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 Site Project Quality Document
INSPECTION AND TEST PLAN - CONCRETE WEIGHT COATING
BREDERO SHAW INTERNATIONAL B.V, RAK
Customer Project PO Number
TechnipFMC AQAM Development EPCI 077607C004-230-PO-5530-012-7010
C: Record & Raise Documents H: Hold Point N: Non-Destructive Testing V: Visual 1: 100%
Legend D: Dimensional Inspection I: Random Inspection R/A: Review/APPROVAL W: Witness 2: 10%
E: Examine/Endorse Documents M: Monitor T: Destructive Testing WFO: Witness First Off S: Surveillance
Approval Inspection
DP-PL-
BSIBV Production Test
No. Activity Description 17 Rev. Method / Acceptance Criteria Verifying doc
QP 08-2 Frequency BSIBV TP FMC DPE / TPI
10

Cement shall conform to ASTM C-150 type II Moderate sulphate

resistance cement with C3A content less than 8% by weight and the
4.1 / alkali content shall be less than 0.6%.
1 Cement 2.3.2 RF 033 Every Delivery H W1 R
7.2.2
Certificate of conformance from manufacturer to be checked for
every Delivery.

The Aggregate Gradation shall be in accordance with BSIBV-QP 08

and ASTM C 33.
Aggregate (Washed Sand -
4.2 / QF 08-9 /
2 light aggregate: Slag & Iron 2.3.1 Certificate of conformance from manufacturer to be checked for Every 3 Days H R R
7.2.3 RF 033
Ore - heavy aggregate) every Delivery.

Note: The large Iron Ore particle shall not be more than 9.5 mm.

Water used in the mix shall be potable and shall comply with the
requirements of BS EN 1008. The mixing water shall be clean and
free from injurious amounts of acid, alcohol, alkali, oil, salt or any
organic material. Water shall be suitable for use in concrete. Salt QF 08-7 /
4.3 /
3 Water 2.3.4 water or brackish water shall not be used. Water that is potable RF 033 / QF First day of production H R R
7.2.4
does not require testing for compliance. 01-3

Note: Independent laboratory test certificate shall be submitted to

Customer prior to commencement of project.

Reinforcement wire shall be galvanized and crimped welded wire

mesh, conforming to ASTM A 810, or conforming to all three
following standards; ASTM A82, ASTM A185 and ASTM A 641. The
reinforcement shall be 25.4mm x 67.0mm or shall be equal to or
4 Reinforcement Wire 4.5 2.3.3 RF 033 Every Delivery H R R
greater steel- to- concrete ratio in both transverse and longitudinal
direction.

Certificate of conformance from manufacturer shall be obtained.

Doc. No.: BSIBV-ITP-08-2, Rev. 0 Page 2 of 9

Revision Date: 08-Oct-18
 Site Project Quality Document
INSPECTION AND TEST PLAN - CONCRETE WEIGHT COATING
BREDERO SHAW INTERNATIONAL B.V, RAK
Customer Project PO Number
TechnipFMC AQAM Development EPCI 077607C004-230-PO-5530-012-7010
C: Record & Raise Documents H: Hold Point N: Non-Destructive Testing V: Visual 1: 100%
Legend D: Dimensional Inspection I: Random Inspection R/A: Review/APPROVAL W: Witness 2: 10%
E: Examine/Endorse Documents M: Monitor T: Destructive Testing WFO: Witness First Off S: Surveillance
Approval Inspection
DP-PL-
BSIBV Production Test
No. Activity Description 17 Rev. Method / Acceptance Criteria Verifying doc
QP 08-2 Frequency BSIBV TP FMC DPE / TPI
10

All the concrete mixing materials such as cement, aggregate, and

water shall be stored in accordance with Manufacturer
5 Storage of Raw Materials 2.1 RF 033 Every Delivery H M M
recommendations (if any). The Reinforcement Wire shall also be
stored in accordance with Manufacturer recommendation.
See below plant calibration for % tolerance for mix design for each
component. Fresh concrete analysis to be compared with theoretical
design. The water/cement ratio shall be maximum 0.45.
Plant calibration once
Concrete Mix Analysis & 4.4 / 5.2 / QF 08-7 / CF per week /
6 2.6 H W1 R
Water/Cement Ratio 7.2.5 040 water/cement ratio in
every shift

