned and re‐coated. Coating repairs are allowed only for line pipes damaged after the coating and quenching process once the visual inspection of the coated pipes is complete (due to handling and storage). Classification of coating damages: Coating damage “Class A”: coating damage not reducing the total coating thickness below the minimum allowed total coated thickness specified in this Specification. Coating damage “Class B”: coating damage reducing the total coating thickness below the tolerances specified in this Specification but not exposing the primer or penetrating down to the steel. Coating damage “Class C”: coating damage exposing the primer or penetrating down to the steel. Maximum 10 coating damages “Class B” are allowed on each line pipe – otherwise the whole line pipe shall be rejected, stripped, re‐cleaned and re‐coated. In case of any individual area greater than 50 cm2 exposing the primer/bare steel (coating damage “Class C) the pipe will have to be stripped. A maximum of three coating damages exposing the primer/bare steel (coating damage “Class C”) are allowed per each pipe but the total damaged area shall not exceed 150 cm2. All repaired areas shall be subjected to the following check and acceptance criteria: 

visual inspection on 100% of repairs: no defects;



thickness test on 100% of repairs: as per this specification;



holiday detection test on 100% of repairs: no holidays at 25 kV.

Each repair of the coating damage “Class B” and “Class C” shall be reported and the relevant report shall include: 

date;

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line pipe number;



type of any damage (classification of damage);



location of any damage;



dimension of any damage;



results of checks.

The following coating repair materials are permitted for repair of the 3‐layer PE coating: 

Melt Stick supplied either by “Berry Plastics” or by “Canusa”: for repair of 3‐layer PE coating damages not exposing FBE layer or bare steel having maximum size of the damage of 20 mm × 20 mm.



Filler mastic “S1137‐50×3×3000” + PE repair patch PERP 60 (supplied by “Berry Plastics”): for repair of 3‐layer PE coating damages not exposing FBE layer or bare steel having maximum size of the damage of 150 mm × 150 mm.



Filler mastic + PE repair patch CRP 65 (supplied by “Canusa”): for repair of 3‐layer PE coating damages not exposing FBE layer or bare steel having maximum size of the damage of 150 mm × 150 mm.



Liquid epoxy primer + filler mastic “S1137‐50×3×3000” + PE repair patch PERP 60 (supplied by “Berry Plastics”): for repair of 3‐layer PE coating damages exposing FBE layer or bare steel having maximum size of the damage of 50 cm2.



Liquid epoxy primer + filler mastic + PE repair patch CRP 65 (supplied by “Canusa”): for repair of 3‐ layer PE coating damages exposing FBE layer or bare steel having maximum size of the damage of 50 cm2.

SUBCONTRACTOR shall prepare a detailed coating repair procedure, including all types of expected defects, and coating stripping procedure for line pipes. Coating repair and stripping procedures shall be both qualified and approved by COMPANY/CONTRACTOR before the commencement of production.

