N-2432 REV.

A JUL / 2007

EXTERNAL COATING
CONTEC SC-14
Painting and Coatings
CONCRETE FOR PIPES
Anticorrosives LAND AND UNDERWATER

1aAmendment

This is the 1aAmendment to the PETROBRAS Norm N-2432 REV. A and is intended to modify its
text in the indicated section below.

Item 8.7.1:

Content change.

Item 8.7.2:

Content change.

Note: The new pages of the changes made are located on the pages
corresponding originals.

_____________

PROPERTY OF PETROBRAS 1 page

 N-2432 REV. A SET / 2004

Exterior coating
CONCRETE FOR PIPES
LAND AND UNDERWATER

Procedure
This standard replaces and cancels its previous revision.
It is up to CONTEC - Authoring Subcommittee, to guide the interpretation of
text of this Standard. The PETROBRAS body using this Standard is the
responsible for the adoption and application of its items.

Technical Requirement: Prescription established as the most suitable and that

CONTEC must be used strictly in accordance with this Standard. A
eventual resolution of not following it ("non-compliance" with this Standard) must
Standards Commission has technical-managerial foundations and must be approved and registered by
Techniques Body of PETROBRAS that uses this Standard. It is characterized by the verbs:
“dever”, “ser”, “exigir”, “determinar” e outros verbos de caráter impositivo.

Recommended Practice: Prescription that can be used under the conditions

foreseen by this norm, but admits (and warns about) the possibility of
alternative (not written in this Standard) more suitable for the specific application. A
the adopted alternative must be approved and registered by the body of
PETROBRAS user of this Standard. É characterized by the verbs:
“recomendar”, “poder”, “sugerir” e advise (verb of character)
non-mandatory). It is indicated by the expression: [Recommended Practice].

Copies of the records of the 'non-conformities' with this Standard, which may
to contribute to your improvement, should be sent to the
SC - 14 CONTEC - Author Subcommittee.

Painting and Coatings

Proposals for the revision of this Standard must be sent to CONTEC -
Anticorrosives Author Subcommittee, indicating its alphanumeric identification and review, the
item to be reviewed, the drafting proposal and the technical-economic justification.
The proposals are discussed during the work to amend this Standard.

This standard is the exclusive property of PETRÓLEO BRASILEIRO

S.A. - PETROBRAS, for internal use in the Company, and any reproduction
for external use or disclosure, without prior and express permission
authorization from the owner constitutes an illegal act under the terms of the legislation
relevant, through which the responsibilities will be attributed
applicable. External circulation will be regulated by a specific clause of
Secrecy and Confidentiality, under the terms of intellectual law and property
industrial.

Presentation
The PETROBRAS Technical Standards are developed by Working Groups.
GTs (formed by specialists from the Company and its Subsidiaries) are commented on by
Units of the Company and its Subsidiaries are approved by the Authoring Subcommittees - SCs.
(formed by technicians of the same specialty, representing the Units of the Company and
its subsidiaries) and approved by the CONTEC Plenary (formed by the representatives of
Units of the Company and its Subsidiaries). A PETROBRAS Technical Standard is subject to
review at any time by its Author Subcommittee and must be reanalyzed every 5 years for
to be revalidated, reviewed, or canceled. The PETROBRAS Technical Standards are drawn up in
compliance with the PETROBRAS standardN - 1For complete information on the Standards
PETROBRAS techniques, see the PETROBRAS Catalog of Technical Standards.

PROPERTY OF PETROBRAS 26 pages and Review Index

 N-2432 REV. A SET / 2004

SUMMARY

2 SUPPLEMENTARY DOCUMENTS............................................................................................................... 4

3 APPLICATION PROCEDURES.................................................................................................................. 5

4 MATERIALS ......................................................................................................................................................... 7

4.1 ANTI-CORROSIVE COATING ................................................................................................... 7

4.2 CEMENT.............................................................................................................................................. 7

4.3 AGGREGATES

4.4 WATER

4.5 REINFORCEMENT SCREEN............................................................................................................................. 8

4.6 WATERPROOF MOVIE ............................................................................................................... 9

5 STORAGE, HANDLING AND TRANSPORT

5.1 STORAGE.............................................................................................................................. 9

5.2 HANDLING AND TRANSPORT

6 APPLICATION OF CONCRETE

11

6.2 ARMOR........................................................................................................................................ 11

6.2.1 CAGE TYPE REINFORCEMENT (CONVENTIONAL PROCESS) ...............................12

6.2.2 CONTINUOUS ARMOR (PROCESS BY PROJECTION AND COMPRESSION)..........................12

6.3 FORMS............................................................................................................................................. 12

6.3.1 CONVENTIONAL PROCESS...................................................................................................12

