GDF svez Project No. & Name 81181/Dahej - Vijaipur_ Pipeline Up gradation Project (DVPL-II) Client GAIL(NDIA)Limited Consultant SUEZ Tractebel S.A. Contractor FERNAS CONSTRUCTION COMPANY LTD. Job Procedure for t CONCRETE COATING» | Comments Gea 01 | 05.11.09 | Incorporated for el Yo\y Construction N. kunay 00 | 13.10.09 | Review & Approval Prepared =Mbproved by Rev. | Date Description | by FCCL-QC FCCL-OC HEAD DOCUMENT NO. REV | pa ge 1 of ONCE FCCLIDVPL-IV/81181/ML/JP/30 01 12TRACTEBEL Engineering ope aves & Project No. & Name [81181/Dahej - Vijaipur Pipeline Up gradation Project (DVPL-II) Client GAIL(INDIA)Limited Consultant SUEZ Tractebel S.A. x Contractor FERNAS CONSTRUCTION COMPANY LTD. TABLE OF CONTENTS 1.0 SECTION 1: PURPOSE 3 2.0 3.0 4.0 5.0 6.0 0 SECTION 2: SCOPE SECTION 3: REFERENCES SECTION 4 : RESPONSIBILITIES SECTION 5 : METHODOLOGY SECTION 6 : HEALTH , SAFETY & ENVIRONMENT SECTION 7: ITP /IR n n CONCRETE COATING aENes DOCUMENT NO.TRACTEBEL Engineering Gor sez Project No. & Name 81181/Dahej - Vijaipur_Pipeline Up gradation Project (DVPL-II) Client GATL(INDIA)Limited Consultant SUEZ Tractebel S.A. Contractor FERNAS CONSTRUCTION COMPANY LTD. 1.0 SECTION 1: PURPOSE The purpose of this work instruction is to establish guidelines and requirements to control the concrete weight coating activity to be used in the 48” Dia. Dahej Vijaipur Pipeline Construction 2.0 SECTION 2: SCOPE The scope covers the concrete materials, application, inspection, handling and other activities for external concrete weight coating of pipeline 3.0 SECTION 3: REFERENCES 1. Tender Document. 2. TE Specification no. GTS-70000-740-GTS/0502 PTS-81181/D/21/0264 3. Alignment sheets. (Released for construction) 4. OISD B-141 4.0 SECTION 4: RESPONSIBILITIES Civil Supervisor Shall report to the Spread in-charge/Construction Manager and shall be responsible for * Preparation of concrete coating schedules addressing specific issues and characteristics of each spread * Overall control and safety management and for the implementation of procedure and supervises the activity. © Generation of reports during the activity * Explaining all other persons involved in concrete coating of the detailed operations to be done during the activity QC Engineer Shall reports to spread in-charge/Construction Manager/Project Manager administratively and to HO for technical matters and shall be responsible for + Ensures proper implementation of this procedure * Checks and verifies the activity. r + Verifies and countersigns report zs DOCUMENT NO. FCCLIDVPbal/81181/MLJP/30 A) CONCRETE COATINGTRACTEBEL Engineering Gor see [ Project No. & Name 81181/Dahej - Vijaipur_Pipeline Up gradation Project (DVPL-II) Client GAIL(INDIA)Limited | Consultant SUEZ Tractebel S.A. i Contractor FERNAS CONSTRUCTION COMPANY LTD. | HSE Officers Shall reports to spread in-charge/ Construction Manager administratively and to HO for technical matters and shall be responsible for + Implementation of all safety requirements during survey operations * Ensuring that the communication system is working properly and that emergency equipment is in place 5.0 SECTION 5: METHODOLOGY 5.1 Materials FCCL shall supply all the materials as minimum necessary for the performance of the work. Materials for concrete weight coating shall comply minimum following requirements. * Cement All Portland cement conforming to IS-269 or high strength OPC conforming to IS-8112 shall be used. Copies of test certificates shall be furnished to TE for all cement delivered at site. * Aggregate Fine aggregates, Natural Sand, Crushed Stone Sand, Crushed Gravel Sand shall be well graded from fine to coarse in accordance with table 4 of 1$:383 and shall be tested in accordance with IS 2386. * Coarse Aggregates Use of coarse aggregates shall be subjected to TE approval. Aggregates shall be clean and free from injurious amounts of salt, alkali, deterious substances or organic impurities. Aggregate shall comply with IS 383 and shall be tested in accordance with IS: 2386 * Water The water shall preferably be fresh and shall be free from injurious amounts of oils, acids, alkalies, salts, sugar, organic materials deterious to steel or concrete. It shall not contain chlorides, sulphates and magnesium salts. Water shall be tested prior to use. DOCUMENT NO. REV 4 CONCRETE COATING ——— a Page ¢ofsTRACTEBEL Engineering Gor sez Project No. & Name __| 81181/Dahej - Vijaipur Pipeline Up gradation Project (DVPL-II) Client GAIL(INDIA)Limited Consultant SUEZ Tractebel S.A. Contractor FERNAS CONSTRUCTION COMPANY LTD. 5.2 Reinforcement Concrete coating shall be reinforced by a layer or layers of steel reinforcement according to the provisions here in described. 