All anticorrosion coated pipes shall be free from contamination and

Visual Inspection & Holiday defects. The anticorrosion coated pipes shall be visually inspected
7 7.1.4 2.4 QF 001 All Pipes H W1 R
Detection and holiday detected prior to Concrete coating. 100% of the coated
pipe surface shall be holiday detected at a voltage of 25 kV.

All coating defects disclosed by visual or holiday detector, any

Damages on the 3LPE / QF 01-3 / QF
8 7.1.4 2.4 damages shall be repaired in accordance with the specific Quality If required H W1 R
3LPP coating 07-9
Procedure / ITP of Anti-corrosion coating (3LPE/3LPP).

Confirm pipe number and length is still visible. The pipe number
9 Verify Pipe Identity 2.4 QF 001 All Pipes H W1 R
shall be entered to tally track system.

The concrete coating thickness shall be as per scope of project.

• ≤ 50 mm concrete coating thickness - 1 wire mesh reinforcement
Reinforcement wire 4.4 / wrap shall be used.
10 2.7 QF 08-3 All Pipes H W1 R
Number of layers 5.3.1
Reinforcement shall terminate between 15 mm to 30 mm from each
end of the concrete coating on the pipe.

Doc. No.: BSIBV-ITP-08-2, Rev. 0 Page 3 of 9

Revision Date: 08-Oct-18
 Site Project Quality Document
INSPECTION AND TEST PLAN - CONCRETE WEIGHT COATING
BREDERO SHAW INTERNATIONAL B.V, RAK
Customer Project PO Number
TechnipFMC AQAM Development EPCI 077607C004-230-PO-5530-012-7010
C: Record & Raise Documents H: Hold Point N: Non-Destructive Testing V: Visual 1: 100%
Legend D: Dimensional Inspection I: Random Inspection R/A: Review/APPROVAL W: Witness 2: 10%
E: Examine/Endorse Documents M: Monitor T: Destructive Testing WFO: Witness First Off S: Surveillance
Approval Inspection
DP-PL-
BSIBV Production Test
No. Activity Description 17 Rev. Method / Acceptance Criteria Verifying doc
QP 08-2 Frequency BSIBV TP FMC DPE / TPI
10

The anode installed area shall be protected during concrete coating

application. A 30 mm to 50 mm gap between anode and concrete
reinforcing steel shall be maintained by washing after concrete
coating application.
All Anode Installed
11 Anode Installation pipes 5.3.2 2.5 / 2.7 Anode Retrofit Process pipes: QP / ITP 04-1 H M M
Pipes
If the anodes are to be installed after concrete coating process, the
concrete application process shall be prevented on approximate
middle of pipe by using steel plate. The anode installation area will
be covered with polythene sheet to avoid contact of concrete
materials on pipe surface.

The reinforcement wire shall be applied spirally to obtain a minimum

Reinforcement Wire of 25 mm overlap between spirals. Minimum of 10 mm cover, and
12 5.3.1 2.7 QF 08-3 Twice per shift H W1 R
(Overlap) the wire placement shall be approximately centre of the concrete
coating.

The Concrete coating thickness shall be 50 mm.

The diameter measurements of the coating shall satisfy the

following two requirements:
QF 08-1
Concrete Thickness 7.1.6 / The radial distance between any high and low areas of the surface
13 3 (Computer All Pipes H W1 R
Measurements 7.3.1 in any 0.5 m lengths of coating shall not exceed 8 mm and 5 mm in
Database)
the last 1 m length at each end.

The diameter of each coated line pipe shall be obtained at five (5) or
more points, spaced at approximately equal intervals with the
distance between the end points at least 80% of the coated length.

