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ABU DHABI MARINE OPERATING COMPANY

Document Ref.:
SP-1024
Control Sheet
ADMA-OPCO STANDARD ENGINEERING DOCUMENTS
PAGE
Page 1 of 36




















D
O
C
U
M
E
N
T
DESIGNATION
SP-1024

SPECIFICATION
FOR
CONCRETE WEIGHT COATING OF
SUBSEA PIPELINE

TITLE


AUTHORITY NAME TITLE
B.UNIT
/
DIV
SIGNATURE DATE

TECHNICAL
CUSTODIAN
Mohamed Yehia SPE
P&E/
DED



TECHNICAL Amr Mohamed Azouz SPETL
P&E/
DED


STANDARDS Khaled Tawfik Hendy ESQASL
P&E/
DED

APPROVAL Hisham Awda MDE
P&E/
DED


ENDORSEMENT Ali Ghanim Bin Hamoodah SVP-PE P&E

CONTROL STAMP


The soft copy of this document
on ADMA-OPCO Web is
Controlled.
When printed, it is considered
Uncontrolled


















1 07/2011 Issued for Implementation


Rev. DATE DESCRIPTION/TEXT AFFECTED



SF / General / 001 Rev.0 sheet 1 of 1
COPYRIGHT ABU DHABI MARINE OPERATING COMPANY - ADMA-OPCO
All rights reserved. The information contained in this document is regarded as confidential. Recipient(s) other than ADMA-
OPCO's employees undertake both during the continuance of their services to ADMA-OPCO and after termination to maintain
in safe custody and not to use any such information for any purpose other than a purpose falling within the scope of the
Agreement or Contract under which this document was supplied. Recipient(s) further agree not to dispose of, make copies, in
whole or in part of such information or permit the use or access of the same by any Third Party unless the prior written
permission of ADMA-OPCO Manager Disciplines Engineering is obtained.
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Liability for utilization by personnel/organizations outside ADMA-OPCO

Whilst every effort has been made to ensure the accuracy of this document,
neither ADMA-OPCO nor its employees will assume liability for any application
or use outside ADMA-OPCO premises/assets.

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TABLE OF CONTENTS
1. INTRODUCTION ....................................................................................................................... 5
1.1 SCOPE ........................................................................................................................................ 5
1.2 COVERAGE ............................................................................................................................... 5
1.3 EXCLUSIONS ............................................................................................................................ 5
1.4 REFERENCES ............................................................................................................................ 5
1.5 ABBREVIATIONS ..................................................................................................................... 6
1.6 DEFINITIONS ............................................................................................................................ 6
1.7 USE OF LANGUAGE ................................................................................................................ 6
1.8 UNITS ......................................................................................................................................... 7
1.9 LESSONS LEARNED ................................................................................................................ 7
1.10 SITE CONDITIONS & DATA ................................................................................................... 7
2. QUALITY ASSURANCE .......................................................................................................... 8
2.1 QUALITY ASSURANCE SYSTEM .......................................................................................... 8
2.2 QUALITY PLAN ........................................................................................................................ 9
2.3 INSPECTION AND CERTIFICATION REQUIREMENTS ..................................................... 9
3. CONCRETE WEIGHT COATING MATERIALS AND REINFORCEMENT ............. 10
3.1 CEMENT .................................................................................................................................. 10
3.2 AGGREGATES ........................................................................................................................ 10
3.3 WATER ..................................................................................................................................... 11
3.4 CONCRETE MIXING .............................................................................................................. 12
3.5 REINFORCEMENT ................................................................................................................. 12
3.6 CURING COMPOUND ............................................................................................................ 12
4. PROPERTIES OF THE CONCRETE WEIGHT COATING ........................................... 13
4.1 CONCRETE MIX DESIGN ..................................................................................................... 13
4.2 BATCHING PLANT ACCURACY ......................................................................................... 13
5. APPLICATION ......................................................................................................................... 13
5.1 PIPE LENGTH PREPARATION ............................................................................................. 13
5.2 INSTALLATION OF REINFORCEMENT ............................................................................. 14
5.3 PLACING OF THE CONCRETE WEIGHT COATING ......................................................... 15
6. TESTING AND INSPECTION OF CONCRETE ................................................................ 17
6.1 TESTING .................................................................................................................................. 17
6.2 INSPECTION ............................................................................................................................ 20
6.3 QUALIFICATION TESTS ....................................................................................................... 20
6.4 INSPECTION AND TEST PLAN ............................................................................................ 20
7. REPAIRS AND CAUSES OF REJECTION ......................................................................... 21
7.1 REPAIR OF SPALLING .......................................................................................................... 21
7.2 CRACKING .............................................................................................................................. 21
7.3 CAUSES FOR REJECTION ..................................................................................................... 22
8. DOCUMENTATION AND REPORTING ............................................................................ 23
8.1 PRODUCTION AND TEST REPORTS ................................................................................... 23
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9. MARKING OF CONCRETE WEIGHT COATED PIPE .................................................. 24
9.1 COLOUR IDENTIFICATION .................................................................................................. 24
10. STORING AND HANDLING CONCRETE WEIGHT COATED PIPE ......................... 24
10.1 HANDLING OF PIPE AFTER COATING .............................................................................. 24
10.2 HANDLING OF PIPE FOR LOAD-OUT ................................................................................ 24
10.3 PIPE HANDING OVER CERTIFICATION ............................................................................ 24
11. CATHODIC PROTECTION (SACRIFICIAL ANODES) ................................................. 25
11.1 ANODES ................................................................................................................................... 25
11.2 METHOD OF ATTACHMENT ............................................................................................... 25
11.3 TESTING AND INSPECTION ................................................................................................ 26
11.4 STORING, STACKING AND HANDLING OF PIPE WITH ANODES FITTED ................. 26
APPENDIX-A: CALCULATION OF NEGATIVE BUOYANCY .............................................. 27
A1 FORMULA FOR COMPUTING "AS APPLIED" NEGATIVE BUOYANCY FOR
CONCRETE FITTED PIPE ............................................................................................................. 27
A2 FORMULA FOR COMPUTING "AS APPLIED" NEGATIVE BUOYANCY FOR
ANODE FITTED & CONCRETED PIPES .................................................................................... 29
APPENDIX-B: CONCRETE COATING DATA SHEET ............................................................ 32
APPENDIX-C: ABBREVIATIONS ................................................................................................. 33
APPENDIX-D: DEFINITIONS ........................................................................................................ 34
APPENDIX-E: REFERENCED DOCUMENTS............................................................................ 35