14 gauge ribbon mesh 1 X 2.5 inches (2 mm thick wire) Manufacturer test certificate shall be submitted for review. Reinforcement shall consist of welded steel wire fabric manufactured in rolls and shall conform to ASTM A -185. Wires shall conform to ASTM A-82. Steel wires shall be galvanized at finished size as per ASTM A-641. The diameter of the wire and spacing of wires (mesh dimensions) shall be selected according to the following criteria Wire fabric manufactured in rolls (ribbon mesh) shall be 1 x 2.5 inches of 14 gauge U.S. Steel wires (2mm wire). The above dimensions will be applied unless otherwise specified by designs. As a rule wire fabric (sheets) shall be used when concrete coating is applied by casting method, while ribbon mesh (rolls) shall be used when concrete coating is applied by impingement method. The source of material once approved by TE shall not be changed. Pipes shall be concrete coated to a minimum thickness of 100 mm as specified in the drawings and documents. The concrete unit weight shall be minimum 2245 Kg ue ee pounds per cubic foot) and the compressive strength shall not be less than 200 Kg/Cm? in 28 days and 135-kg/sq. cm in 7 days. Concrete coating shape shall be circular and concentric to pipe out side diameter. Other concrete shapes are not allowed. FCCL shall be permitted to select any proportion of materials to achieve the specified requirements of concrete density and weight during the procedure qualification test. Procedure Qualification Concrete coating shall be applied using impingement methods. FCCL shall submit the procedure specification (mix design) to TE for review and approval prior to start of qualification work. FCCL shall conduct site procedure qualification and establish it at site in presence of TE. The total thickness of concrete coating should be applied in single pass. Pipes shall be concrete coated to a thickness as specified in the drawings and documents. After concrete has been applied, each pipe shall be weighed in presence of TE/GAIL. Minimum 3 m length of concrete coated pipe mock up test to be carried out for procedure qualification test in presence of TE/GAIL CONCRETE COATING r _DOCUMENT NO. REV | page 5 of FCCL/DVPL-1V81181/ML/JP/30 12Fez TRACTEBEL Engineerit [Project No. & Name [81181/Dahej - Vijaipur Pipeline Up gradation Project (DVPL-I) | Client |GAIL(INDIA)Limited Consultant SUEZ Tractebel S.A. Contractor FERNAS CONSTRUCTION COMPANY LTD. 5.3 The type of mix, to be designed by FCCL and get it approved by TE before siarling work, i.e. the correct combination of the cement, aggregates and water which results in the desired properties of concrete shall be at first determined. For each mix the following shall be checked and recorded. «Proportions and weights of the respective materials used. «The Water/Cement ratio. * The grading of the aggregates. Samples shall be prepared and tested in accordance with ASTM C-642 to determine the dry specific gravity of the concrete. In parallel, test according to ASTM C-138 shall be performed so as to determine the expected correlation between concrete weight after placing and dry specific gravity (28 days placing). Test for concrete specific gravity at intermediate time (7 days after coating) shall be performed. When the results of the above tests do not meet the requirements, the mix shall be modified and concrete samples tested until a proper mix has been determined. The mix so determined shall then be used for sampling of concrete to be submitted to compressive strength tests as per ASTM C-39 Frequency of sampling for tests for density and compressive strength of concrete shall be as follows: “Quantity” of Concrete in the Work M° Number of Samples One sample for every 20 M° of concerting or part thereof for each days concreting (1 Sample consist of minimum 3 test cubes. Up to 25 3 26 to 50 4 51 and above 4 plus one additional. V additional 50 M° or part thereof. “Quantity” means the volume of concrete to be used for each qualified max. Pipes Coating At Yard & Field Joint Coating Two test cubes each per day shall be obtained from batches and tested at the end of 7 days after coating, for compressive strength and specific gravity. The moisture content of the aggregates used shall be such as to maintain a satisfactory control on the Water/Cement ratio of the concrete mix, | CONCRETE COATING DOCUMENT NO. | FCCL/DVPL-I/81181/ML/JP/30TRACTEBEL Engineering & doe ser [ Project No. & Name 