QF 08-1
Concrete Thickness The tolerance on the concrete coating thickness shall be ±10% of
14 7.3.1 3 (Computer All Pipes H W1 R
Tolerances the nominal concrete thickness.
Database)

Doc. No.: BSIBV-ITP-08-2, Rev. 0 Page 4 of 9

Revision Date: 08-Oct-18
 Site Project Quality Document
INSPECTION AND TEST PLAN - CONCRETE WEIGHT COATING
BREDERO SHAW INTERNATIONAL B.V, RAK
Customer Project PO Number
TechnipFMC AQAM Development EPCI 077607C004-230-PO-5530-012-7010
C: Record & Raise Documents H: Hold Point N: Non-Destructive Testing V: Visual 1: 100%
Legend D: Dimensional Inspection I: Random Inspection R/A: Review/APPROVAL W: Witness 2: 10%
E: Examine/Endorse Documents M: Monitor T: Destructive Testing WFO: Witness First Off S: Surveillance
Approval Inspection
DP-PL-
BSIBV Production Test
No. Activity Description 17 Rev. Method / Acceptance Criteria Verifying doc
QP 08-2 Frequency BSIBV TP FMC DPE / TPI
10

The fully saturated submerged weight of each coated line pipe shall QF 08-1
15 Concrete Weight Tolerance 7.3.2 3.8 be that stated with a tolerance of ±10 kg/m on any one pipe and a (Computer All Pipes H R R
tolerance of ±10% on each day's production of line pipe. Database)

The Density of Concrete Coating shall be tested in accordance

BSIBV Test Method TM 23. As applied concrete density shall be
minimum 190 pcf or 3044 Kg/m³. The tolerance for concrete coating
QF 08-8 / QF Once per shift and after
16 Density of Concrete 3 / 7.2.7 3.4 density shall be +/-5% of the specified value. H W1 R
08-12 mix changes
A 6"X 6" concrete coating sample shall be cut from the pipe in order
to perform the tests.

An electrical resistance check shall be made between the pipe and

the inner reinforcement and anode using an ohm meter or light and
Reinforcement Electrical bulb method. The resistance shall be at least 1000 Ohms on coated QF 08-4 /
17 7.1.5 3.9 Two pipes per day H W1 R
Resistance Check pipes. The resistance test shall be carried after 4 days of coating. In QF 08-2
the event of a failure, the pipe shall have the concrete removed and
recoated.

The internal surface of the pipe shall be clean and there shall be no
18 Concrete Cut Back 5.4 2.7 visual damage to the concrete coating. The Cut back shall be 240 QF 08-4 All Pipes H W1 R
mm - 0 / +10mm, this is from the bevel end of the each pipe ends.

Freshly coated pipes shall be placed in the curing area and covered
19 Fog Cure 5.5.4 2.7 by tarpaulins. Identify each bay, record curing start time and % QF 08-5 All Bays H M R
humidity.

Verification of Anode The thickness of anode shall be verified with concrete coating
All Anode Installed
20 Thickness with Concrete 5.3.2 2.5 thickness visually. Anode shall not be protruded above Concrete - H W1 R
Pipes
Coating Thickness Coating.

5.5.1 / Initial compressive strength of the cube shall be 16 MPa after 24 Once at first day of
21 Initial Compressive Strength 3.6 QF 08-10 H W1 R
7.2.6 hours. production

Doc. No.: BSIBV-ITP-08-2, Rev. 0 Page 5 of 9

Revision Date: 08-Oct-18
 Site Project Quality Document
INSPECTION AND TEST PLAN - CONCRETE WEIGHT COATING
BREDERO SHAW INTERNATIONAL B.V, RAK
Customer Project PO Number
TechnipFMC AQAM Development EPCI 077607C004-230-PO-5530-012-7010
C: Record & Raise Documents H: Hold Point N: Non-Destructive Testing V: Visual 1: 100%
Legend D: Dimensional Inspection I: Random Inspection R/A: Review/APPROVAL W: Witness 2: 10%
E: Examine/Endorse Documents M: Monitor T: Destructive Testing WFO: Witness First Off S: Surveillance
Approval Inspection
DP-PL-
BSIBV Production Test
No. Activity Description 17 Rev. Method / Acceptance Criteria Verifying doc
QP 08-2 Frequency BSIBV TP FMC DPE / TPI
10

A set of 4 cubes shall be prepared and used as following:

2 cubes for 7 days (100mm x 100mm Cube).
2 cubes for 28 days (100mm x 100mm Cube).

