BRAHMAPUTRA PETROCHEMICAL COMPLEX PROJECT

CONTRACT NO.: 6907/T-006/09-10/SPL/36

WORK PROCEDURE

FOR

CONCRETE COATING FOR 18” DIA TWIN PIPE

DOCUMENT NO. : GIL /BCPL/ CO/WP/18

CLIENT : BRAHMAPUTRA CRACKER & POLYMER LIMITED.

EIC : ENGINEERS INDIA LIMITED.

CONTRACTOR : GAMMON INDIA LTD.

GAMMON INDIA LTD. EIL EIL

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY
SIGNATURE

NAME S Ash R.B.Tripathi

DATE 23.02.2010 23.02.2010

1.0 PURPOSE
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 To execute concrete weight coating (Gunniting) of pipeline for anti-buoyancy
measures.

2.0 REFERENCE

2.1 BCPL Doc No. 6-71-00 46 REV.03

2.2 ASTM A-185: Welded steel wire fabric for concrete reinforcement
2.3 ASTM A-82: Specification for steel wire, plain, for concrete
reinforcement
2.4 All material be conform to respective IS codes.
2.5 IS 383/2386-part 1 to part 8
2.6 IS 269-Ordinary port land cement
3.0 EQUIPMENT

3.1 Compressor
3.2 Mixer
3.3 Water pumps
3.4 Concrete coating equipment

4.0 CEMENT

Ordinary Portland Cement (Conforming IS: 269) which has hardened or partially
set or which has become lumpy shall not be used be used.

5.0 AGGREGATE

Fine aggregates used shall be graded from coarse aggregates, according to IS 383.
Stone aggregate shall be 10mm down size and shall be tested in accordance with
IS: 2386. Aggregates shall be free from injurious amounts of salt, alkali etc.

6.0 SAND

Sand shall comply with the requirement given in Table 4 of IS 383.

Coarse aggregates shall be clean and free from clay and injurious amount of salt,
alkali, deleterious substances or organic impurities.

7.0 WATER

Water used for mixing and curing of concrete shall be portable limpid, fresh and
clean and shall free from injurious amounts of chlorides, sulphates,magnesium
salts and other substances that may be deleterious to concrete and steel.

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8.0 REINFORCEMENT

Concrete coating of min. thickness 65-70 will be reinforced by layer or layer of

steel reinforce according to the provision herein after described. Reinforce will be
consist of welded steel wire fabric manufactured in flat steel or in roll (Ribbon
Mesh) and will be confirmed ASTM A-185 and steel wire conforming to ASTM
A-82 shall be used. Steel wire will be galvanized at finished size as per ASTM A
64.Wire fabric in rolls (ribbon mesh) shall be of 1” x 2.5” mesh size of 14 gauge
(US) steel wire (2mm).The above dimensions will be applied unless other wise
specified by designs. As a rule wire fabric (sheet) shall used when concrete
coating is applied by casting method, while ribbon mesh (roll) will be used when
concrete coating is applied by impingement method. Welded steel wire fabric
manufactures in rolls and shall confirm ASTM A-185 and steel wire conforming
to ASTM A-82 shall be used. Wire fabric in rolls (ribbon mesh) shall be of 1” x
2.5” mesh size of 14 gauge (US) steel wire (2mm).

9.0 COATING REQUIREMENT

The concrete unit weight shall be minimum 2245 Kg/m3 and with cube
compressive strength not less than 200Kg/cm2 in 28 days and
135Kg/cm2 in 7 days.

10.0 PROCEDURE

Concrete coating shall be done with impingement method. Prior to placing of the
reinforcement, protective coating of each pipe length shall be carefully inspected
for damage. All damage shall be repaired before the placing of the concrete.

The pipe shall be placed on the supports located at the ends of the pipe. The pipe
ends shall be braced with internal struts or rings to prevent undue ovalisation of
the pipe during concrete coating and handling. If required, temporary supports
shall be provided in between the end supports during concrete coatings. The
welded steel wire mesh shall be placed over the surface of pipe by providing the
PVC or Neoprene spacers. Circular or longitudinal joints of wire mesh shall be
lapped and binding with 1.5mm dia. Steel wire shall do attachments. Since the For
to achieve 70mm concrete coating thickness single layers of wire mesh with
spacers shall be provided.
Placing of reinforcement shall be as per the relevant drawings. Concrete coating
shall be carried out by dry mix process.
The welded steel wire mesh shall be placed over the surface of pipe by providing
the PVC cover block.(Size: 50mmX50mmX50mm)

Before commencing of work, procedure qualification test shall be performed.

