DEP SPECIFICATION

CONCRETE COATING OF LINEPIPE

(AMENDMENTS/SUPPLEMENTS TO ISO 21809-5)

DEP 31.40.30.30-Gen.

February 2012
ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

© 2012 Shell Group of companies

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.

This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an
embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F.R. Parts 746) nor can be made available to any national of such
country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export
Administration Regulations (15 C.F.R. Parts 744)..
ECCN EAR99 DEP 31.40.30.30-Gen.
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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturer/Suppliers use DEPs, they shall be solely responsible for such use, including the quality
of their work and the attainment of the required design and engineering standards. In particular, for those requirements not
specifically covered, the Principal will typically expect them to follow those design and engineering practices that will
achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier
shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part
of a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturer/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after
use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
ECCN EAR99 DEP 31.40.30.30-Gen.
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TABLE OF CONTENTS
PART I INTRODUCTION ........................................................................................................5
1.1 SCOPE........................................................................................................................5
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........5
1.3 DEFINITIONS .............................................................................................................5
1.4 CROSS-REFERENCES .............................................................................................6
1.5 SUMMARY OF MAIN CHANGES...............................................................................6
1.6 COMMENTS ON THIS DEP .......................................................................................6
1.7 DUAL UNITS...............................................................................................................6
PART II GENERAL REQUIREMENTS ....................................................................................7
1.1 GENERAL ...................................................................................................................7
1.2 DOCUMENT HIERARCHY .........................................................................................7
1.3 SAFETY ......................................................................................................................7
1.4 PRINCIPAL ACCESS .................................................................................................7
1.5 PRE-JOB MEETING ...................................................................................................8
PART III AMENDMENTS/SUPPLEMENTS TO ISO 21809-5: 2010 .......................................9
1. Scope .........................................................................................................................9
3. Terms and definitions...............................................................................................9
4. Symbols and abbreviated terms .............................................................................9
4.2 Abreviated terms.........................................................................................................9
6. Information supplied by the purchaser ..................................................................9
6.1 General information ....................................................................................................9
7. Materials.....................................................................................................................9
7.1 Pipe .............................................................................................................................9
7.2 Cement........................................................................................................................9
7.4 Aggregate – Fine and course....................................................................................10
7.6 Lightweight aggregate...............................................................................................10
7.7 Recycled concrete as aggregate ..............................................................................10
7.8 Water.........................................................................................................................10
7.9 Steel reinforcement...................................................................................................10
9. Coating application.................................................................................................10
9.1 Qualification ..............................................................................................................10
9.2 Application of concrete coating.................................................................................12
9.4 Pipe ...........................................................................................................................12
9.5 Steel reinforcement...................................................................................................12
9.6 Concrete cutback ......................................................................................................13
9.7 Anode installation......................................................................................................13
9.7 Anodes ......................................................................................................................13
10. Curing methods ......................................................................................................13
11. Inspection and testing............................................................................................13
11.1 General .....................................................................................................................13
11.2 Test procedures ........................................................................................................15
11.3 Restesting .................................................................................................................19
12. Repair of concrete coated pipe .............................................................................19
12.1 General .....................................................................................................................19
12.2 Damaged areas ........................................................................................................19
12.3 Cracks .......................................................................................................................20
12.4 Gaps..........................................................................................................................20
13. Markings ..................................................................................................................20
14. Handling and storage .............................................................................................20
15. Test reports and certificates of compliance ........................................................21
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Annex C (normative) Data Sheet...........................................................................................22

PART IV REFERENCES .........................................................................................................23
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PART I INTRODUCTION

1.1 SCOPE
This DEP specifies requirements and gives recommendations for materials, qualification,
application, testing and handling of materials required for the application of reinforced
concrete coating externally to pre-coated pipe for use in pipeline transportation systems for
the petroleum and natural gas industries in marine environments, estuaries, rivers, wadis,
swamps, etc. It is based on to ISO 21809-5:2010.
The external application of concrete is primarily used for the negative buoyancy of pipes
used in buried or submerged pipeline systems and/or for the mechanical protection of the
pipe and its pre-coating.
This DEP is applicable to concrete thicknesses of 25 mm (1 in) or greater.
Part III of this DEP gives amendments and supplements the clauses of ISO 21809-5:2010.
This DEP includes the installation of anodes (including pin brazing) into the qualification but
excludes the design or purchase of anodes.
The scope of this DEP does not include:
a) specific design requirements (these would be established in the pipeline design);
b) the choice of anti-corrosion coating or its application;
c) the design, purchase and installation of buckle/crack arrestors;
d) the use of intermediate coatings (e.g. anti-slip coatings);
e) slotting of the concrete to reduce bending stiffness.
This is a revision of the DEP of the same number dated December 1999; see (1.5)
regarding the changes.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturer/Suppliers nominated
by them.
This DEP is intended for use in facilities related to oil and gas production, distribution and
supply/marketing. Application in other facilities may also apply.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regard to the safety, environmental, economic and legal aspects. In all
cases the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
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The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
1.3.2 Specific definitions
To maintain proper context with ISO 21809-5 terminology, the phrases “Purchaser” and
“applicator” have been maintained in this DEP where such context and alignment with
ISO 21809-5 terminology is important. In such cases, the phrases “Principal” and
“Contractor” as used in this DEP are generally equivalent to the phrases “Purchaser” and
“Applicator” respectively.