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1. INTRODUCTION

1.1 Scope

This Specification is intended to provide & highlights the minimum basic
requirements for materials and application of uniform concentric reinforced concrete
weight coating for ADMA-OPCO subsea pipelines and shall not relieve the
Contractor of his contractual obligations. Any deviation from this Specification shall
be identified by Contractor and shall require written approval from ADMA-OPCO.

1.2 Coverage

This Specification covers concrete coating application, inspection, repairs, coated
pipes handling and storage at coating plant.

1.3 Exclusions

This Specification excludes coated pipes transportation and any intervention works
outside the coating plant.

1.4 References

1.4.1 General

The latest edition (at the time of the contract award) of the reference documentation
as listed in Appendix-E shall be read as an integral part of this Document.

The latest edition/revision of ADMA-OPCO Standard Engineering Documents as
indicated in Status List SL-001 shall be utilized.

1.4.2 Equivalent Standards

Standard Documents equivalent to those referred to herein shall not be substituted
without written approval from ADMA-OPCO. Approval of equivalent Standard
Documents will not, in any way, release/relieve responsibility from the Contractor to
meet the best practices and/or requirements of the Standard Engineering Documents
referred to herein, in the event of conflict.

Where differences and/or conflicting issues occur between the referenced documents
themselves or the requirements of this document, the requirements of this document
shall overrule unless otherwise advised by ADMA-OPCO. However, major conflicts
shall be reported in writing to the ADMA-OPCO Standards Authority/Technical
Custodian nominated in the front sheet of this document for determination.

The following hierarchy of adherence to standards shall be followed:
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a. Whenever ADMA-OPCO Standard Engineering Documents (SEDs) relevant to
the system, service and/or equipment design are available, the same shall be
utilized first.
b. ADMA-OPCO Shareholder SEDs (tailored to suit ADMA-OPCO needs) shall
be utilized next in the hierarchy, if the relevant subject is not covered by
ADMA-OPCO Standards.
c. National or International standards (tailored to suit ADMA-OPCO needs) shall
be utilized, if the required subject is not covered either by ADMA-OPCO or
Shareholder SEDs.

The Contractor shall equip himself with copies of all the referenced Standard
Engineering Documents referred in Appendix-E of this Document and shall make
them readily available to all ADMA-OPCO, or nominated representative, personnel
involved in the work.

1.5 Abbreviations

The abbreviations used in this Specification are listed in Appendix-C.

1.6 Definitions

The definitions used in this Specification are listed in Appendix-D.

1.7 Use of Language

Throughout this document, the words will, may/can, should and shall/must,
when used in the context of actions by ADMA-OPCO or others, have specific
meanings as follows:

a. Will is used normally in connection with an action by ADMA-OPCO and / or
nominated representative, rather than by a Contractor or Vendor.
b. May / Can is used where alternatives / action are equally acceptable.
c. Should is used where provision is preferred.
d. Shall / Must is used where a provision is mandatory / vital.

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1.8 Units

Units shall be in accordance with ADMA-OPCO STD-00, Part-1.

1.9 Lessons Learned

Upon completion of works related to the scope of this document, a descriptive
summary of lessons learned shall be prepared and made available by the
Contractors/Consultants/Job Officer and shall be forwarded to ADMA-OPCO
Lessons Learned System as appropriate.

1.10 Site Conditions & Data

Site Conditions & Data of existing ADMA-OPCO facilities (Umm Shaif and Zakum
fields) shall be in accordance with ADMA-OPCO STD-00, Part-2. For new Fields
development, project specific requirements should be followed or refer to ADMA-
OPCO.

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2. QUALITY ASSURANCE

2.1 Quality Assurance System

2.1.1 All activities and services associated with the scope of this Specification shall be
performed by Contractors/Vendors approved by ADMA-OPCO.

2.1.2 The Contractor/Vendor shall operate Quality Management Systems (QMS) within
his organizations, which ensure that the requirements of this Specification are fully
achieved.

2.1.3 The Contractor/Vendors Quality Management System shall be based on ADMA-
OPCO Specification SP-1009 or the latest issue of ISO 9001 Series and accredited by
an international certifying agency.

The Contractors Quality Manual shall provide details for the preparation of a
Quality Plan, which shall include provisions for the QA/QC of services activities.

Where an approved Contractor/Vendor revises their Quality Management System
that affect the ADMA-OPCO approved Quality / Inspection and Test Plan, then the
revised Quality Plan / Inspection and Test Plan shall be submitted for ADMA-OPCO
approval before initiating any service activities.

2.1.4 The effectiveness of the Contractors Quality Management System may be subject to
monitoring by ADMA-OPCO or its representative and may be audited following an
agreed period of notice.

2.1.5 The Contractor/Vendor shall make regular QA audits on all their Sub-
Contractors/Suppliers. Details of these audits shall be made available to ADMA-
OPCO when requested.