6.3.2 PROCESSES BY COMPRESSION AND PROJECTION...................................................................13

6.4 CONCRETING

6.5 METHODS OF APPLICATION OF CONCRETE................................................................................... 14

6.5.1 CONVENTIONAL PROCESS...............................................................................................14

6.5.2 PROCESSES BY COMPRESSION AND BY PROJECTION OF CONCRETE ..............................14

6.5.3 CONCRETE PROJECTION PROCESS .......................................................................15

6.6 TREATMENT

6.7 IDENTIFICATION................................................................................................................................. 16

7 INSTALLATION OF ANODES

8 INSPECTION AND TESTS...................................................................................................................................... 17

8.1 VISUAL INSPECTION OF PIPES...................................................................................................... 18

8.2 ANTI-CORROSIVE COATING ................................................................................................. 18

8.3 REINFORCING SCREEN........................................................................................................................... 18

8.4 AGGREGATES

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8.5 FORM AND ARMOR....................................................................................................................... 19

8.6 CONCRETE POUR INSPECTION....................................................................................................... 19

8.7 WEIGHT OF THE CONCRETE PIPE....................................................................................................... 20

8.8 WATER ABSORPTION.......................................................................................... 20

8.9 COMPRESSION RESISTANCE

8.10 NEGATIVE FLUCTUATION................................................................................................. 22

8.11 ECCENTRICITY BETWEEN THE CONCRETE COATING AND THE STEEL TUBE................. 22

8.12 ADHERENCE OF CONCRETE TO THE PIPE......................................................................................... 23

9 REPAIRS ON CONCRETE ............................................................................................................................. 23

9.1 PROCESS BY COMPRESSION AND PROJECTION

9.1.1 BEFORE THE HEALING

9.1.2 AFTER THE CURE ............................................................................................................................24

9.2 CONVENTIONAL PROCESS........................................................................................................... 24

9.2.1 BEFORE THE HEALING

9.2.2 AFTER THE HEALING

10 QUALIFICATION OF THE CONCRETE COATING PERFORMED IN PLANT .................................... 25

TABLES

TABLE 1 - DIMENSIONS AND REINFORCEMENT RATES............................................................................................ 8

TABLE 2 - TYPES OF REINFORCEMENTS BASED ON THE CONCRETE APPLICATION PROCESS......... 11

TABLE 3 - COMPRESSION RESISTANCE - MINIMUM SAMPLINGS...................................................... 21

TABLE 4 - MINIMUM COMPRESSIVE STRENGTH VALUES OF CONCRETE

FIGURES

FIGURE 1 - CIRCUMFERENTIAL FRAME

FIGURE 2 - LONGITUDINAL REINFORCEMENT............................................................................................................. 9

FIGURE 3 - CONCRETE TUBES WITH ANODE ASSEMBLY .......................... 17

_____________

OBJECTIVE

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1 OBJECTIVE

1.1 This Standard establishes the minimum conditions required for the application of external coating.
of concrete in pipes intended for the assembly of terrestrial and submarine ducts.

1.2 This Standard considers the processes of spraying, compression, and concreting.
conventional, the latter applicable only to land pipelines.

1.3 This Standard applies to concretes produced by conventional processes,

projection and compression.

1.4 This standard applies to procedures initiated from the date of its publication.

1.5 This Standard contains Technical Requirements and Recommended Practices.

2 SUPPLEMENTARY DOCUMENTS

The related documents below contain valid prescriptions for the current Standard.

PETROBRASN-1265 Coal Tar Epoxy Polyamide Paint;

PETROBRASN-1643 Installation of Galvanic and Inert Anodes;
PETROBRASN-1644 Construction of Foundations and Structures
Reinforced Concrete;
PETROBRASN-1729 Aluminum Alloy Anode;
PETROBRASN-1879 Inspection of Galvanic Anodes;
PETROBRASN-1989 Galvanic Cathodic Protection Installation in Pipeline
Submarine
PETROBRASN-2238 Repair of Buried Duct Coating Using
Polyethylene tape;
PETROBRASN-2719 Storage of Pipe in Open Area;
ABNT NBR 5735 High Furnace Portland Cement
ABNT NBR 5736 Pozzolanic Portland Cement;
ABNT NBR 5737 Sulfur Resistant Portland Cements;
ABNT NBR 5738 Concrete - Procedure for Molding and Curing
Proof Bodies;
ABNT NBR 5739 Rehearsal of Compression of Specimens
Concrete Cylinders;
ABNT NBR 5741 Sample Extraction and Preparation of Cements;
ABNT NBR 6118 Concrete Structures Project - Procedure;
ABNT NBR 7211 Additive for Concrete;
ABNT NBR 7481 Welded Steel Mesh for Concrete Reinforcement;
ABNT NBR 7680 Extraction, Preparation, Testing and Analysis of Samples
of Concrete Structures;
ABNT NBR 9775 Aggregates - Determination of Surface Moisture in
Fine Aggregates through the Chapman Bottle;
ABNT NBR 9832 Concrete and Mortar - Determination of Times
of Pega through Penetration Resistance;
ABNT NBR 9937 - Aggregates - Determination of Absorption and Mass
Specific to Coarse Aggregate;