1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced by this DEP are listed in
(Part IV).

1.5 SUMMARY OF MAIN CHANGES

This DEP is a revision of the DEP of the same number dated December 1999. It
incorporates the content of and supersedes DEP 31.40.30.30-DWP, Concrete Coating of
Line Pipe, and 26TS-006, Application and Field Removal of Concrete Weight Coating on
Line Pipe.

1.6 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the Administrator at standards@shell.com, using
the DEP Feedback Form. The DEP Feedback Form can be found on the main page of
“DEPs on the Web”, available through the Global Technical Standards web portal
http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.

1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.
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PART II GENERAL REQUIREMENTS

1.1 GENERAL
Part III of this DEP is written as amendments and supplements to ISO 21809-5:2010.
Whenever reference is made to ISO, it shall be understood to mean ISO 21809-5:2010 as
amended/supplemented by this DEP.
For ease of reference, the clause numbering of ISO 21809-5:2010 has been used
throughout (Part III).
Unless specified in this DEP, all occurrences of the word “should” in ISO shall be replaced
with the word “shall”.
Clauses in ISO 21809-5:2010, which are not mentioned in this DEP shall remain valid as
written.

1.2 DOCUMENT HIERARCHY

In the event of conflicts between contract documents, AFC drawings, specifications and
other referenced standards, the following document hierarchy shall apply:
• Contract or agreement (including any approved exceptions)
• AFC drawings – latest revisions
• Principal’s specifications (including project specific information)
• Industry Standards (e.g. ISO, NACE)

1.3 SAFETY
Application of coatings can include the use of hazardous materials, operations and
equipment. This DEP does not purport to address all the potential safety concerns
associated with their use. It is the responsibility of the Applicator to establish appropriate
safety and health requirements and determine any regulatory requirements or limitations
prior to use
Health, Safety and Environment concerns shall be identified and included in the detailed
coating procedure and pre-job discussions. All surface preparation and coating application
systems shall undergo a complete safety inspection and checkout prior to use.
Adequate exhaust/ventilation equipment shall be used, as required, for removal of any air
contaminated products to achieve acceptable air quality standards and to protect
personnel.
The safe practices recommended in industry standards shall be followed. Waste material
shall be handled and disposed of properly. Protective equipment requirements in the
Manufacturer’s Material Safety Data Sheet(s) shall be followed.
Coating work pieces shall be electrically grounded (earthed) as required to eliminate static
charges associated with surface preparation and coating operations.

1.4 PRINCIPAL ACCESS

The Principal’s representative, including independent inspectors or consultants as may be
engaged by the Principal, shall be permitted access to the coating application site at any
time to conduct performance analyses, including quality control tests of the materials being
used.
The Principal’s representative has the right to reject any or all work or equipment that in
his/her opinion does not conform to these requirements. Any work that in the opinion of the
Principal’s representative does not comply with these requirements shall be rectified at the
Contractor’s expense.
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The Principal’s representative has the right to request quality control tests at any time in
addition to those completed at pre-determined intervals.

1.5 PRE-JOB MEETING

The Applicator shall schedule a pre-job meeting to ensure that job requirements are fully
understood.
The personnel present at the meeting shall include, but not be limited to, the Principal’s
representative, and the Applicator’s representatives for coating supervision, quality control
and safety. If required a technical representative of the Manufacturer shall be present.
Roles and responsibilities shall be clarified at the pre-job meeting, such as when the
Principal deals with the Applicator, who are the focal points and how administration
procedures are executed. It shall be confirmed that all parties have the latest version of the
Contract, technical specifications, AFC drawings and ITP.
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PART III AMENDMENTS/SUPPLEMENTS TO ISO 21809-5: 2010

1. Scope
Delete this section and refer to (Part I, clause 1.1)
3. Terms and definitions
Add new terms:
3.38 qualification batch
the amount of materials produced within one (1) uninterrupted production run under
constant production conditions for qualification purposes only
3.39 pin brazing
A metallurgical process of making electrical connections to metallic structures based mainly
upon electric-arc silver soldering using a pin brazing unit and a hollow brazing pin
containing silver solder and flux
3.40 Shift
a set of pipes coated in one (1) production run of which the beginning and end coincide with
a change in personnel
4. Symbols and abbreviated terms

4.2 Abreviated terms

Add new abbreviations:

FBE Fusion Bonded Epoxy

MPa Megapascal
PE Polyethylene
PVC Polyvinyl Chloride
psi Pounds per Square Inch

6. Information supplied by the purchaser

6.1 General information

Add to clause:
The Data Sheet in Annex C shall be used to track Principal specified information. This data
sheet will be used as part of the purchase order.
7. Materials

7.1 Pipe
Add to clause:
Unless otherwise indicated by Principal, pipe shall be provided with an FBE coating
according to DEP 31.40.30.32-Gen. with a thickness of 0.45-0.56 mm (18-22 mils).