The materials, cement & aggregates will be mixed to meet the coating
requirement. Moist sand and coarse aggregate shall be thoroughly mixed in the

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 ratio, so as to obtain min. compressive strength, with cement & then forced by air
pressure through a rigid pipe system and through a connected flexible rubber hose
into a spray gun. The gun is also connected to a water pressure system through a
regulating valve, controlling the ratio of mixing water with dry mix.

Water shall be such as to keep rebound and other losses to a minimum and also
prevent dusting & blowing of the material. The ends of pipe covered shall be also
ensure deposition of concrete on the surface without sagging. The concrete shall
be built up layers and each layer permitted to obtain its initial set before
subsequently layers are placed. The maximum thickness of each layer shall vary
depending upon the size of area and finished thickness of concreting required.
The air operating pressure shall be less than 3 Kg/ Cm2 and water pressure of
discharge nozzle shall be greater than operating air pressure. Cubes for
compressive strength.

Water cement ratio of dry mix concreting shall be in the range of 0.3 – 0.5 by
weight. The concrete coating shall terminate about 50mm short of the ends from
the each length of pipe.
The thickness of the concrete coating on the pipe length shall be increased to
achieve the required weight to prevent flotation so as to avoid in-site concrete
coating of the joint at the fields.

11.0 CURING

Curing shall be performed in by using jute bags with continuous wetting.

12.0 TOLERANCES

Surface tolerance of 8mm maximum for the radial distance between high and low
areas of the surfaces. The diameter of each coated pipe shall be obtained at 3 or
more points, spaced at equal intervals between the end points. The weight
tolerance for any single pipe shall be limited to plus (5) to minus (2) percent of
the weight. The theoretical weight shall be calculated using total weight of the
pipe with concrete and corrosion coating.

13.0 WEIGHING

One sample pipe shall be weighed when dry prior to shipment.

One sample pipe shall be weighed after 28 days of concrete placing.

14.0 INSPECTION & TEST PLAN

Each concrete coated pipe shall be visually checked and megger to be done for
insulation between steel reinforcement and pipe. After visual inspection damages
and/or defects shall be repaired as per repair procedure.

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15.0 REPAIRS

For damages due to spelling of an area of less than 0.1m2 (1 sq.foot) where the
remaining concrete is sound, may be accepted without repairs. For area more than
0.1m2 less than 0.3m2 repair shall be done by using a stiff mixture of cement,
water and aggregate shall be trowel led into and through the reinforcement and
built up until the surface is level with the coating around the repair and cured for a
minimum of 36 hours before further handling.

For area more than 0.3m2 repair shall be done by satisfactory restoring the
reinforcement, forming the area with a metal form and pouring a complete
replacement of materials similar to that from which the coating was made. The
mixture shall be one part of cement to three parts of aggregate and necessary
water to produce a slump not to exceed 100mm and cured for a minimum of 36
hours before further handling.

16.0 DOCUMENTATION

Inspection Report : GIL /BCPL/CO/IR/18

Inspection Test Plan : GIL /BCPL/CO/ITP/18
Cube Test Reports sieve Analysis for
Agrregate IMIR, Construction
Register for Cement, Steelwire.

In case of any conflict between the requirements of this procedure and that of the
above referred specifications the requirements of the latter shall govern, until and
unless specific intention is meant.

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Project: BCPL
Buoyancy Calculation
(Continuous Concreting)

Input Data:
Pipe External Dia, mm D 457.2
Thickness of PE Coating, mm δcoat 5
Pipe External Dia with coating, mm Dout+coat 467.2
Wall thickness of pipe, mm δp 8.5
Weight of disposal water, kg/m³ ρw 1100
Density of concrete coating, kg/m³ ρconc 2245
Thickness of concrete coating, mm δconc 65
Pipe external dia with concrete coating, mm Dout+coat+conc 597.2
Total length of ballasted pipe, m L 12
Concrete coating length, m Lconc 12

Calculation:
Buoyancy force of water, kg/m
GL =(Л*Dˆ2out+coat/4)*ρ w*L GL 8688.34

Weight of pipe with PE coating , kg W1 8721.1

Weight of concrete coating, kg W2 2921.27

G b=W1+W2 GB 11642.37

Output computation:
Safety Factor=1.3
(IF GB/GL>1.3 thickness of concrete coating
is sufficient) GB / GL 1.34

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