Minimum compressive strength shall be minimum 37 MPa after 7 4 cubes for each sample
days. taken at every 4 hours
Compressive Strength on
22 7.2.6 3.6 QF 08-10 or at mix change or after H W1 R
Cubes
Minimum compressive strength shall be minimum 50 MPa after 28 all shutdown periods (7
days. & 28 Days)

The test shall be conducted from BSIBV laboratory using a

calibrated compression machine at 7 and 28 days. Sampling,
storing and testing of cubes shall be in accordance with BS1881.

One core shall be tested at 7 days and the other at 28 days. The
cores shall have a minimum compressive strength of not less than
30 MPa after 7 days and 40 MPa after 28 days.
Compressive Strength on 3 core samples per 15
23 7.2.6 3.6 QF 08-10 H W1 R
Cores The minimum diameter of the core shall be at least 35mm. A single line pipes coated
core diameter shall be used throughout the coating operation. Three
cores shall be taken, one at each end within 1-2m from pipe end
and one at middle 2 m

6"X 6" Coupon shall have a minimum of 4 days cure prior to testing.
The maximum water absorption shall not be greater than 5% by
weight. Once per 24 Hrs (day) Pipe full-scale water absorption test Once per shift and after
24 Concrete Water Absorption 7.2.8 3.5 QF 08-8 H W1 R
shall be carried out at start of production in accordance with BSIBV mix changes
test method TM -27. Pre-qualification test or first day’s one
production pipe shall be performed full-scale Water Absorption test.

Doc. No.: BSIBV-ITP-08-2, Rev. 0 Page 6 of 9

Revision Date: 08-Oct-18
 Site Project Quality Document
INSPECTION AND TEST PLAN - CONCRETE WEIGHT COATING
BREDERO SHAW INTERNATIONAL B.V, RAK
Customer Project PO Number
TechnipFMC AQAM Development EPCI 077607C004-230-PO-5530-012-7010
C: Record & Raise Documents H: Hold Point N: Non-Destructive Testing V: Visual 1: 100%
Legend D: Dimensional Inspection I: Random Inspection R/A: Review/APPROVAL W: Witness 2: 10%
E: Examine/Endorse Documents M: Monitor T: Destructive Testing WFO: Witness First Off S: Surveillance
Approval Inspection
DP-PL-
BSIBV Production Test
No. Activity Description 17 Rev. Method / Acceptance Criteria Verifying doc
QP 08-2 Frequency BSIBV TP FMC DPE / TPI
10

Internal surface and cut back area clean, no damage to concrete

25 Visual Inspection 7.1.8 3.1 QF 08-4 All Pipes H W1 R
coating.

The temperature anti-corrosion coated pipe prior to coating,

temperature of concrete mix and ambient temperature shall be
26 Environment Checks 2.7 QF 01-3 Two times in a shift H W1 R
recorded morning, afternoon and end of shift for information
purpose.

Colour bands shall be applied as given in the scope of work and

attached in Appendix 2 of BSIBV QP 08-2, Quality Procedure for
27 Colour Band 2.8 - All Pipes H M M
Concrete Weight Coating. The colour band size shall be 50 mm
wide.

Spalling due to compression or shearing caused by impact against

other objects which causes a loss of not more than 25% of the total
thickness of the coating shall be repaired. An area of less than 0.09
m² per line pipe where the concrete remaining on the line pipe is
sound will be accepted without repairs.
Repairs to spalling damage shall be performed by the following
procedures:

concrete.
28 Repairs - Spalling 7.4.2 2.9 QF 08-6 All repairs H M/R M/R
around the entire pipe circumference throughout the length of
damaged area.

point of coating damage for a minimum of two hours.

steel until the surface is level with the coating around the repair.