7.2 Cement
Modify the following clauses:
a) Certified by the Supplier to be in compliance with the requirements of ASTM C150
types I and II, or BS12. ASTM C595 or BS 146. Portland blast furnace cement
meeting ASTM C 595 or EN 197-4 standard may be substituted when the ambient
temperature is greater than 20°C (70°F) with Principal’s approval.
b) No more than three (3) months from the date of manufacture, unless it is retested
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and proven to be in compliance with the original standard.

Add to clause:
Cement that has hardened, partially hardened or become lumpy shall not be used.
Additional laboratory testing is required to determine the alkali percentage if it is not stated
on the certificate.

7.4 Aggregate – Fine and course

Add to clause:
Principal retains the right to sample aggregate at the job site or at the supply source, and
to reject any aggregate that is not deemed acceptable.

7.6 Lightweight aggregate

Add to clause:
Lightweight aggregate shall only be used with Principal approval.

7.7 Recycled concrete as aggregate

Add to clause:
The use of recycled concrete shall only be used with Principal approval.
Principal retains the right to sample sand at the job site or at the supply source, and to
reject any sand that is not deemed acceptable.

7.8 Water
Add to clause:
Well water, underground water and industrial water shall not be used without approval of
Principal.

7.9 Steel reinforcement

Add to clause:
Purchaser retains the right to reject wire mesh rolls that show signs of rust or have been
mangled due to mishandling.
9. Coating application

9.1 Qualification
Replace 1st paragraph with the following clause:
A qualification test in accordance with Table 1 shall be performed prior to the start of
concrete coating production. Five (5) test pipes representative of the requirements of the
purchase order and agreed on with the purchaser shall be concrete coated and test results
shall be in compliance with Table 1.
Add to clause:
Qualification tests shall also include the installation of one (1) anode (if applicable), three
(3) pin braze welds fabricated from the process, coating of one (1) pipe with an anode (if
applicable) and repairs to small and large areas including core hole repairs. If required by
Principal a bin braze qualification shall be performed to DNV OS F101, Appendix J of
DEP 37.81.40.31-Gen. or Annex C of DEP 61.40.20.30-Gen. Alternatively, a 1.0 kg
hammer test may be requested by the Principal.
Replace ISO 21809-5, Table 1 with (Table 1):
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Table 1
Frequency
Property Subclause Test method Requirements Tolerance
qualification
Aggregates 7.4, 7.5, 7.6 ASTM C33, EN Applicator’s Applicator’s Once per
12620 purchase order to purchase order to qualification
supplier supplier batch
Recycled 7.7 As in 7.7 Applicator’s values Applicator’s values Once per
aggregates when approved when approved qualification
batch
Water content 8 ASTM D4643, Applicator’s mix Applicator’s mix Start and stop
ASTM D4959, design design of qualification
ASTM D2216 batch
Pre-concrete 9.1 N/A Applicator’s Applicator’s Each pipe
coated pipe purchase order to purchase order to
length supplier if pipe not supplier if pipe not
provided by the provided by the
Principal Principal
Concrete 11.2.1 11.2.1 As stated in ± 6 mm Ten
coating purchase order measurement
thickness a on each pipe
Cement content 8 EN 206-1 Applicator’s mix Applicator’s mix Start and stop
and design and a design of qualification
water/cement water/cement ratio batch
ratio ≤ 0.40
Pre-concrete 11.2.3 Measurement As stated in N/A Each pipe
coated pipe purchase order (for informational
weight in air /data sheet purposes)
Concrete coated 11.2.4 Measurement As stated in +7.5%, -5% for Each pipe
pipe weight in purchase order each pipe;
air /data sheet +5%,-2.5% for
average
Concrete 11.2.5 ASTM C642 or As stated in ± 5% Each pipe
a
coating density EN 12390-7 purchase order
/data sheet
Concrete 9.6 Measurement As stated in ±12.5 mm Each end of
coating cutback purchase each pipe
length order/data sheet
Reinforcement 9.5.5 9.5.5 As stated in 9.5.5 As stated in 9.5.5 Each pipe
placement
Reinforcement 9.5.5.1 9.5.5.1 9.5.5.1 As stated in 9.5.5.1 Each pipe
electrical
isolation
Reinforcement 9.5.5.2 11.2.2 9.5.5.2 9.5.5.3 9.5.5.2 or 9.5.5.3 Each pipe
overlap 9.5.5.3 as applicable
Preparation of 11.2.6.1 ASTM C31, N/A N/A One (1) set of
compressive ASTM C172, or five (5)
strength EN 12390-2 specimens
specimens from ASTM C1435 or
fresh concrete ASTM C1176 d
Preparation of 11.2.6.2 ASTM C42, N/A N/A One (1) set of
compressive ASTM C1604, three (3)
strength or EN 12504-1 visually
specimens from acceptable
hardened specimens per
concrete pipe
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Frequency
Property Subclause Test method Requirements Tolerance
qualification
Compressive 11.2.6.3 ASTM C39, 20 MPa after Minimum average All specimens
strength b ASTM C42, or 7 days of all 28 day tests is
EN 12390-3 25 MPA.
Water 11.2.7 Annex A of ISO Not to exceed 5% None One (1) test per
c
absorption 21809-5:2010 pipe
Shear 11.2.9 Annex B of ISO 0.34 MPa minimum N/A One (1) pipe per
resistance 21809-5:2010 qualification
batch
Impact 11.2.8 11.2.8 11.2.8 N/A One (1) set on
resistance one (1) pipe,
when specified
Environmental 9.3 ASTM D6176 9.3 N/A Start of a
conditions qualification
batch