2.1.6 The Contractor/Vendor shall maintain sufficient Inspection and Quality Assurance
staff, independent of the service provider management, to ensure that the QMS is
correctly implemented and that all related documentation is available.

2.1.7 Using Sub-Contractors is not allowed for services/functions carried out by a
Contractor without ADMA-OPCO approval.



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2.2 Quality Plan

2.2.1 Contracted activities shall be performed in accordance with an approved Quality Plan
(QP).

2.2.2 The level of detail required in the Quality Plan shall be commensurate with the scope
of services provided.

2.2.3 The quality of works is an essential factor in carrying out all services & activities
covered by this Document.

2.2.4 During services/activities, Quality Assurance/Quality Control issues are the
responsibility of the Contractor, and shall be approved and certified by TPA.

2.2.5 Conflicts between Contractor & TPA shall be reported in writing to ADMA-OPCO
for resolution.

2.3 Inspection and Certification Requirements

Inspection and certification requirements for material shall be certified to ADMA-
OPCO CP-102 and BS EN 10204.
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3. CONCRETE WEIGHT COATING MATERIALS AND REINFORCEMENT

3.1 Cement

All cement used for the preparation of the concrete shall comply with the following
requirements:

a. Certified by the supplier to be in compliance with the requirements of ASTM
C150 Type V.
b. The cement shall be adapted for sea water hardening and shall resist the effects of
sulphates.
c. Identified with the following information on the certification and delivery
documents for each shipment of cement:
c1. Cement producer's name and location,
c2. Product description including type and classification of cement,
c3. Year and month of production.
d. Handled, transported and stored in compliance with the cement manufacturer's
recommendations and the applicable standards.
e. No more than six months from the date of manufacture, unless it is retested and
proven to be in compliance with the original standard.
f. Cement shall be stored in covered areas or covered by plastic sheeting if supplied
in bags. Bulk cement shall be stored in water proof containers.
g. Cement that has hardened, partially hardened or become lumpy shall be rejected.
h. Test certificates from the cement manufacturer shall be supplied for every cement
delivery to site.

3.2 Aggregates

3.2.1 Sand (Silica Type)

Sand aggregates used shall be round grained and shall be obtained by sieving. Sand
shall be free of injurious amounts of salt, alkali, deleterious substances, or organic
impurities. Natural sand and aggregate shall conform to BS EN12620 or ASTM C 33
requirements.
Sand grading shall be within the range of values as shown in Table 3.2.1 herein under

Mesh size, as per
ASTM C 33
Per Cent Passing
Minimum Maximum
4.75 mm -- 100
2.36 mm 80 100
1.18 mm 50 100
600 microns 25 60
300 microns 5 30
150 microns 0 10
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3.2.2 Heavy Aggregate

Heavy aggregates made of crushed iron ore or barites shall conform to BS EN 12620
or ASTM C 33 requirements.

A maximum size of 9.52mm aggregate shall be added to the mixture to achieve the
required negative buoyancy after submersion in sea water.

The aggregate gradation shall be within the range of values shown in Table 3.2.2
below:-


Mesh size, as per
ASTM C 33
Per Cent Passing
Minimum Maximum
9.52 mm 100 -
4.75 mm 100 -
2.36 mm 80 100
1.18 mm 50 85
600 microns 10 30
300 microns 5 30
150 microns 0 10

Table 3.2.2 Aggregate Grading

N.B:

a. The heavy aggregate shall be clean and free of clay, organic and deleterious
materials.
b. The cleanliness of the aggregate shall be controlled by screening at the crusher.
c. The aggregate shall be stored on paved area to avoid its contamination.

3.3 Water

Water used in the production of concrete shall comply with BS EN 1008. The water
shall be clean and free from oils, acids, alcohols, salts or organic materials. Water that
is potable does not require further testing for compliance.

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3.4 Concrete Mixing

3.4.1 The total amount of chlorides in the concrete mix, calculated as the free calcium
chloride (CaCl
2
) shall not exceed 0.15% of the weight of cement.

3.4.2 The total amount of sulphates in the concrete mix, calculated as sulphur trioxide
(SO
3
) shall not exceed 3.5% of the weight of cement.

3.4.3 The constituent parts of the concrete mix shall be weigh-batched using a weigh-
batching plant of suitable design. The weigh-batcher shall be accurate to within 2%
of the indicated values.

3.4.4 A water gauge accurate to within 3% of the indicated values shall be used for
adding water to the mix.

3.5 Reinforcement

3.5.1 The reinforcement shall be manufactured from high quality billet steel conforming to
ASTM A 810 or approved equivalent, formed into galvanized wire mesh/fabric
reinforced type. The wire shall be galvanized before weaving.

3.5.2 The resultant proportion of reinforcement shall not be less than 0.5% of the cross
sectional area of the weight coat taken in the plane perpendicular to the longitudinal
axis of the pipe and shall be not less than 0.08% of the circumferential axis of the
pipe as given in DNV-OS-F101.

3.6 Curing Compound

The curing compound shall be of a type approved by ADMA-OPCO and shall be
evenly applied over the complete surface of the concrete. The curing compound shall
be prepared and applied in strict conformity with the manufacturer's written
instructions.

The compound performance shall conform with ASTM C 309. Data sheets shall be
submitted for ADMA-OPCOs approval.
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4. PROPERTIES OF THE CONCRETE WEIGHT COATING

4.1 Concrete Mix Design

4.1.1 Concrete mixes shall be carried out in such a way that the required densities and
strengths are obtained. To this end full details shall be furnished as follows:-

a. The proportion and weights of the respective dry aggregates.
b. The cement weight per cubic meter of concrete.
c. The volume of water per cubic meter of concrete.
d. The results of preliminary tests for water absorption.
e. The density of the proposed mix.