Doc. No.: BSIBV-ITP-08-2, Rev. 0 Page 7 of 9

Revision Date: 08-Oct-18
 Site Project Quality Document
INSPECTION AND TEST PLAN - CONCRETE WEIGHT COATING
BREDERO SHAW INTERNATIONAL B.V, RAK
Customer Project PO Number
TechnipFMC AQAM Development EPCI 077607C004-230-PO-5530-012-7010
C: Record & Raise Documents H: Hold Point N: Non-Destructive Testing V: Visual 1: 100%
Legend D: Dimensional Inspection I: Random Inspection R/A: Review/APPROVAL W: Witness 2: 10%
E: Examine/Endorse Documents M: Monitor T: Destructive Testing WFO: Witness First Off S: Surveillance
Approval Inspection
DP-PL-
BSIBV Production Test
No. Activity Description 17 Rev. Method / Acceptance Criteria Verifying doc
QP 08-2 Frequency BSIBV TP FMC DPE / TPI
10

Crack repair is required in following conditions:

180° circumferentially around the line pipe.

irrespective of width.

Crack repair shall be as per below procedure:

29 Repairs - Cracks 7.4.3 2.9 QF 08-6 All repairs H M/R M/R
the length of the crack, without damaging the reinforcement steel

The repaired area shall be kept moist and allowed to remain

undisturbed for a period of not less than 36 hours.

Repairs to cured concrete will be carried out by gunniting process

30 Repairs to cured concrete 7.4 2.9 after 12 hours of fog curing. Curing of cured concrete repairs shall QF 08-6 If required H M/R M/R
be a minimum of 36 Hours.

Core holes shall be manually repaired using stiff mix similar to the
31 Repairs to core holes 7.4 2.9 mix used in the coating process; Cosmetic repair shall be carried QF 08-6 All repairs H M M
out in the field after curing.

Twice per Shift

Weigh bridge shall be calibrated using certified weight with a
32 Weigh Bridge Calibration 7.3.2 2.2 CF 041 (Beginning & End of H W1 R
maximum tolerance of +/-1%.
Shift)

Doc. No.: BSIBV-ITP-08-2, Rev. 0 Page 8 of 9

Revision Date: 08-Oct-18
 Site Project Quality Document
INSPECTION AND TEST PLAN - CONCRETE WEIGHT COATING
BREDERO SHAW INTERNATIONAL B.V, RAK
Customer Project PO Number
TechnipFMC AQAM Development EPCI 077607C004-230-PO-5530-012-7010
C: Record & Raise Documents H: Hold Point N: Non-Destructive Testing V: Visual 1: 100%
Legend D: Dimensional Inspection I: Random Inspection R/A: Review/APPROVAL W: Witness 2: 10%
E: Examine/Endorse Documents M: Monitor T: Destructive Testing WFO: Witness First Off S: Surveillance
Approval Inspection
DP-PL-
BSIBV Production Test
No. Activity Description 17 Rev. Method / Acceptance Criteria Verifying doc
QP 08-2 Frequency BSIBV TP FMC DPE / TPI
10

Calibrate each component of mix. (Mix Design shall be made

according to the calibration and it will be recorded).
4.4 / 5.2 /
33 Concrete Plant Calibration 2.2 Tolerance :3% For each aggregate (heavy Aggregate or light) type. CF 040 Once per Week H W1 R
7.2.5

Tolerance : 1% for cement.

3.13 /
Inspection release notes shall be submitted to BSIBV from TPI,
34 Weekly Release Appendix QF 032 (IRN) Once per week H H H
when all QC Documents are approved.
2

Final documentation shall be submitted to TPI by BSIBV once all the

Appendix QF 032 (IRN)
35 Final Documentation testing completed. The final documentation shall be prepared in Completion of project H H H
2 / MRB
accordance with approved MRB Index.

Appendix The pipe identification shall be checked against the packing list prior
36 Packing List Verification TF 014 All pipes H H H
2 to load out.

Doc. No.: BSIBV-ITP-08-2, Rev. 0 Page 9 of 9

Revision Date: 08-Oct-18