81181/Dahej - Vijaipur Pipeline Up gradation Project (DVPL-II) Client | GAILCNDIA)Limited Consultant SUEZ Tractebel S.A. Contractor FERNAS CONSTRUCTION COMPANY LTD. | 54 5.5 5.6 To maintain the Water/Cement ratio constant at its correct volume, determination of moisture contents in both fine and coarse (if used) aggregates shall be made as frequently as possible. Pipe Length Preparation Prior to placing of reinforcement, the protective coating of each pipe length shalll be inspected visually and by holiday detectors and, if damages are found, they shall be repaired as per approved procedure before concerting. Foreign matters, if any, shall be removed from the surface of the protective coating. Reinforcement Application Reinforcement shall be placed around the pipe in such a way so as to cover the whole pipe length or sections to be concrete coated. Reinforcement shall rest on spacers synthetic resin/ concrete forming a” Crown” whose number shall be such as to avoid any contact with the pipe’s protective coating. Spacing between the two consecutive “Crown” centers shall be 500 to 1000mm. Splices and attachments shall be done by binding with steel wire having 1.5mm diameter. Circular and longitudinal joints of wire fabrics in sheets shall be lapped atleast for one mesh. When wire fabric in rolls (ribbon mesh) is used, the spiral lap shall be one mesh while the spliced lap shall be three meshes One layer of reinforcement steel shall be provided for concrete thickness less than 50 mm. The reinforcing steel shall be embedded approximately midway in the concrete coating thickness. For concrete thickness 50 mm and above two layer of reinforcing steel shall be provided. Concrete Placing Concrete shall be placed within 30 minutes from the time of mixing (adding water to mix) and shall be handled in such a way so as to prevent aggregate segregation and excessive moisture loss. Concrete container shall be kept clean and free from hardened or partially hardened concrete. Impingement method will be used for concreting and placement of concrete shall be upto the specific thickness in one continues course, allowance being made for splices of reinforcement and providing reinforcement in the right location CONCRETE COATING DOCUMENT NO. V81181/MLIJP/30 Page 7 of 12TRACTEBEL Engineering & cor scan [ Project No. & Name 81181/Dahej - Vijaipur_Pipeline Up gradation Project (DVPL-I)_ | | Client GAIL(INDIA)Limited _| Consultant SUEZ Tractebel S.A. | Contractor TFERNAS CONSTRUCTION COMPANY LTD. | 5.7 Before placing fresh concrete against the joint, the contact surfaces shall be carefully cleaned and wetted to obtain a good bond between the fresh material and the previously placed material. Suitable means shall be provided to ensure that the temperature of the concrete, when placed does not exceed 32° centigrade. Bevel protectors shall be kept in place throughout the coating application and thereafter. The citing at each end of the pipe shall be beveled to a slope of approximately 2: 1 which shall terminate about 50 mm short of the end of the corrosion coating applied on the pipe surface. All pipes shall be kept clean and free from cement, concrete and grout, either inside or outside of the uncoated section. Curing Immediately after conereting, the exposed surface of the concrete shall be protected during hardening from sunshine, drying winds, rain etc. and then initial set has taken place, the concrete coating shall be properly cured. The coated pipe shall be handled gently by suitable means to prevent undue distortion. Curing shall be performed by application of an approved curing membrane using sealing compounds and shall meet the requirement of ASTM C-309. This shall be stored, prepared and applied in conformity with the instruction of Manufacturer. The ingredients of any such compound shall be non-toxic and non-inflammable and shall not react with any ingredient of the concrete, the reinforcement, the protective coating or pipe. The application of the curing compound shall take place immediately after the coating is completed. The surface of the concrete shall be lightly sprayed with water before applying the curing compound. The membrane-curing period shall not be less than 4 days, during which period the freshly coated pipes shall not be disturbed. The pipe surface shall be kept wet during daylight hours for seven days after application of the concrete coating. The concrete coating shall not be allowed to dehydrate. Before handling and hauling the concrete coated pipes, a check shall be made to make sure that the concrete