4.1.2 The component parts of the concrete shall be properly mixed to provide a
homogenous and consistent mix. A number of mixes with different gradings, cement
contents and water ratios shall be tested until the correct mix is attained.

4.1.3 The proposed composition shall meet the minimum mechanical strengths and water
absorption specified and shall ensure easy and satisfactory application of the concrete
coating.

4.1.4 The water/cement (W/C) ratio should not exceed 0.40 and shall not be less than 0.25,
the cement content should not be less than 400 kg/m
3
.

4.2 Batching Plant Accuracy

The batching plant and water gauge accuracies should be within 3%. Calibration
should be checked weekly during production.

5. APPLICATION

5.1 Pipe Length Preparation

5.1.1 Prior to placing of reinforcements and anode bracelets, the whole anti-corrosion
coating of each pipe length shall be visually inspected and if damages are found, they
shall be repaired to the ADMA-OPCO approved specification before starting the
placing of any concrete.

5.1.2 After repairs, the anti-corrosion coating shall be electrically inspected using a holiday
detector with minimum 20,000 volts.

5.1.3 At the beginning of each work period, the length of the detector's spark shall be
calibrated on sample with a known defect.

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5.1.4 The appropriate output voltage shall be established either by:-

a. Positioning the electrode away from the bare steel, the same distance as the
coating thickness and increasing the voltage until a spark jumps the gap.
b. Using a spark gap setter.

5.1.5 The minimum operating voltage of the detector shall be maintained at or above the
established level throughout the testing works.

5.1.6 The maximum operating voltage for the electrode shall be established such that no
damage to sound coating is caused, and this value shall not be exceeded during the
testing.

5.1.7 Pipes requiring mid-section supports, when so required during concrete placing, shall
be adequately supported to prevent undue flexure during coating.

5.1.8 The installation of anodes shall be performed in accordance with Clause 11.1.2 prior
to the placing of concrete.

5.2 Installation of Reinforcement

5.2.1 The galvanized wire reinforcement shall be carefully placed around the pipe without
causing damage to the anti-corrosion coating.

5.2.2 The resultant proportion of reinforcement shall not be less than 0.5% of the cross
sectional area of the weight coat taken in the plane perpendicular to the longitudinal
axis of the pipe and shall be not less than 0.08% of the circumferential axis of the
pipe.

5.2.3 A minimum overlap of 25 mm is required for the spirally wound reinforcement.

5.2.4 A single wrap of reinforcement can be applied if the concrete coating thickness is
50mm or less. This wrap shall be a minimum of 15mm from the outside surface of the
anti-corrosion coating except at the start of the winding operation. A double wrap of
reinforcement shall be applied if the concrete coating exceeds 50mm.

5.2.5 Additional wraps of reinforcement may be required to be applied for thickness in
excess of 102mm. The number of additional wraps shall be determined in agreement
with ADMA-OPCO according to the minimum cross sectional areas required by this
specification and would be as shown in the Data Sheet, see Appendix-B of this
Specification.

5.2.6 The external wire mesh wrap shall have a minimum of 15mm of concrete cover.

5.2.7 The concrete coated pipe shall be tested with an ohm-meter to ensure that there is no
contact between the wire reinforcement and the pipe or anode.
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5.2.8 Should the Contractor propose alternative reinforcement, then it shall be
demonstrated to the satisfaction of ADMA-OPCO that it provides similar benefits to
the reinforcement specified above. The Contractor shall, specify the alternative type
of reinforcement and the methods to be used to prove the adequacy of the alternative
design, for acceptance by ADMA-OPCO.

5.3 Placing of the Concrete Weight Coating

5.3.1 General Method

a. The concrete coating shall be placed by impingement. In all cases, each pipe joint
shall be coated in a continuous operation and in such a manner that the concrete is
applied uniformly throughout the total length and free from any abrupt
irregularities or variations in thickness.

b. If more than one application is required, the total time allowed for the completion
of the operation shall not exceed 30 minutes.

c. The application method in all cases, shall ensure that the concrete coating satisfies
the minimum requirements of this Specification for:-

c1. Concrete coating sizing and shaping.
c2. Concrete coating specific gravity.
c3. Concrete coating water absorption.
c4. Concrete coating compression strength.
c5. Emplacement of reinforcement.
c6. Negative buoyancy.

5.3.2 Pipe Length with Anodes or Mid-Section Supports

a. The placing of concrete coating on those pipe lengths which have anodes attached
or mid-section supports shall be performed in such a way so that the concrete
coating is terminated 30mm from the anode or mid-section support.

b. The procedure for handling this pipe before and after concrete application shall be
submitted for ADMA-OPCO approval.

c. The procedure for coating small diameter pipe with mid-section supports shall be
submitted for ADMA-OPCO approval.

5.3.3 Time Limitations

In all cases, the time interval from adding water to the mix and final placing of the
concrete shall not exceed 30 minutes.

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Concrete placing shall be completed as quickly as possible and the surface of the
concrete covered to prevent rapid evaporation.

5.3.4 Curing of the Concrete

a. The curing compound shall be applied to the exposed surfaces immediately after
concrete application and shall be evenly applied over the complete surface of the
concrete. The curing compound shall be prepared and applied in strict conformity
with the manufacturers written instructions. Number of coats shall be determined
and applied as per manufacturers recommendation to ensure complete coverage.
Data sheets shall be submitted for ADMA-OPCOs approval.

b. The use of curing membranes, polyethylene sheet wrapping membranes or
coatings shall generally be permitted but the Contractor must provide means to
satisfy the water absorption tests specified in Clause 6.1.2.

c. The concrete coated pipe shall be stored in a single layer for a minimum period of
3 days and until a minimum compressive strength of 2100 psi is achieved.

d. All concrete coated pipes shall be cured for a minimum of 10 days and until a
minimum compressive strength of 3850 psi is achieved. No concrete coated pipe
shall be skipped from the coating plant without satisfying both conditions unless
otherwise specified by ADMA-OPCO.