NOTES a) If the applicator has calculated the thickness and density of the concrete coating from the specific
gravity or negative buoyancy stated in the purchase order, then the results shall be approved by the
purchaser prior to the qualification test.
b) For qualification, the method of testing compressive strength shall be agreed on between the
purchaser and the applicator. Cores shall not be taken if the concrete thickness is less than 40 mm.
c) Hardened concrete coating field specimens that have achieved a minimum compressive strength of
20 MPa shall be tested in compliance with Annex A for water absorption.
d) ASTM C1435 and ASTM C1176 are acceptable with approval from the Principal.

9.2 Application of concrete coating

Modify the following clause:
Concrete coating shall be applied by either of the following processes:
a. compression (wrap);
b. impingement;
NOTE If an impingement application technique is utilized on fusion bonded epoxy coating, then the Contractor
shall demonstrate that the impingement process does not create holidays in the coating.

c. form and/or pour, subject to prior agreement from the Principal.

9.4 Pipe
9.4.2 Bare pipe
Delete this section

9.5 Steel reinforcement

9.5.1 General
Modify the following clause
The reinforcement provided shall be a cage, welded wire mesh or a combination thereof.
Add to clause:
Two (2) layers of reinforcement shall be used for thickness greater than 65 mm (2.5 in).
9.5.4 Woven wire mesh reinforcement
Delete this section
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9.6 Concrete cutback

Add to clause:
Tolerance on cutbacks shall be ± 12.5 mm (0.5 in), unless otherwise specified by Principal.

9.7 Anode installation

Replace this entire section with:
9.7 Anodes
9.7.1 Installation
Anodes shall be located at the pipe mid-length and at least 150 mm (5.9 in) from a girth
weld (if applicable). Bracelet anodes shall have a suitable protective material (#15 felt,
fibreglass matting, 1.5 mm (0.06 in) thick neoprene mat, or equivalent approved by
Principal) underneath the anode to protect the corrosion coating.
Anodes shall be fitted tightly over and around the anti-corrosion coating by use of a tension
applicator or Purchaser approved method. Cages and straps shall be fillet welded together
in accordance with a pre-qualified welding procedure developed to a national/international
code, or one proposed by the Contractor and approved by the Principal.
All galvanising and coating shall be removed for at least 15 mm (0.6 in) around the
intended weld areas. The fillet welds shall also be continuous around all edges and shall be
visually inspected for compliance with the approved code or standard. The anti-corrosion
coating shall be protected from an arc being struck on it during welding.
9.7.2 Electrical connections
Two (2) bonding leads will be supplied with each anode half, either separate or pre-welded
at one (1) end, as specified by the Principal in the Scope of Work. Bent or out-of round
cable ends shall be removed using a proper cable cutter. The Contractor shall remove
25 mm (1 in) of the PVC insulation at the cable ends. The cable ends shall be clean, dry
and free from grease and oil. The cable connection shall be made in an area where no
concrete will be applied (in the gap between the two (2) half-shells, if possible). Pipe
surface areas shall be clean, to ISO 8501-1, grade St-3, prior to bonding the clean cable
ends to the pipe surface by a pin braze weld. The gaps between the concrete and the
anodes shall be filled using a suitable type of concrete or mastic.
A gap of at lease 15 mm shall be maintained between the anode and the concrete coating
reinforcement.
The anode cable connection to the pipe surface shall be located at least 150 mm (6 in) from
a seam or girth weld.

10. Curing methods

Replace the last paragraph with the following:
Whichever method is used, concrete coating shall remain moist until a minimum
compressive strength of 20 MPa (2 900 psi) is achieved as tested by field specimens.