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10 CONCRETE COATING REPAIR AND STRIPPING OF CONCRETE COATED PIPES The COMPANY/CONTRACTOR may reject concrete‐coated pipes when any of the previously stated acceptance criteria are not met, and in such case the coating shall be completely removed rather than partially repaired. Where repairs are permitted in accordance with this Specification, they shall be repaired in accordance with this section. Concrete used for repairs shall contain the same proportions of dry constituents as the original coating but the water/cement ratio may be higher, to improve workability. Prior to application of repair material, the defective area shall be thoroughly cleaned by removing concrete coating sufficiently to clean under the reinforcing bars and the concrete edges shall be cut so as to form a holding key. The underlying anti‐corrosion coating shall be examined for damage that may have occurred during concrete removal and tested by holiday detector. Any damaged anti‐corrosion coating shall be repaired and retested before subsequent re‐coating with concrete. All repairs shall be moist‐cured for a minimum period of 48 hours, or until the repaired area has attained a compressive strength of 14 MPa. The SUBCONTRACTOR shall demonstrate that the procedures for repair application and cure will result in an acceptable coating with the compressive strength of repair being at least equal to the strength of the coating. All repair methods shall be subject to the COMPANY/CONTRACTOR's approval. Damaged areas shall be repaired when they are considered defects as defined in 8.16. Areas of damage not exceeding 0.8 m2 in any 3 m length of pipe (restricted to two such areas in any 12 m length of pipe) may be repaired by hand patching, providing that such repairs are carried out while the concrete is in a 'green' state (i.e. within 4 hours of coating application and prior to curing). In the event that the COMPANY/CONTRACTOR wishes to repair areas on cured concrete, a guniting process shall be used and the procedure shall be approved by the COMPANY/CONTRACTOR. Areas where the coating has been damaged during coating application in excess of 0.8 m2 but not more than 25% of the total coating area shall be repaired. All such repairs shall be carried out immediately prior to the pipe being removed from the coating applicator, by reapplication of concrete to the spa lied areas using the application machine used to coat the pipe. Where damage to concrete is in excess of 25% of the total coating area, repairs shall not be allowed. All concrete coating shall be removed and the pipe re‐coated. The SUBCONTRACTOR shall propose, for COMPANY/CONTRACTOR’s approval, a procedure for removing rejected coating. Longitudinal cracks in excess of 250 mm in length shall be repaired as specified below with the addition that the ends of each crack shall be drilled with a hole of 10 mm nominal diameter to prevent crack propagation. The bottom of this hole shall be 7 to 10 mm from the anti‐corrosion coating. Repairs to cracks shall be made by chiselling out the crack to a width of at least 25 mm throughout its length. The prepared area shall be undercut to form an adequate key for the repair material. The repair concrete, which shall have a density equal to that originally applied, shall be trowelled or impinged into the prepared area and smoothed down to the level of the original coating. Prior to repairing, the prepared area shall be inspected for damage to the coating or metal surface. Area Loc. Typ. Disc. No. Rev. 05 SSPL SPC U 0005 0 Page 40 of 50 File

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(CONTRACT NO. CHO/2012/D316/1000) Core holes shall not be refilled without prior inspection. The core holes shall then be handfilled with a stiff mix similar to that used in the coating process. The SUBCONTRACTOR shall propose, for COMPANY/CONTRACTOR's approval, a detailed procedure for inspection and refilling of core holes and inspection areas. The pipes on which the concrete coating has been removed shall be submitted to the visual and holiday inspection prior to re‐application of concrete coating.

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11 PIPE MARKING The items to be marked on the concrete coated pipes shall be defined by COMPANY/CONTRACTOR. Unless otherwise agreed or communicated by COMPANY/CONTRACTOR the pipe marking on concrete coated pipe shall be applied as stated below within this paragraph. Beside the marking required to be applied after application of the 3‐layer PE coating, all concrete coated pipes shall have the following applied on the internal pipe surface of both pipe ends irrespective of the pipe external diameter using the waterproof and weatherproof white stencil: 

pipe number;



pipe length in [m];



mass of concrete coated pipe in [kg].

All concrete coated pipes shall also be colour coded in order to readily identify different categories as follows: 

pipe MANUFACTURER (if more than one MANUFACTURER supplied bare pipe);



pipe nominal external diameter and pipe nominal wall thickness;



concrete coating nominal thickness (if there are more different nominal concrete coating thicknesses).

SUBCONTRACTOR shall apply marine paint colour bands on both pipe ends approximately 300 mm from the end of the concrete coating cutback toward the centre of the pipe. The paint shall be clearly visible on applied concrete coating and shall be suitable for long term storage at the designated final delivery location. The painted bands shall be 100 mm wide and each band shall be applied around entire circumference of the concrete coated pipe. The bands shall be applied immediately after completion of concrete curing. Example for marking of concrete coated pipes: 1st band: pipe MANUFACTURER if more than one pipe MANUFACTURER supplied the pipes for concrete coating in this PROJECT (different colour for each pipe MANUFACTURER); 2nd band: combination of different pipe outside diameter vs. pipe nominal wall thickness (different colour for each different nominal wall thickness); 3rd band: concrete coating nominal thickness (different colour for each different concrete thickness). The legend of colour for each band shall be specified in the SUBCONTRACTOR’s procedure.