5.3.5 Reclaimed/Rebound Material

The amount of reclaimed material used shall not exceed 5 percent of total mix by
weight and shall not be added in an even flow during continuous coating operation.
The reclaimed material is used within less than 10 minutes from the time when it was
originally mixed.

5.3.6 Cutback

The non-concrete coated section "cutback" at the ends of each pipe length shall
typically be 300mm to 330mm, the cutback may extend to 400mm to satisfy the
requirement of welding machine in case of automatic welding. The ends and inside of
the pipe shall be free of concrete debris. The cutback should be square shoulder
section unless otherwise specified by the project requirements.

5.3.7 Tolerances

The concrete coating shall be concentric with the pipe and have a thickness equal to
the nominal thickness calculated from the specified pipe dimensions and required
submerged weight taken from pipeline data sheet.

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6. TESTING AND INSPECTION OF CONCRETE

6.1 Testing

6.1.1 Compressive Strength and Density of the Concrete

a. The concrete coating compressive strength shall be checked by means of test
cubes and core samples.

b. Minimum dry densities measured after a minimum of 10 days shall be 3040 kg/m
3
(190 lb/cu.ft).

c. The method of determining dry density must be provided for ADMA-OPCO
approval.

d. No change will be authorized without the written approval of ADMA-OPCO.

e. The compressive strength shall be a minimum of 3600 psi at 7 days and a
minimum of 5000 psi at 28 days. The strength shall be measured on test cubes and
core samples as follows.

e1. Cube Samples

Cube samples shall be taken every 4 hours at every mix change and after every
shutdown period with a minimum of 2 cubes samples taken per occurrence.

e2. Core Samples

e2.1 Where the coating is applied by the impingement or "Compression Coat"
processes the concrete strength shall be determined by removing 1 core from
the coating on one pipe to be selected from every ten pipes by ADMA-OPCO.
The cores shall be extracted using a diamond core cutter modified to ensure
that the core is cut perpendicular to the coating surface. Cores shall be
removed in such positions that the main reinforcement will not be
damaged. Should the main reinforcement be damaged then that section of
weight coating shall be removed and recoated, or repaired by agreement with
ADMA-OPCO. The core cutter shall have a positive depth of cut limit stop
fitted to ensure that the core barrel cannot penetrate to within 8 mm of the
pipe wrapping.

e2.2 At least 2 core samples shall be drilled from the concrete weight coating on
every 20th pipe length.

e2.3 The diameter of core specimens shall be at least 50mm (preferably 75mm). A
single core diameter shall be used throughout the job.

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e2.4 The height to diameter (h/d) ratio shall be, as nearly as practicable, equal to
2.0. A core having a height of less than its diameter (h/d 1.0) after capping
shall not be tested.

e2.5 Evaluation of test results shall be carried out in accordance with BS EN
12504-1 or ASTM C42

e2.6 For samples failing these tests, 2 more samples shall be cored and tested. If
the test on these 2 samples fails, no more samples shall be taken, and the
concrete shall be rejected.

e2.7 All pipe lengths on which such tests indicate that the concrete does not reach
the minimum specified values shall be rejected.

e2.8 The coring procedure and method of evaluation shall be subject to the
approval of ADMA-OPCO. The equipment used must include positive means
to ensure that the depth of cut leaves at least 8mm of undamaged concrete
between the coring tool and the anti-corrosion coating.

e2.9 Core holes shall not be filled without prior inspection by ADMA-OPCO.

e2.10 The method of refilling core holes is subject to the approval of ADMA-OPCO
and shall be in line with the requirements of Clause 6.2.4 of this specification.

6.1.2 Water Absorption Test

a. The water absorption test procedure shall be submitted to ADMA-OPCO for
approval.

b. A water absorption test shall be carried out at the beginning of production and
subsequently on one pipe in every 150 pipes.

c. Further water absorption tests shall be carried out in the laboratory on cube and
core samples.

d. The water absorption shall not exceed 5%.

e. Water absorption exceeding 5% shall result in rejecting all pipe lengths
represented by the test.

6.1.3 Location of Reinforcement

a. At the centre of the first pipe of each production shift a water jet shall be used to
clear away the freshly placed concrete down to the anti- corrosion coating for an
area approximately 50mm wide and 200mm long in the longitudinal direction.
This exposed area (slot) shall be used to confirm that the reinforcement is
positioned and covered with the concrete as specified.
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b. If the reinforcement is not positioned correctly, the pipe shall be rejected and
recoated. Each pipe in succession shall be inspected in this manner until the
position of the reinforcement is acceptable. The repair of the inspection slot shall
be as specified in Sub-section 7.1 of this Specification.

6.1.4 Weight Control

a. Pipe lengths shall be weighed using calibrated load cells. Calibration certificates
for weighing equipment shall be provided for approval by ADMA-OPCO.

b. At least once every shift, all weighing equipment used during the concrete coating
operations shall be calibrated against a standard test weight of the same order of
magnitude as a concrete coated pipe length.

c. The weighing procedure shall be subject to approval by ADMA-OPCO.

6.1.5 Negative Buoyancy

a. Each pipe length shall be weighed immediately before and after concrete coating.
Girth measurements at approximately 5 equidistant locations shall be taken, in
order to calculate the average girth.

b. The maximum permitted tolerances on negative buoyancy are for each pipe
length, with or without an anode shall be as follows: -

b1. Single pipe -2 % +10 %.
b2. Shift Production -0 % +5 % calculated on the specified negative buoyancy.

c. The negative buoyancy requirements are based on concrete in the as-applied
condition, and not on concrete in a fully saturated condition.

d. The formulae to be used in calculating the "as applied" negative buoyancy is as
given in Appendix- A of this Specification.