11. Inspection and testing

11.1 General
Replace ISO 21809-5, Table 2 with (Table 2):
Table 2
Frequency
Property Subclause Test method Requirements Tolerance
qualification
Aggregates 7.4, 7.5, 7.6 ASTM C33, Applicator’s Applicator’s Twice per week
EN 12620 purchase order to purchase order to
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Frequency
Property Subclause Test method Requirements Tolerance
qualification
EN 12620 supplier supplier
Recycled 7.7 As in 7.7 Applicator’s values Applicator’s values Each 100 m3 of
aggregates when approved when approved processed
material
Water content 8 ASTM D4643, Applicator’s mix Applicator’s mix Minimum of one
ASTM D4959, design design (1) every 2 hour
ASTM D2216 of production
EN 1008, or
ASTM C685
Concrete 11.2.1 11.2.1 As stated in ± 6 mm Six (6)
coating purchase order measurements
thickness /data sheet on each pipe
Cement content 8 EN 206-1 Applicator’s mix Applicator’s mix Minimum of one
and design and a design (1) every 2 hours
water/cement water/cement ratio of production
ratio ≤ 0.40
Concrete 11.2.4 Measurement As stated in +7.5%, -5% for Each pipe a
coated pipe purchase order each pipe; +5%,
weight in air /data sheet -2.5% for rolling 25
consecutive pipe
average
Submerged 11.2.4.1 Calculation As stated in +7.5%, -5% for Each pipe a
pipe weight purchase order each pipe; +5%,
/data sheet -2.5% for rolling 25
consecutive pipe
average
Concrete 11.2.5 ASTM C642 or As stated in ± 5% One (1) sample
coating density EN 12390-7 purchase order for every
/data sheet 25 pipes up to
three (3) times
per shift
Concrete 9.6 Measurement As stated in ±12.5 mm Each end of each
coating cutback purchase order pipe
length /data sheet
Reinforcement 9.5.5 9.5.5 9.5.5.2 or 9.5.5.3 As stated in 9.5.5.1 Twice per shift
placement as applicable
Reinforcement 9.5.5.1 9.5.5.1 9.5.5.1 As stated in 9.5.5.1 Twice per shift
electrical 11.2.11
isolation
Reinforcement 9.5.5.2 11.2.2 9.5.5.2 or 9.5.5.3 As stated in 9.5.5.1 Once per shift
overlap 9.5.5.3 as applicable per pipe size or
concrete
thickness
Preparation of 11.2.6.1 ASTM C31, N/A N/A A set of three (3)
compressive ASTM C172, or test specimens
strength EN 12390-2 from the first 50
3
specimens from m , then each
fresh concrete 150 m3
thereafter, or
three (3) test
specimens at
least twice per
production shift,
whichever is
more frequent
ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 15

Frequency
Property Subclause Test method Requirements Tolerance
qualification
Preparation of 11.2.6.2 ASTM C42, N/A N/A A set of three (3)
compressive ASTM C1604, visually
strength or EN 12504-1 acceptable test
specimens from specimens from
hardened one (1) pipe of
concrete every 25 pipes
coated
Compressive 11.2.6.3 ASTM C39, 20 MPa after Minimum average All test
strength ASTM C42, or 7 days. of all 28 day tests is specimens
EN 12390-3 25 MPA.
Water 11.2.7 Annex A of ISO Not to exceed 5% None Minimum of
absorption 21809-5:2010 once per
production
shift, test
specimens as
in Annex A
Shear 11.2.9 Annex B of ISO 0.34 MPa minimum N/A Purchase order
resistance 21809-5:2010 /data sheet
Impact 11.2.8 11.2.8 11.2.8 N/A Once per day b
resistance
Environmental 9.3 ASTM D6176 9.3 N/A Start of each
conditions production shift
and during
obvious weather
changes
Holiday 7.1 ASTM G62 No holidays N/A Each pipe
detection (for detected
coated pipes)
Visual 11.2.10 11.2.10 11.2.10 N/A Each pipe
Inspection

NOTES: a) Pipes with anodes, crack arrestors, and buckle arrestors shall have this weight added to the uncoated
weight for tolerance.
b) Impact testing shall be done once per day for the first three (3) days.

11.2 Test procedures

11.2.1 Concrete coating thickness – Diameter measurement
Replace the second sentence of the first paragraph with the following sentence:
The diameter of each coated pipe shall be measured either continuously by automatic
measuring device, or by using a girth tape in six (6) positions spaced at approximately
equal intervals with the two (2) end measurements being approximately 600 mm (23.6 in)
from the ends of the concrete coating.
Add to clause:
The radial distance between any high and low points of the coating surface shall not
exceed 8 mm (0.3 in) in any 500 mm (19.7 in) length, nor 5 mm (0.2 in) in the last 1 m (3 ft)
length at each end.
Replace the last paragraph with the following:
Coated pipes outside the stated tolerances of this section, Table 1 or Table 2 shall be
repaired or stripped and re-coated, at the discretion of the Principal.
ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 16

11.2.2 Placement of reinforcement

Modify the first paragraph:
A section of freshly applied concrete approximately 100 mm x 200 mm (3.9 x 7.9.in) shall
be removed from the first pipe of each day’s production down to the pre-coating.
11.2.4 Concrete coated pipe weight in air
Add to clause:
Calibration shall be carried out at the beginning of each working shift, using weights which
have an accuracy of 0.1% or better.
Add new section
11.2.4.1 Submerged Pipe Weight
The submerged pipe weight shall be calculated and be within the acceptance limits as
stated by the Principal in the Scope of Work for each coated pipe in accordance with the
following equations:

Equation 1

Where: W = total weight of concrete coated pipe in air (N) or (lb/ft)

B = buoyancy of pipe (as defined by Equation 2) (N) or (lb/ft)
L = length of pipe (m) or (ft)
w = unit weight of bare steel pipe (N/m) or (lb/ft), to be specified by the Principal
c = length of concrete cutback (m) or (ft), to be specified by the Principal