coating is properly cured. Stacking and shipment of the coated pipes shall be initiated only after seven days provided that the concrete coating suffers no damage. CONCRETE COATING DOCUMENT NO. REV = Page 8 of FCCL/DVPL-IV81181/ML/JP/30 12TRACTEBEL Engineering Gor aves Project No. & Name 81181/Dahej - Vijaipur Pipeline Up gradation Project (DVPL-II) Client GAIL(NDIA)Limited Consultant SUEZ Tractebel S.A. ra Contractor FERNAS CONSTRUCTION COMPANY LTD. 5.8 Tolerances FCCL shall maintain a surface tolerance of 8 mm (5/16") maximum for the radial distance between high and low areas of the surface. The diameter of each coated pipe shall be obtained at three (3) or more points, spaced at equal intervals between the end points. The acceptable weight tolerance for any single pipe shall be limited to plus five (5) or minus two (2) percent of the calculated theoretical weight. The theoretical weight shall be calculated using total weight of the pipe with concrete and corrosion coating. 5.9 Weighing The test specimen shall be selected at equal interval during the course of production. FCCL shall weigh each pipe by weighing bridge on trailers. When dry prior to shipment and 28 days after placing of concrete and mark the weight with paint on the inside of the pipe. The weight marked shall be followed with letter DW meaning dry weight or FCCL shall apply 20% additional concrete coating thickness to avoid weighing of each pipe at Weigh Bridge. Weight of additional 20% concrete coating to be verified during qualification test only. 5.10 Inspection and Tests After curing, every length of concrete coated pipe shall be tested by means such as “ringing” to determine if any suspected defects are present. In case this indicates faulty coating, cores shall be removed from coating and inspected. When defective coating appears from cores, the concrete coating shall be removed from the pipe lengths Every length of concrete coated pipe shall be checked to verify insulation between steel reinforcement and pipe by means of a megger or equivalent device. To this purpose provisions should be made during placing of concrete such as to leave atleast a point of exposed steel reinforcement whenever the latter shall terminate inside of concrete coating, During the tests as above and before transporting of concrete coated pipes, every pipe length shall be visually inspected to detect whether any damages and/or defects are present. Repairable concrete coating shall be clearly marked while the non-repairable ones shall be removed from the pipe length r CONCRETE COATING DOCUMENT NO. FCCL/DVPL-II/81181/ML/JP/30TRACTEBEL Engineering ore Project No. & Name 81181/Dahej - Vijaipur Pipeline Up gradation Project (DVPL-II) GAILONDIA)Limited Consultant SUEZ Tractebel SA. Contractor FERNAS CONSTRUCTION COMPANY LTD. 5.11 The Coating of Field Welds FCCL shall coat the uncoated pipe surface at field weld joint, concrete coating at site by manual mix with shuttering around the pipe to be coated. The reinforcement for the field welds shall be same as that for line pipe coating with the same number of layers and the same spaces between layers. The edges of this netting shall be carefully secured with wire to the reinforcement extending from the existing coating. The composition of the concrete shall be the same as that of the concrete coating of the pipe. When using moulds, FCCL shalll prevent air being trapped by applying mechanical vibrators or by striking outside of the moulds with sticks. If the moulds remain around the pipe, e.g. in the case of submerged pipes floated into position, FCCL shall take appropriate measures to prevent water entering the mould by continuous dewatering. This can be achieved by clamping strips of burlap between the ends of the mould and the existing concrete coating. After the mould has been filled with concrete clamping a strip to burlap under the sealing cover must close off the filling opening. 