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ABNT NBR 9939 - Aggregates - Determination of Total Moisture Content,

by Drying, in Coarse Aggregate;
ABNT NBR 12654 Technological Control of Component Materials
Concrete;
ABNT NBR 12655 Concrete - Preparation, Control, and Receipt;
ABNT NBR 13070 Molding of Plates for Mortar Testing
Shotcrete
ABNT NBR NM26 Aggregates - Sampling;
ABNT NBR NM67 Concrete - Determination of Consistency by
Reduction of the Cone Trunk;
ABNT NBR NM137 Mortar and Concrete - Water for Mixing and
Curing of Mortar and Portland Cement Concrete;
ASTM A 82 Standard Specification for Steel Wire, Plain, for
Concrete Reinforcement
ASTM A 185 Standard Specification Steel Welded Wire
Reinforcement, Plain, for Concrete;
ASTM C 29 Standard Test Method for Bulk Density (“Unit Weight”)
and Voids in Aggregate;
ASTM C 33 Standard Specification for Concrete Aggregates;
ASTM C 171 Standard Specification for Sheet Materials for Curing
Concrete
BSI BS 8010 Part 3 Code of Practice for Pipelines Part 3: Pipelines
Subsea: Design, Construction and Installation;
DNV - 2000 Submarine Pipelines Systems;
SIS 055900 Pictorial Surface Preparation Standards for Painting
Steel Surfaces.

3 APPLICATION PROCEDURES

3.1 The procedure, or the set of procedures, must include at least the following
topics:

a) objective;
b) reference standards;
c) definitions;
d) receipt, handling, and storage of materials:
criteria for receipt;
acceptance criteria;
locations, criteria and storage period;
handling methods;
traceability systems;
e) installation of the reinforcement screen (framework):
- type;
cleaning process;
forming method;
- fastening system, guarantee of positioning, spacing, and coverage;
amendments (execution process, location, and overlap);
covering;
overlap;
f) experimental dosage of concrete:
dosage resistance calculation;
compatibility between the maximum characteristic size of the coarse aggregate,
the mesh of the screen and the thickness of the coating;

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- characterization of coarse and fine aggregates (type, origin, mass

specific
superficial, powdery materials, salts, chlorides and sulfates, according to standards
ABNT NBR 12654
- characterization of cements (type, brand, and physical characteristics, according to
standard ABNT NBR 12654
chemical and physical characteristics of water;
characteristics of additives (when applicable);
thickening (process and identity);
- criteria for determining the water/cement ratio (strength, durability);
presentation of the specified dosing method;
determination of consistency (workability) of concrete;
unit trace and material consumption (m³);
proof of the dosage resistance for the stipulated FCK;
g) technological control of concrete and the reinforcement mesh:
control of the characteristics of the constituent materials, including additives,
when applicable (tests and frequency);
control of dosage (frequency, process of measuring materials
constituents and corrections based on the moisture of the aggregates;
verification of concrete consistency (when applicable) according to standards
ABNT NBR NM67 (frequency);
control of concrete resistance, according to ABNT NBR 12655 standard - type
of sampling (formation of batches, verification of mechanical resistance and
acceptance of the structure);
verification of mechanical resistance;
control of specific mass and absorption of concrete, when applicable
(sampling and method);
h) execution of mold:
type of material;
fixing devices;
dimensions;
release agent
deadlines for deregistration;
i) concrete pouring execution:
- description of the application process (compression, projection, or conventional);
- characteristics of concrete (mix, workability for pouring, factor
water/cement, additive and deadline;
method of measuring materials;
concrete thickness;
- compaction method (when applicable);
- method and healing time;
dimensions of the coating;
geometry and verification criteria of the coating;
weight of the coated tube in air and submerged;
j) equipment and human resources;
k) methodology for recording results;
l) inspections and tests;
m) execution of repairs;
transport, handling and storage of the tubes.

3.2 Concrete Plant by Projection/Compression

These processes must have their procedures previously qualified.

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4 MATERIALS

4.1 Anticorrosive Coating

4.1.1 In order to ensure its adherence to the concrete coating, the

The anti-corrosive coating must have an anchorage profile according to one of the alternatives.
below

a) helical profile with a height between 1 mm and 3 mm above the surface of

coating, following a maximum step of 250 mm;
b) application, by extrusion, of a polyethylene or polypropylene strip with width
minimum heights of 15 mm and 2 mm, respectively, following a step
maximum of 150 mm.