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12 STORAGE, HANDLING AND TRANSPORTATION OF CONCRETE COATED PIPES Concrete coated pipes shall be handled, stored and transported in a manner that the pipe steel, anticorrosion coating and concrete coating shall not be damaged. Concrete coated pipes can be handled using slings, lifting hooks padded with soft material with suitable spreader bars, forklifts having lifting forks padded with soft material, front loaders padded with soft material and vacuum lifting. Chains or wire ropes or any other device that may damage the pipe steel or coating shall not be used. When more than one pipe is lifted, separate slings or hooks shall be used for each pipe. Pipes shall be picked up from the stacking point and at no time shall be dragged or rolled. Coated line pipe shall not be subjected to jar or impact and all pipe supports shall be padded. Pipe supports shall be spaced to avoid bending of line pipes. During the curing process, the concrete coated pipes shall be stored in a single row until they reach the compression strength measured on core samples of minimum 14 MPa. Concrete coated pipes may be lifted from the curing area and stacked in more than one layer when the concrete coated pipes reach the compression strength measured on core samples of minimum 14 MPa. However, in case the polyethylene wrapping is used for curing process, the polyethylene wrapping shall not be removed from the concrete coated pipe for minimum seven days after application of concrete coating. The polyethylene wrapping shall be removed from the pipes maximum immediately before the load out from the storage area. The coated line pipes shall always be stacked to avoid surface contact with the ground. The pipes shall be stacked on approved supports which shall be free of any material that could potentially damage the applied coating. The stacking height of concrete coated pipes shall be limited to avoid damage of concrete coating due to the weight of other pipes. The maximum number of stacking layers for concrete coated line pipes shall be calculated by SUBCONTRACTOR and relevant calculation showing calculation steps and results shall be submitted to COMPANY/CONTRACTOR for review and approval considering the allowed compression strength of concrete coated pipes for stacking of 14 MPa (unless SUBCONTRACTOR intends to leave the pipes stacked in a single row for minimum seven days). In case the period when the concrete coating reaches compression strength of 14 MPa tested on core samples was not qualified in front of COMPANY/CONTRACTOR’s representatives during the pre‐qualification test, the pipes shall be stacked in a single layer for minimum seven days. However for safety reasons, the pipes shall not be stacked more than 3 m high even if presented calculation shows that the pipes could be stacked higher than 3 m. The stacks of coated pipes shall be separated for each of the following combinations: 

Pipe MANUFACTURER vs. pipe nominal OD x pipe nominal wall thickness vs. concrete coating nominal thickness.

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(CONTRACT NO. CHO/2012/D316/1000) Concrete coated pipes having anodes shall be stacked separately from the concrete coated pipes without anodes. The pipes shall be stacked at a slight angle to allow drainage of any rainwater. The concrete coated pipes shall not be stacked below and near electrical lines or near any facility which may increase residual magnetism in the pipes (at all times it shall be kept the minimum distance of 30 m between the stored pipes and any electrical cable measured from the vertical projection to the ground of the nearest electrical cable). Depending on the mean of the transport, the transport shall be performed in accordance with the standards API 5L1 and API 5LW. All foreign substances such as excessive dirt, debris of coating materials or any other foreign objects shall be removed from internal pipe surface before stacking and load out.

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13 DOCUMENTATION 13.1 GENERAL REQUIREMENTS All documents and correspondence related to the activities described by this Specification shall be written in English Language. SUBCONTRACTOR may translate relevant work instructions and other documents to any language according to SUBCONTRACTOR’s convenience adapted to the local work force, however, the translation in English language shall be binding. All documents issued by SUBCONTRACTOR to COMPANY/CONTRACTOR shall be prepared in the format approved by COMPANY. 13.2 TECHNICAL DOCUMENTATION TO BE SUBMITTED DURING THE BIDDING PHASE During the Bidding Phase the SUBCONTRACTOR shall submit the following: 

Statement of compliance with technical documents issued by CONTRACTOR to SUBCONTRACTOR during the bidding stage.



List of deviations from technical requirements specified in technical documents issued by SUBCONTRACTOR to COMPANY/CONTRACTOR during the bidding stage. The list of deviations shall contain the following (in case SUBCONTRACTOR presents the list of deviations not mentioning only one of the items listed below, CONTRACTOR reserves the right to consider deviation presented by SUBCONTRACTOR as not valid): - Document number and document revision number and relevant paragraph of the document from which SUBCONTRACTOR intends to deviate; - Quotation of the text within the document from which SUBCONTRACTOR intends to deviate; - SUBCONTRACTOR ’s proposal explaining the reason for deviation and proposed actions; - Quantification of cost impact and of the impact on delivery schedule of coated pipes in case the deviation is not accepted;



Work program and delivery schedule of coated pipes;



SUBCONTRACTOR ’s organisation chart;



Layout of the coating facilities including storage and office areas;



Technical data sheets of the concrete coating materials that SUBCONTRACTOR intends to use in the PROJECT; cement, sand, heavy aggregates (gravel and iron ore), water (certificate for compliance with Appendix A of the BS 3148 standard), reinforcing steel;



Any other document beside above mentioned requested by COMPANY/CONTRACTOR.