Equation 2a

Where: D= outside diameter of concrete (mm), average of 6 measurements. If D is given

in inches, the equation changes to:

Equation 2b

ρ = density of the displaced water (kg/m3) or (lb s2/ft)

g = gravitational acceleration (m/s2) or (ft/s2)
If a pipe requires scraping or additional concrete to control or adjust its weight, the
minimum specified cover shall remain over the reinforcement and any additional concrete
shall be applied within 30 minutes of the first concrete application.
Any pipes that are rejected for being outside the submerged weight tolerances shall have
all concrete coating removed.
11.2.5 Concrete coating density
Add to clause:
Cores shall be removed with a diamond cutter.
ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 17

Cores shall be cut within four (4) days of concrete application and stored in a curing tank
until tested.
Density of the applied concrete shall be determined seven (7) days after core removal.
11.2.6 Compressive strength
11.2.6.1 Preparation of Specimens from Fresh Concrete
Add to clause:
Specimens prepared by ASTM C1176 or ASTM C1435 shall be approved by the Principal.
11.2.6.2 Preparation of Specimens from Hardened Concrete
Add to clause:
Manufacturer/Supplier shall provide the time required for the concrete specimens to
sufficiently hardened. If the Manufacturer/Supplier does not have this information available,
then a time of seven (7) days will be assumed.
11.2.6.3 Testing of Specimens from Hardened Concrete
Add to clause:
Compressive strength shall be no less than 20 MPa (2,900 psi) at seven (7) days. Shorter
durations are acceptable based on demonstrated qualification tests and/or subsequent core
tests.
11.2.7 Water absorption
Modify the following clause:
Hardened concrete coating specimens that have achieved a minimum compressive
strength of 20MPa shall be tested in accordance with Annex A using water saturated tests.
11.2.8 Impact resistance
Add to clause:
DNV RP F-111 shall be used to determine the appropriate scenario for impact testing as
defined in the purchase order.
If no scenario is provided or if for qualification, the requirements below shall be used.
Figure 1 provides an example of the test rig setup.
Impact testing shall be performed as follows for qualification or if no scenario is provided:
a) The concrete coated test pipe shall be rigidly supported from the rear over its full
length by moist sand. The pipe shall be held rigidly at its ends by wooden cradles
and wedges to prevent movement of the pipe under impact.
b) The point of impact on the concrete shall be at the 3 o’clock position. The pipe shall
be supported so that impact of the concrete is made when the hammer is at the
lowest point in its swing.
c) Testing shall be carried out with the maximum impact load 90° to pipe axis. The test
pipe shall be supported with a minimum of 2 m (7 ft) concrete section either side of
the section under test. Impact blows shall be directed on the same location and the
condition of the concrete recorded after each blow, until the anti-corrosion coating is
exposed. Testing shall be performed with 2.68 tonnes (5 908 lb) at one (1) location
90° to the pipe axis
d) Testing shall be carried out with a reduced impact load 60° to the pipe axis. The test
pipe or rig shall be moved along at least another 2 m (7 ft) and the pipe impacted in
the 60° position to the line of motion of the hammer. Five (5) impact blows shall be
directed on the same location and the condition of the concrete recorded after each
blow. Testing shall be performed with 1.84 tonnes (4056.5) at one (1) location 60° to
the pipe axis.
ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 18

e) Test results shall include:

i. A photograph after each impact
ii. Diagram(s) of crack patterns and spalled areas including lengths and widths of
major cracks.
iii. Dimensional changes of the pipe.
f) 90° location acceptance criteria:
i. The anti-corrosion coating shall not be visible and the steel pipe wall shall not be
indented or damaged after 5 blows.
ii. Spalling shall not occur over an axial distance greater than 300 mm (12 in) each
side of the points of impact, after 5 blows.
g) 60° location acceptance criteria:
i. The anti-corrosion coating shall not be visible after five (5) blows.

Figure 1: Impact Test Rig

Pipes subject to impact testing shall be scrapped and not repaired or incorporated in the
pipeline.

11.2.9 Shear resistance

Add new note:
NOTE As a means of meeting shear requirements the Contractor may utilize an adhesive. If an adhesive is
utilized it shall cover the entire length of concrete coating.
ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 19

Add new section:

11.2.11 Electrical resistivity
Pipes which fail the electrical resistance test shall be stripped and re-coated after the
reinforcement has been correctly installed. If any there pipes fail the test sequentially, then
all of the shifts production shall be tested and acceptance shall be on a pipe by pipe basis.

11.3 Restesting
11.3.2 Density
Modify the following clause:
If the spare test specimens meet the density requirements, the previously suspect concrete
coated pipes shall be accepted with Principal approval.
11.3.3 Compressive strength
Modify the following clause:
If the spare test specimens meet the specified strength requirements, the previously
suspect concrete coated pipes shall be accepted with Principal approval.
11.3.4 Water absorption
Modify the following clause:
If the spare test specimens meet the specified water absorption requirements, the
previously suspect concrete coated pipes shall be accepted with Principal approval.

