ITP No.

KHI-RCL-001

WORK INSTRUCTION
of
Cement Lining Repair

Customer : PT Contromatic Prima Mandiri

Project : RDMP PROJECT RU V BALIKPAPAN

Issued for
0 03-Feb-20
Information KW TE MF
QA Customer
Rev. Date Description Prepared by Reviewed by
Checked by Approved by

This Document is the property of KHI and must not be handed to a third party or reproduced completely or in a part without the explicit
written consent of KHI

PT. KHI PIPE INDUSTRIES

CILEGON - BANTEN
 Doc. No KHI-RCL-001
WORK INSTRUCTION Page 1 of 3
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Date 3 February 2020
Cement Lining Repair
Revision 0

I. SCOPE

This procedure covers the method of repair works for Cement Internal Lining (CL) at coating plant
and the field due to production processes, handling, transportation, cutting pipe and installation
damages. This procedure develops for used by coating applicator or contractor which is handle
pipe on the site.

II. CODE, SPECIFICATIONS, STANDARD AND REFERENCES

The following code, specifications, standards and reference are relevant to this document:

1. AWWA C205-2012 : Cement–Mortar Protective Lining and Coating for Steel Water
Pipe—4 In. (100 mm) and Larger—Shop Applied
2. ASTM C150 : Standard Specification for Portland Cement
3. ASTM C33 : Standard Specification for Concrete Aggregates
4. ASTM C40 : Test Methode for Organic Impurities in Fine Aggregates for Concrete

III. MATERIAL FOR REPAIR CEMENT MORTAR LINING

1. Cement : Cement for mortar shall conform to ASTM C150 Type V.
2. Sand : Sand shall be natural sand conform to ASTM C33. Quality
standards of sand shall conform to ASTM C40.
3. Water : Water for mixing mortar shall corform to AWWA C205.
4. Curing Membrane Calcurer B

IV. CEMENT LINING REPAIR

4.1 CEMENT LINING REPAIR WORK AREA

1. Both end of pipes completed cement lining with the machine.

2. Cement lining condition cracked more than 1,6 mm in width or circular on pipes or accessories.
Crack under 1,6 mm in width do not required repair due to autogenous healing effect.
3. Any spalling of cement lining area due to pipe cutting or installation modify at working site.

4.2 ITEM 1, REPAIR BOTH END OF PIPES ON CEMENT LINING

1. Use PPE appropriate to the situation and conditions of service.
2. Check the condition of the engine and the working environment is in a condition safe or unsafe.
If it becomes unsafe conditions and there is a potential danger, coordination with relevant
parties to fix the place / machine / tooling.
3. All repairs must be within 2 hours after application of lining. The paching material shall bond
to the cement and not crack upon curing.
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Cement Lining Repair
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4. After being released End Cap, both end of the surface is cleaned of mud cement + sand due to
the rotation of the pipe in the engine, until the surface becomes rough.
5. Apply cement + sand mortar according to mortar mixer, using a repair tool that has been
prepared.
6. Similarly, with the repair tool ends surface smoothed by paying attention to preferred lining
thickness.
7. To reduce and prevent cracking in end of pipes, having obtained a good surface it is applied
aditive (Calcurer B) mixed with water.
8. After completion of repair, end of pipes is closed with plastic (progress Curing) minimum 4 days
(4 x 24 hours).

4.3 ITEM 2 REPAIR CEMENT LINED ON THE SURFACE CRACKS IN PIPES AND
ACCESSORIES (TRANSVERSE AND LONGITUDINAL)
1. Use PPE appropriate to the situation and conditions of service.
2. Check the condition of the engine and the working environment is in a condition safe or unsafe.
If it becomes unsafe conditions and there is a potential danger, coordination with relevant
parties to fix the place / machine / tooling.
3. Strip off cracked area up to clean from ash or dust of demolition.
4. Using the brush, the area is wetted and smeared with cement water that has been mixed with
calcure B (curing membrane)
5. Cement and sand mortar for the repair mixed expanding aditive
6. Then the mortar cement + sand that had been prepare, poured on the area that has been wetted
and smeared, flatten and spread the cement to get good surface.
7. Apply calcure B (curing membrane) evenly on the surface.

4.4 ITEM 3 REPAIR CEMENT LINED ON THE SPALLED IN PIPES AND ACCESSORIES
1. Use PPE appropriate to the situation and conditions of service.
2. Check the condition of the engine and the working environment is in a condition safe or unsafe.
If it becomes unsafe conditions and there is a potential danger, coordination with relevant
parties to fix the place / machine / tooling.
3. Remove spalled area up to clean from ash or dust of demolition. Make the chamfer surface
around the spalled area. Clean the inside of the pipe with water before repair.
4. Using the brush, the area is wetted.
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Date 3 February 2020
Cement Lining Repair
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5. Prepare a mixture by using a concrete mixer mortar between materials portland cement, stone
dust or sand and fresh water by using the following weight ratio:
a. Portland cement and stone dust or sand 1 : 2 (Maximum)
b. Cement portland and water (water ratio) 1 : 0.6 (Maximum)
The mix time from adding water to mix shall be minimum 10 minutes, and maximum time
interval from adding water to mix and final placing of mortar shall be 45 minutes.
6. Then the mortar cement + sand that had been prepare, apply on the area that has been wetted
and smeared, flatten by spatula to get uniform thickness and good surface.
7. Apply calcure B (curing membrane) evenly on the surface.
8. To avoid quick hydration, the humidity of repaired area shall be maintain, using wetted gunny
sack or other material.