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(CONTRACT NO. CHO/2012/D316/1000) 13.3 TECHNICAL DOCUMENTS TO BE SUBMITTED AFTER AWARD OF THE CONTRACT TO SUBCONTRACTOR When the contract for coating of pipes has been awarded by CONTRACTOR to SUBCONTRACTOR, SUBCONTRACTOR shall submit for review/approval the following documents at least six weeks before the commencement of the Pre‐Qualification Test: 

concrete coating application procedure;



calculation for stacking of 3‐layer PE coated pipes (for each combination of pipe diameter × pipe wall thickness) and for stacking of concrete coated pipes (for each combination of pipe diameter × pipe wall thickness × concrete coating thickness);



inspection and test plan for Pre‐Qualification Test;



inspection and test plan for production;



material and safety data sheets of the concrete coating materials;



inspection and test report formats;



3‐layer PE coating repair report format;



concrete coating repair report format;



list of inspection and test equipment and relevant calibration certificates;



daily report format;



any other document beside above mentioned requested by COMPANY.

The Pre‐Qualification Test and production cannot start when the above mentioned documents have not been approved by COMPANY/CONTRACTOR. After performance of the Pre‐Qualification Test, SUBCONTRACTOR COMPANY/CONTRACTOR the Pre‐Qualification Test Report for review/approval.

shall

submit

to

During production, SUBCONTRACTOR shall submit to COMPANY/CONTRACTOR for review, the certificates for each batch of the following materials supplied by the material MANUFACTURER to SUBCONTRACTOR: cement, sand, gravel, iron ore, reinforcing steel and material used for curing of concrete coating. During production, SUBCONTRACTOR shall submit to COMPANY/CONTRACTOR for review/approval the following documentation within 12 hours after the completion of each particular working shift: 

daily report (in electronic format);



inspection and test reports related to the production performed during the shift;



3‐layer PE coating and concrete coating repair reports;



list of pipes on which remedial action has been performed after not conformance has

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occurred and the pipe was quarantined (date of not conformance, pipe number, reason for quarantine and date of successful implementation of the corrective action);



release note related to the pipes intended for load out operation (format shall be agreed between SUBCONTRACTOR and COMPANY/CONTRACTOR).

13.4 FINAL TECHNICAL DOCUMENTATION Final documentation and relevant format shall be agreed between SUBCONTRACTOR and COMPANYandCONTRACTOR. However, the SUBCONTRACTOR shall prepare also the Final Manufacturing Book which shall contain the following: 

table of content of the Final Manufacturing Book;



pipe tracking system in electronic and paper format;



revisions of all of the PROJECT documents related to the SUBCONTRACTOR ’s scope of work issued by COMPANY/CONTRACTOR to SUBCONTRACTOR which have been used during the production;



revisions of all of the documents issued by SUBCONTRACTOR which have been used during the production;



Non‐Conformity Notes/Corrective Action Requests issued by COMPANY/CONTRACTOR to SUBCONTRACTOR (if any);



Non‐Conformity Reports issued by SUBCONTRACTOR (if any);



Minutes of Meeting between COMPANY/CONTRACTOR and SUBCONTRACTOR ;



any communication issued to SUBCONTRACTOR where any concession related to the PROJECT documents has been given to SUBCONTRACTOR ;



technical and safety data sheets of all materials used by SUBCONTRACTOR related to their scope of work;



batch certificates of all materials used by SUBCONTRACTOR during the production;



list of the inspection and testing equipment used by SUBCONTRACTOR during the production;



copies of the inspection and testing equipment calibration certificates;



Pre‐Qualification Test reports;



production inspection and tests reports;



release notes;



any other document issued by SUBCONTRACTOR related to the load out operations.