5.12 Repairs The following are repairs that will be permitted to coating due to unavoidable damage in handling and in storage are Spalling due to compression or shearing caused by impact against other objects. Spalling is defined as damage, which causes a loss in concrete of more than 25 percent of the total thickness of the coating at the point of damage. Damage due to spalling of an area of less than 0.1 m? (1 square foot) where the remaining concrete is sound will be accepted without repairs.Damage due to spalling of an area of more than 0.1 m**"! less than 0.3 m? shall have the concrete remaining in place over that area removed as necessary to expose the reinforcing steel throughout the damaged area. Edges of the spelled area shall be under cut so as to provide a key lock for the repair material. A stiff mixture of cement, water and aggregate shall be throttled into a through the reinforcement and built-up until the surface is level with coating around the repair. The pipe shall then be carefully laid with the repaired area at the top and shall be moist cured for thirty-six (36) hours before further handling Reinforcement, forming of materials similar to that from which the coating was made. The mixture shall be one (1) part of cement to three (3) parts of aggregate and the necessary water to produce a slump not to exceed 100 mm (four inches). The resulting coating shall be equal in weight, density, uniformity, thickness, strength and characteristics to the originally applied coating. The pipe shall then be carefully laid in a position where it shall be allowed to remain for a minimum of 36 hours before further handling. DOCUMENT NO. [REV ] page 10 of FCCUDVPL-IV/81181/ML/JP/30 [concn COATINGProjectNo.&Name ___| 81181/Dahej - Vijaipur_ Pipeline Up gradation Project (DVPL-ID) | Client GAIL(INDIA)Limited Consultant SUEZ Tractebel S.A. Contractor FERNAS CONSTRUCTION COMPANY LTD. 5.13 Marking 5.14 After pipe has been coated, the pipe number shall be individually written on the outside surface, near the end of each joint of coated pipe. All other pipe data, keyed to the pipe number, shall be entered on a tally sheet. The tar weight shall also be written on the pipe. Whenever a purchase order consists of more than one combination of pipe wall thickness, material grade, or concrete coating thickness for pipe of a given diameter, pipe shall be marked with a colored band that uniquely identifies each combination of these three items. Color band shall be at least 5 cm (2 inches) wide and shall be painted around the circumference at one end of each joint of pipe. For each concrete coated pipe length, at one of the two ends, the field identification number and the date of concrete placing while dry as well as the weight as well as the number of days. after coating shall be marked at other end. Unloading, Transportation, Storing and Hauling During loading, transportation, unloading and hauling of inert aggregates, any contact and mixing with mud, earth, grease and any other foreign material shall be carefully avoided. Precaution shall be taken to prevent contamination and climatological condition During unloading, loading and stock-piling the pipe shall be handled in such a way to avoid the damages to the concrete coating especially at the bevel ends concrete coating. Stacks shall be limited to number of layers such that the pressures exercised by the pipes own weight shall not damage the coating. Cube test records shall be maintained by testing the same as approved laboratory. 60. SECTION 6: HEALTH, SAFETY & ENVIRONMENT 1. Machine operator involved shall be an experienced person. ______ DOCUMENT NO. REV | pa f K | Ne ge 11 of CONES ee. | FCCUDVPL-I/81181/ML/JP/30 12TRACTEBEL Engineering Gor sves Project No. & Name 81181/Dahej - Vijaipur_Pipeline Up gradation Project (DVPL-ID) Client GAIL(NDIA)Limited Consultant SUEZ Tractebel S.A. Contractor FERNAS CONSTRUCTION COMPANY LTD. 2. Itis to be noted that the special care fo be adopted against snake / insects bite. 3. PPE shall be used in this activity. 4. Only trained rigging personnel to be deployed for this activity. 5. Personnel around the machine (if any) should be cautious about overhead falling objects. 6. During the movement of earth moving equipment the operator should blow horn to caution the people around 7. All Measuring & Test Equipment used shall be well maintained. 8. Allliffing devices & Tolls used shall be well maintained. 7.0 SECTION 7: ITP/IR Appendix 1 itp FCCLLIDVPL-IV81181/ML/TP/30 Appendix 2 IR FCCLUDVPL-II/81181/ML/IR/30/F 1 Appendix IR FCCLUDVPL-IV81181/ML/R/Z0/F2 Appendix Note - Th ease Sk any conflict between the wequirenest of this procedure RTE Spec. the, beter shall govern, DOCUMENT NO. FCCL/DVPL-IN/81181/ML/JP/30 CONCRETE COATINGG=> FERNAS CONSTRUCTION COMPANY LTD. TRACTEBEL Enginesing INSPECTION AND TEST PLAN FOR CONCRETE COATING ae aer me aiid syrcc. | sy Te | submitted by FOCL oo —— aa 3. [Calibration of holiday detector w = Wwe1184/MU30 3 eae i baal wette1mU/s0 9 [Cube testing w w 18118 1/MU30 10 |Inspection of coating = w 181481/MU30_ 11. [Repair of defects. w eM 1W81481/NLI30_ 42 |Meggering test w ” 8148130 13. 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