12. Repair of concrete coated pipe

12.1 General
Add to clause:
The Principal may reject concrete-coated pipes when any of the previously stated
acceptance criteria are not met, and in such case the coating shall be completely removed
rather than partially repaired. Where repairs are permitted in accordance with this DEP,
they shall be repaired in accordance with this section.
Concrete used for repairs shall contain the same proportions of dry constituents as the
original coating but the water/cement ratio may be higher, to improve workability.
Prior to application of repair material, the defective area shall be thoroughly cleaned by
removing concrete coating sufficiently to clean under the reinforcing bars and the concrete
edges shall be cut so as to form a holding key.
All repairs shall be moist-cured for a minimum period of 48 hours, or until the repaired area
has attained a compressive strength of 14 MPa (2030 psi).
The Contractor shall demonstrate that the procedures for repair application and cure will
result in an acceptable coating with the compressive strength of repair being at least equal
to the strength of the compressive strength requirements in Table 2. All repair methods
shall be subject to the Principal’s approval.

12.2 Damaged areas

Add to clause:
Pipe may be repaired by hand patching, providing that such repairs are carried out while
the concrete is in a ‘green’ state (i.e. within 4 hours of coating application and prior to
curing).
If the Contractor wishes to repair areas on cured concrete, a guniting process that is
approved by the Principal shall be used.
ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 20

12.3 Cracks
Add to clause:
Longitudinal cracks in excess of 1000 mm (39 in) in length or extending the full depth of
the coating are not acceptable and coating with such a crack shall be removed for the
entire length of pipe.

12.4 Gaps
Modify the following clause:
Gaps between the pre-coated pipe and the concrete coating in excess of 1,5 mm (0.06 in) ,
extending more than 150 mm (6 in) from the beginning of the concrete cutback, that have a
length of more than 60° around the circumference of the pipe, and which remain for at
least 30 minutes after the pipes have been taken out of stockpile shall be repaired.

13. Markings
Add to clause:
Unless otherwise instructed in the purchase order, the following is considered good
practice:
• All concrete-coated pipes shall be colour-coded in order to readily identify the
different categories of pipe thickness, coating thickness and attachments. A colour
coding scheme shall be specified in the Scope of Work. Colour bands using marine
paint shall be applied near both ends of the concrete coating. The paint shall also be
suitable for long-term storage at the designated final delivery location. These bands
shall be 50 mm (2 in) wide starting at 150 mm (6 in) from each end of the concrete
coating. The bands shall be applied immediately after concrete curing.
• Contractor shall present a method of identifying Principal materials. If no method
exists, a Yellow band [50 mm (2 in) minimum wide] shall be placed at the middle of
the joint to identify Principal owned pipe.

14. Handling and storage

Add to clause:
Maximum stacking height shall be 4 m (13 ft), unless local regulations are more stringent.
All pipe shall be stored at an angle to allow rain water to drain from the interior.
Pipes shall be stored on prepared sand rows or on timber covered with non-metallic soft
material. Sand rows shall be kept clean and clear of vegetation, large and injurious
aggregates or any other deliterous substances.
Storage in excess of two (2) months shall have a layer of polyethylene sheeting and
bottom pipes, at a minimum, shall be secured with wedges or clips to prevent collapse of
the stockpile.
Coated pipe shall be handled using web slings or padded end hooks. Forklift tractors that
are properly padded may be used for in-plant handling, but coated pipe that has been
nested in storage shall be handled using a crane with padded end hooks and a spreader
bar.
Concrete-coated pipe shall be stockpiled at the Contractor’s yard prior to load-out. Pipe
stacks shall be segregated by pipe diameter, wall thickness, anode/arrestor installation and
concrete coating thickness, and if applicable source.
Before application of concrete coating, FBE corrosion coated pipe, when stored or
shipped, shall have at least four (4) Purchaser approved spacers (rope or nylon rings)
completely encircling the pipe for each joint length.
ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 21

15. Test reports and certificates of compliance

Add to clause:
An English language translation of all documents submitted shall be provided in addition to
the original documents. Company’s name and project identification shall also be
referenced.
The following information will also be provided:
a) Manufacturer/Supplier product literature, batch certifications, quality control
documentation and MSDS sheets for concrete coating materials, reinforcement,
adhesive, and curing membranes
b) All materials and application test results by applicator
c) Details and documentation of repairs
 ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 22

add new Annex

Annex C (normative) Data Sheet

PROJECT: SPECIFICATION:
CONCRETE COATING OF LINE PIPE
DEP 31.40.30.30-Gen.