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(CONTRACT NO. CHO/2012/D316/1000) 13.5 CONTENT OF PARTICULAR TECHNICAL DOCUMENTS 13.5.1 CONCRETE COATING APPLICATION PROCEDURE The SUBCONTRACTOR’s coating application procedure shall contain the following: 

scope of the document;



definitions of various Parties involved in the PROJECT related to the SUBCONTRACTOR’s scope of work and definition of abbreviations used in the document;



list of reference documents related to the SUBCONTRACTOR’s scope of work;



list of materials used for production: cement, sand, gravel, iron ore, reinforcing steel and material for curing of concrete coating including trade names and supplier’s name where applicable (for each material it shall be specified the methods for their storage);



procedure for receipt of 3‐layer PE coated pipes, handling of 3‐layer PE coated pipes within SUBCONTRACTOR’s facilities, their storage and their transport;



description of the concrete coating plant and the list of equipment;



description of the verification of calibration of the concrete coating batching plant;



detail production steps describing the activities on each concrete coating station;



inspections and tests (each single inspection or test shall be inserted in separate section and the following shall be described: the test/inspection name, brief testing procedure when there is no reference international standard, test frequency, testing equipment, acceptance criteria, remedial actions in case the acceptance criteria have not been met);



procedure for handling of concrete coated pipes within SUBCONTRACTOR’s facilities, their storage and their transport;



concrete coated pipes marking procedure;



3‐layer PE coating repair procedure;



concrete coating repair procedure;



procedure for removal of the fresh and hardened concrete coating;



material technical data sheets of the materials used for production (cement, sand, gravel, iron ore, reinforcing steel, certificate for mixing water, material used for curing of concrete coating).



According to his convenience, SUBCONTRACTOR can divide this procedure as separate documents but all above mentioned items must be included in these documents.

Omission to insert into the concrete coating application procedure any technical requirement specified in this specification and in other contractual documents shall not relieve SUBCONTRACTOR from the obligation to fulfil that particular requirement even if this concrete coating application procedure has been approved by COMPANY/CONTRACTOR unless this requirement has been waived by COMPANY through Page 48 of 50

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(CONTRACT NO. CHO/2012/D316/1000) Concession Request or approved by COMPANY as a deviation when the list of deviations has been presented to COMPANY/CONTRACTOR during the bidding phase. 13.5.2 INSPECTION AND TEST PLAN The inspection and test plan shall be issued separately for the Pre‐Qualification Test and for production. The inspection and test plan shall contain the following: 

item number;



activity;



reference to the relevant sections of the documents supplied by COMPANY/CONTRACTOR or



SUBCONTRACTOR ’s documents or international standard applicable to this particular activity;



test frequency;



acceptance criteria;



reference to the inspection and test report number issued by SUBCONTRACTOR for this particular activity;



action codes for SUBCONTRACTOR, CONTRACTOR, COMPANY and any other Third Party appointed by COMPANY/CONTRACTOR if the latest is required.

Omission to insert into the inspection and test plan any technical requirement specified in this Specification and in other contractual documents shall not relieve SUBCONTRACTOR from the obligation to fulfil that particular requirement even if this inspection and test plan has been approved by COMPANY/CONTRACTOR unless this requirement has been waived by COMPANY through Concession Request or approved by COMPANY as a deviation when the list of deviations has been presented to COMPANY/CONTRACTOR during the bidding phase. 13.5.3 DAILY PRODUCTION REPORT Daily production report shall be composed of the following items: 

master sheet (pipe number, nominal pipe external diameter, nominal pipe wall thickness, pipe material, pipe length, mass of bare pipe in kg, type of applied coating, coating date, shift, pipe sequence number, pipe status accepted/quarantined);



material batch number (pipe number, coating date, shift, pipe sequence number, material trade name and material batch number for each coated pipe for primer, adhesive, topcoat and rough coat);



list of quarantined pipes (pipe number and reason for quarantine);



production stops (date, shift, plant stoppage start time, plant stoppage end time, reason);

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external coating repair (classification of damages, pipe number, coating damage class, coating repair date, repair status, remarks);



load out of coated pipes (number, pipe number, nominal pipe external diameter, nominal pipe wall thickness, pipe material, pipe length, pipe mass in kg, type of applied coating, vessel and destination).

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Concrete Weight Coating

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