N.B:

a. If the pipe requires additional concrete to increase the weight or thickness, the
additional concrete shall be added within 30 minutes after the first concrete was
applied.
b. If the tolerances and conditions cannot be obtained, the pipe over its full length
shall be stripped and recoated.
c. For each pipe size and concrete thickness negative buoyancy limits based or
pipeline data sheet shall be calculated and submitted for ADMA-OPCO approval.
d. Separate procedure for weighing concrete coated and anode fitted pipes, and
determination of negative buoyancy and density of weight coating shall be
submitted for ADMA-OPCO approval.
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6.1.6 Cleanliness

Testing and inspection shall include regular check of cleanliness and grading of
aggregates e.g. every third day during production.

6.2 Inspection

6.2.1 Every length of coated pipe shall be non-destructively tested, not less than 3 days
after coating, by such means as "ringing" to determine whether any defects are
present.

6.2.2 Where this procedure indicates faulty coating, the Contractor shall remove cores from
the suspected pipe. If these cores indicate defective concrete coating the, Contractor
shall remove the coating by a method agreed with ADMA-OPCO. The coating shall
not be replaced without the agreement in writing of ADMA-OPCO.

6.2.3 Areas where coating has not adhered during placement or has been damaged
subsequently (in particular the ends of the concrete coating), may be patch repaired
by hand where the area of defective coating is not in excess of 0.1 sq. metre in any 1
metre length of coated pipe. Any more extensive damage shall cause that section of
pipe coating to be rejected.

6.2.4 Patching shall be carried out only by removing the affected coating down to at least
the reinforcement level, taking care not to damage the reinforcement, and making
good the cavity using a similar mix to that used in the coating process with the
addition of just sufficient water to allow hand application. A bonding agent or
additive agreed by ADMA-OPCO shall be used, in strict accordance with the
manufacturer's instructions. A similar mix shall be used to fill core holes after
inspection of the holes by ADMA-OPCO.

6.3 Qualification Tests

Qualifications tests shall be performed in accordance with a procedure agreed
between ADMA OPCO and the concrete coating Contractor and witnessed by the
Third Party Agency.

6.4 Inspection and Test Plan

The Inspection and Test Plan shall be developed by the coating Contractor and
approved by the Third Party Agency.

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7. REPAIRS AND CAUSES OF REJECTION

7.1 Repair of Spalling

7.1.1 If spalling, due to impact or from improper application of the concrete is found to be
not more than 25% of the depth of the coated surface. The following repairs shall be
undertaken for each pipe length:

a. If the damage zone is less than 1000 cm
2
no repairs shall be undertaken.
b. If the damage 2 surface is between 1000cm
2
and 3000cm
2
, the concrete coating
shall be repaired as follows:-
b.l The concrete coating on the damaged area shall be removed until the
reinforcement is visible and shall be undercut to ensure that a key lock is formed.
Sufficient cover to the corrosion protection layer (min. 10mm) shall be
maintained.
b.2 The edges of the damaged zone shall be trimmed square.
b.3 Fresh concrete shall be gunnited into the hole until the surface is at the same level
with the surrounding coating around the repair.
b.4 The repaired area shall be protected and properly cured to prevent rapid
evaporation.
b.5 The pipe shall be allowed to cure for a minimum of 48 hours.
c. If the damage exceeds 3000 cm
2
,

the coating shall be removed down to the
corrosion coating on the entire periphery of the pipe at the damaged area. If
damaged wire reinforcement shall be replaced. The cavity shall be refilled with
fresh concrete of the required density as per the requirements of Sub-section 5.3
of this Specification.

7.1.2 If the depth of the spalled area exceeds 25% of the coating depth and the damage is
less than 500cm
2
and does not expose the anti-corrosive coating, then the procedure
in Clause 7.1.b shall be followed. For damaged zones of 500cm
2
or more, the
procedure specified in point (c) above shall be followed.

7.2 Cracking

7.2.1 Every effort shall be made to avoid concrete cracking during handling or stockpiling
operations.

7.2.2 The following cracks shall be repaired:

a. Deep cracks exceeding 1.6mm in width and extending for 180 or more
circumferentially around the pipe.
b. Cracks over 30 cm in length longitudinally along the pipe, irrespective of width.

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7.2.3 Repairs shall be made by chiselling out the crack to a width of at least 2.5cm
throughout the length of the crack. The crack shall then be refilled with fresh concrete
having a density equal to that originally applied. A suitable additive to render the
concrete shrinkage free shall be used. However, the additive type shall be approved
by ADMA-OPCO prior to its use.

The pipe shall then be allowed to cure for a minimum of 48 hours.

7.3 Causes for Rejection

Causes for rejection of the concrete coating shall include, but not be limited to, the
following:-

7.3.1 Negative Buoyancy

Negative buoyancy less than or greater than the tolerances allowed in Clause 6.1.5 of
this Specification.

7.3.2 Concrete

Concrete which does not meet the specified requirements.

7.3.3 Reinforcement

Improper placement of the reinforcement.

7.3.4 Spalling

a. If the damage of the surface extends to the anti-corrosive coating. A holiday
detection shall be made of the anti-corrosion coating before the concrete is re-
applied.
b. If the damaged zone is more than 3000cm
2
.

7.3.5 Handling

Pipe coating damaged during handling operations shall be treated as per Sub-section
7.1 of this Specification.