PIPE USED FOR: PREPARED BY: DATE PREPARED:

INQUIRY/P.O. NO.: ITEM NO.:

GENERAL SCHEDULE
QUANTITY__________________________________ PIPE ARRIVAL DATE____________________________
JOINT LENGTH/TOLERANCE___________________ TRANSPORTATION MEANS______________________
PIPE SIZE/WALL THICKNESS___________________ REQ. COATING COMPLETION DATE_______________
PIPE ADDITIONAL
MANUFACTURER/SUPPLIER___________________ INFORMATION_________________________________
______________________________________________
CORROSION COATING ______________________________________________
TYPE/THICKNESS____________________________ ______________________________________________
WEIGHT IN AIR REQUIREMENTS
PRE-COATED PIPE Yes/No COLOR CODING
COATED PIPE Yes/No _________________________________________
_________________________________________
CONCRETE COATING
_________________________________________
COATING THICKNESS_________________________ _________________________________________
COATING DENSITY___________________________ _________________________________________

LENGTH OF PIPE JOINT WITH ADHESIVE_________ OTHER REQUIREMENTS

COATING CUTBACK ______________________________________________

______________________+/-____________________
ADDITIONAL REQUIREMENTS
SHEAR RESISTANCE TESTING
IMPACT RESISTANCE TESTING
SUBMERGED PIPE WEIGHT
PIN BRAZE QUALIFICATION (Circle One)
Hammer Strike / DNV OS F101 /
Appendix J of DEP 37.81.40.31-Gen. /
Annex C of DEP 61.40.20.30-Gen.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Yes/No
______________________________________________
Yes/No ______________________________________________
______________________________________________
Yes/No
______________________________________________
______________________________________________
OTHER COMMENTS
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
_____________________________________________
ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 23

PART IV REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS
External fusion-bonded epoxy powder coating for line pipe DEP 31.40.30.32-Gen.
(amendments/supplements to ISO/DIS 21809-2:2009)
Welding of deepwater pipelines, flowlines and steel catenary risers DEP 37.81.40.31-Gen.
(amendments and supplements to API 1104)
Welding of pipelines and related facilities DEP 61.40.20.30-Gen.
(amendments/supplements to ISO 13847:2000)

AMERICAN STANDARDS
Standard Practice for Making and Curing Concrete Test ASTM C31
Specimens in the Field
Standard Specification for Concrete Aggregates ASTM C33
Standard Test Method for Compressive Strength of Cylindrical ASTM C39
Concrete Specimens
Standard Test Method for Obtaining and Testing Drilled Cores ASTM C42
and Sawed Beams of Concrete
Standard Specification for Portland Cement ASTM C150
Standard Practice for Sampling Freshly Mixed Concrete ASTM C172
Standard Specification for Blended Hydraulic Cements ASTM C595
Standard Test Method for Density, Absorption, and Voids in ASTM C642
Hardened Concrete
Standard Specification for Concrete made by Volumeteric ASTM C685
Batching and Continuous Mixing
Standard Practice for Making Roller-Compacted Concrete in ASTM C1176
Cylinder Molds Using a Vibrating Table
Standard Practice for Molding Roller-Compacted Concrete in ASTM C1435
Cylinder Molds Using a Vibrating Hammer
Standard Test Method for Obtaining and Testing Drilled Cores of ASTM C1604
Shotcrete
Standard Test Methods for Laboratory Determination of Water ASTM D2216
(Moisture) Content of Soil and Rock by Mass
Standard Test Method for Determination of Water (Moisture) ASTM D4643
Content of Soil by Microwave Oven Heating
Standard Test Method for Determination of Water (Moisture) ASTM D4959
Content of Soil by Direct Heating
Standard Practice for Measuring Surface Atmospheric ASTM D6176
Temperature with Electrical Resistance Temperature Sensors
Standard Test Methods for Holiday Detection in Pipeline Coatings ASTM G62
ECCN EAR99 DEP 31.40.30.30-Gen.
February 2012
Page 24

BRITISH STANDARDS
Cement – Part 1: Composition, specifications and conformity BSI BS 12
criteria for common cements
Specification for Blastfurnace Cements with Strength Properties BSI BS 146
Outside the Scope of BS EN 197-1

EUROPEAN STANDARDS
Cement – Part 4: Composition, specifications and conformity EN 197-4
criteria for low early strength blastfurnace cements
Concrete - Part 1: Specification, performance, production and EN 206-1
conformity
Mixing water for concrete - Specification for sampling, testing and EN 1008
assessing the suitability of water, including water recovered from
processes in concrete industry, as mixing water for concrete
Testing hardened concrete - Part 2: Making and curing specimens EN 12390-2
for strength tests
Testing hardened concrete - Part 3: Compressive strength of test EN 12390-3
specimens
Testing hardened concrete - Part 7: Density of hardened concrete EN 12390-7
Testing concrete in structures - Part 1: Cored specimens - Taking, EN 12504-1
examining and testing in compression
Aggregates for concrete EN 12620

INTERNATIONAL STANDARDS
Preparation of steel substrates before application of paints and ISO 8501-1
related products – Visual assessment of surface cleanliness –
Part 1: Rust grades and preparation grades of uncoated steel
stubstrates and of steel substrates after overall removal of previous
coatings
Petroleum and natural gas industries – External coatings for buried ISO 21809-5
or submerged pipelines used in pipeline transportation systems –
Part 5: External concrete coatings

NORWEGIAN STANDARDS
Interference between Trawl Gear and Pipelines DNV RP-F111
Submarine Pipeline Systems DNV OS F101