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8. DOCUMENTATION AND REPORTING

8.1 Production and Test Reports

The Contractor shall submit to ADMA-OPCO for approval example of all reports
required to document accurately the production, testing and reporting.

As a minimum, the following shall be recorded for each and every pipe length:

a. Serial number.
b. Length meters.
c. Condition of end bevels and surface receipt.
d. Weight (bare) (kg).
e. Weight after concrete coating (kg).
f. Fitted with anode if applicable.
g. Date and time of placement of coating.
h. Calculated fully saturated negative buoyancy.
i. Details of water absorption test.
j. Concrete details including;
j.l Quantity and type of cement, sand & aggregate,
j.2 Quantity of water and density of mix,
j.3 Crushing strength,
j.4 Thickness of coating.
k. Conditions of end bevels on shipping.
l. Colour Code.
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9. MARKING OF CONCRETE WEIGHT COATED PIPE

9.1 Colour Identification

Contractor shall propose the colour coding requirements.

It shall be necessary to ensure that every concrete coated pipe has at one end indelibly
marked circumferential band to show the specific gravity.

10. STORING AND HANDLING CONCRETE WEIGHT COATED PIPE

10.1 Handling of Pipe after Coating

10.1.1 After completion of the concrete weight coating the pipe shall be carefully handled
during removal from the coating machine to the curing yard.

10.1.2 The pipe shall remain in a single layer for a minimum of 3 days before being removed
from the curing yard and until a minimum compressive strength of 2100 psi is
achieved.

10.1.3 The maximum allowable stacking heights of concrete weight coated pipe shall be
determined so that no pipe is overstressed and coatings are not damaged.

10.1.4 Pipe with anodes fitted shall always be stacked on the top of the stockpile, without
exception.

10.2 Handling of Pipe for Load-out

The procedure for handling concrete weight coated pipe to an appointed load-out
location and loading onto trucks, barges or supply boats shall be subject to prior
approval by ADMA-OPCO.

10.3 Pipe Handing Over Certification

It shall be necessary on completion of all load-outs, to issue, in respect to each and
every pipe, a "Pipe Handing Over" certificate.

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11. CATHODIC PROTECTION (SACRIFICIAL ANODES)

Cathodic Protection shall be in accordance with ADMA-OPCO Specification SP-1053 and
the following:-

11.1 Anodes

11.1.1 Number and Location

When a single anode is to be installed, it shall be placed approximately at the mid
point of the pipe.

Where two anodes are to be installed on a pipe they shall be placed at approximately
1/3 of the pipe length from each pipe end.

11.1.2 Installation

Each anode must be securely attached so that it cannot be rotated and no damage
should be inflicted to the corrosion coating. After bolting the straps must be
tackwelded to insure continuity. The anode external diameter should be the same as
the concrete coating and must not protrude beyond the weight coating thickness.

11.2 Method of Attachment

11.2.1 Electrical Connections

Connections shall be made by connecting strips, which are to be bolted or welded
between the 2 halves of the anode bracelet.

Each half bracelet shall be attached to the pipe by two 16mm
2
diameter double layer
PVC insulated copper cables.

Connections shall be made to the ADMA-OPCO approved thermo weld method.

11.2.2 Coating of Anodes and Connections

After completion of the connections and testing of the electrical continuity, two pack
patching compound / paint shall be applied, to the connecting strips.

11.2.3 Concrete Weight Coating Application

Concrete weight coating shall be applied in the same manner as for the pipe without
bracelets, except that the concrete coating is terminated 30mm from each side of the
anode. The gap shall be filled with HDPUF infill material to same diameter of
Concrete Coating. Same concrete mix may be used as a filler material between the
anode and the concrete coating after ADMA OPCOs approval.

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11.3 Testing and Inspection

11.3.1 An electrical continuity test shall be performed prior to the coating of the connection
strips.

11.3.2 On completion of concrete weight coating, a further electrical continuity test shall be
performed to confirm that there is no contact between the reinforcement wire and the
anodes.

11.4 Storing, Stacking and Handling of Pipe with Anodes Fitted

11.4.1 Storing & Stacking

a. Stacking calculations shall be provided for ADMA-OPCOs approval.

b. Concrete coated pipe shall be stacked only after the concrete has attained the
minimum required design strength.

c. The pipe shall be stacked on a minimum of two loose graded sand windrows at
least 15 cm deep and not less than 2 m wide (each), approximately 7 m apart, and
shall not be separated by bearers.

d. The pipe shall be carefully lowered to limit impact effects and stacked in such a
way that water, mud and sand cannot accumulate within the pipe.

e. Pipe with anodes fitted shall be carefully removed from the curing yard and
stacked on top of the stockpipe.

11.4.2 Handling

In the case of small diameter pipe, it shall be necessary to utilize a three point lifting
system. Contractor shall submit to ADMA-OPCO all calculations related to the
number of lifting points to utilize.







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APPENDIX-A: CALCULATION OF NEGATIVE BUOYANCY

A1 Formula for Computing "As Applied" Negative Buoyancy for Concrete Fitted
Pipe

Definitions

L = Length of the Pipe Joint, m.

Ll = Length of the cutback, mm (assumed same for anti-corrosion
coating and weight coating).

D = Outside pipe diameter, mm

Dl = Outside pipe diameter, including anti-corrosion coating, mm.
D2 = Outside pipe diameter, including weight coating, mm.

W = Weight of the pipe joint, including anti-corrosion coating, kg.
Wl = Weight of the pipe joint, including weight coating, kg.

B = Buoyancy of the pipe joint in sea water, kg.

Sea = Density of seawater, (1031 kg/m
3
).
Conc = Density of weight coating, kg/m
3


NB: Refer to Fig. 6.1.

Computations

1. Dry weight of the pipe joint = Wl.

2. Buoyancy of the pipe joint:

B = Sea D2
2
(L - 2Ll )+ D
2
x 2L1
4 1000 1000 1000 1000


3. "As applied" negative buoyancy:

WSUB = Submerged weight.
= Negative buoyancy.
= (W
1
- B)/L. kg/m.

If required, the density of "as applied" weight coating and the specific gravity of the
pipe joint can be checked as follows:-


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Density of weight coating

conc = density of weight coating.

= Wl - W x 4 X 10
6
x 1 kg/m
3

D2
2
-Dl
2


(L - 2L1)


1000


Specific Gravity of the Pipe


SG = Wl
B





Figure 6.1
Concrete Fitted Pipe
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A2 Formula for Computing "As Applied" Negative Buoyancy for Anode Fitted &
Concreted Pipes

Definitions

L = Length of the Pipe Joint, m.

Ll = Length of the cutback, mm (assumed same for anti-corrosion coating
and weight coating).

LA = Length of Anode mm.

D = Outside pipe diameter, mm

Dl = Outside pipe diameter, including anti-corrosion coating, mm.

D2 = Outside pipe diameter, including weight coating, mm.

DA = Outside diameter of Anode.

W = Weight of the pipe joint, including anti-corrosion coating, kg.

Wl = Weight of the pipe joint, including weight coating, kg.

B = Buoyancy of the pipe joint in sea water, kg.

sea = Density of seawater, (1031 kg/m
3
).

Conc = Density of weight coating, kg/m
3

NB:

Refer to Fig. 6.2.


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Computations

1. Dry weight of the pipe joint = Wl.

2. Buoyancy of the pipe joint:

B = Sea D2
2
(L - 2Ll-LA )+ D
2
x 2L1 + DA
2
x LA
4 1000 1000 1000 1000 1000 1000

3. "As applied" negative buoyancy:

WSUB = Submerged weight.
= Negative buoyancy.
= (Wl - B)/L. kg/m.

If required, the density of "as applied" weight coating and the specific gravity of the pipe
joint can be checked as follows:-

Density of weight coating

conc = density of weight coating.

= Wl - W x 4 X 10
6
x 1 kg/m
3

D2
2
- D1
2


(L - 2L1-LA)


1000



Specific Gravity of the Pipe


SG = Wl
B

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Figure 6.2
Concrete /Anode Fitted Pipe

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APPENDIX-B: CONCRETE COATING DATA SHEET
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APPENDIX-C: ABBREVIATIONS

Abbreviation Description
ADMA-OPCO Abu Dhabi Marine Operating Company
HDPUF High Density Polyurethane Foam
QA Quality Assurance
QAS Quality Assurance System
QC Quality Control
QMS Quality Management Systems
SI Systeme International dUnites
TPA Third Party Agency




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APPENDIX-D: DEFINITIONS

D.1 General Definition

Term Definition
Contractor
Is the Company contracted to undertake the works of a Project and is
accountable to ADMA-OPCO's or its nominated representative.
Quality Assurance
All those planned and systematic actions (QA) necessary to ensure quality
i.e. to provide adequate confidence that a product or service will be fit for
its intended purpose.
Quality Manual
A Document setting out the general quality policies, procedures and
practices of an organization.
Quality Plan
A document prepared by the Contractor/Vendor setting out the specific
quality practices, resources and activities relevant to a particular project.
Quality
Management
System
The structure organization, responsibilities, activities, resources and events
that together provide organized procedures and methods of implementation
to ensure the capability of the organization to meet quality requirements.
TPA
Is the Company contracted to undertake the Third Party Inspection &
Verification Tasks (TPA) on behalf of ADMA-OPCO.
Vendor
Is the named Manufacturer or Supplier in the ADMA-OPCO Purchase
Order. The term Vendor as used herein includes all Manufacturers and
sub-suppliers of equipment covered by this Document.


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APPENDIX-E: REFERENCED DOCUMENTS

Unless otherwise specified, the latest edition of the Standard Engineering Documents listed below
shall to the extent specified herein, represent part of this document.
Designation Title
ADMA-OPCO
CP-102
Third Party Inspection and Certification Requirements for New Equipment
and Materials in Manufacture.
MNL-01 Painting Manual
SL-001 Status List for ADMA-OPCO Standard Engineering Documents.
SP-1009 Requirements for Contractors Quality Systems on Major Projects
SP-1053 Cathodic Protection of Submarine Pipelines
STD-00
Part-1: Measurements Units
Part-2: Site Condition & Data
British Standards Institution (BSI)
BS EN 10204 Metallic Products Types of Inspection Documents.
BS 410 Specification for test sieves.
BS 812 Testing Aggregates
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
Supersedes BS 3148:1980
BS EN 12390 Testing Hardened Concrete
BS EN 12504-1
Testing concrete in structures Part 1: Cored specimens Taking, examining
and testing in compression
BS EN 197-1
CEMENT Composition, Specifications and Conformity Criteria for
Common Cements
BS EN 12620 Aggregates for concrete
International Organization for Standardization (ISO)
ISO 9001 Quality Management Systems - Requirements.
ISO 21809-5 External Concrete Coating

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APPENDIX-E: REFERENCED DOCUMENTS (CONTD)

Designation Title
ASTM
ASTM A 810
Standard Specification for Zinc-Coated (Galvanized) Steel Pipe Winding
Mesh
ASTM C 33 Specification for Concrete Aggregates.
ASTM C 150 Specification for Portland Cement.
ASTM C 171 Standard Specification for Sheet Materials for Curing Concrete
ASTM C 309
Specification for Liquid Membrane-Forming Compounds for curing
concrete.
Det Norske Veritas (DNV)
DNV-OS-F101 Offshore Standard: Submarine Pipeline Systems