4.1.2 Alternatives that ensure the adhesion of concrete to polyethylene or

polypropylene, previously agreed upon between the coating company and the client.

4.2 Cement

The cement to be used must be of the "Portland" type and may be:

sulfate resistant Portland cement (RS) according to ABNT NBR 5737 standard;
b) pozzolanic 'Portland' cement, in accordance with ABNT NBR 5736 or cement
"Portland" from blast furnace, according to ABNT NBR 5735 standard, both with content of
tricalcium aluminum between 4% and 8%.

4.3 Aggregates

4.3.1 The aggregates must meet the requirements of the ABNT NBR 7211 standard.

4.3.2 The contents of fine aggregate present in coarse aggregate must be considered
in the concrete dosage.

4.3.3 The total content of harmful substances, defined in the ABNT NBR 7211 standard, must be
considered in the mixture of aggregates.

4.3.4 Fine aggregates must have their grain sizes between

zones 2 and 3 of the ABNT NBR 7211 standard.

4.3.5 The coarse aggregates must have their particle sizes between the
graduations 0 and 1 of the ABNT NBR 7211 standard.

4.3.6 The iron ore (limonite, hematite, or magnetite) must have a grain size according to
zone 4 of standard ABNT NBR 7211 and minimum specific mass of 4,410 kg/m3, determined
according to the ABNT NBR 9937 standard.

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4.3.7 The ratio between coarse and fine aggregates must be such that it results in the greatest
unit mass.

4.3.8 All aggregates must be free from harmful amounts of salts.

4.4 Water

4.4.1 The ABNT NBR NM137 standard must be followed.

4.4.2 The water must be free from oil, acid, alkalies, salt, or organic material. The quantity
the maximum allowed for dissolved solids in water is 2,000 ppm, with carbonates and
alkaline bicarbonates must not exceed 1,000 ppm.

4.5 Reinforcement Screen

4.5.1 The cage type armor screen, applicable only to terrestrial ducts, must be made of steel.
CA-50 or CA-60, according to ABNT NBR 7481 standard.

4.5.2 The continuous armor screen, applicable to terrestrial and submarine ducts, must be made of
carbon steel, galvanized, according to the ASTM A 185 standard.

4.5.3 The screens must meet at least the following requirements explicitly stated in TABLE 1.

TABLE 1 - DIMENSIONS AND REINFORCEMENT RATES

Type of Type of Pipes

Armor Terrestrial Submarine
Mesh 100 mm x 100 mm x 3.2 mm
Cage NA
Steel - ABNT NBR 7481 (CA-50 or CA-60)
The concrete reinforcement screen must meet the following parameters:

a) distance between longitudinal wires to the tube (parallel to the axis

longitudinal of the tube) equal to 75 mm;
b) distance between the cross wires to the tube equals 25 mm;
Continues
c) overlap of 25 mm for 2 subsequent screens;
d) circumferential armor rate on the tube equal to 0.5% (see
FIGURE 1);
e) longitudinal reinforcement rate for the tube equal to 0.1% (see
FIGURE 2)

4.5.4 A prior check must be made to see if this screen section meets the efforts of
launch.

4.5.5 The dimensions of the meshes must be such as to meet, at a minimum, the following
armor rates:

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a) cage fabric for ground ducts, according to TABLE 1;

b) continuous fabric, as per FIGURES 1 and 2.

FIGURE 1 - CIRCUMFERENCE ARMATURE

FIGURE 2 - LONGITUDINAL REINFORCEMENT

4.6 Waterproof Film

The waterproof film used in projection and compression processes must meet the
requirements of the ASTM C 171 standard.

5 STORAGE, HANDLING AND TRANSPORT

5.1 Storage

5.1.1 All materials must be stored appropriately in order to be protected.

of deterioration, contamination, or any other damage that may affect the quality of
final product.

5.1.2 Storage plans for materials and pipes must be developed before the start of the
services.

5.1.3 The storage must meet the requirements of PETROBRAS standardsN-1644

eN-2719, as well as the requirements ofwritten in items [Link] to [Link].

[Link] Portland Cement:

a) the bagged cement must be in perfect condition, not being

do you accept damaged packaging or those containing hardened cement;
b) the stacking of cement bags must be done on wooden pallets
and, at most, 10 units;
c) the storage location for cement bags must be covered and dry,
ventilated, protected from sunlight or rain and in such a way that allows for the
removal in the first place of the oldest cement.

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[Link] Aggregates:

a) the different aggregates must be stored directly on a base

of the material itself, below ground level, with a minimum thickness of
200 mm apart from each other, so as to prevent their mixing;
b) the aggregates must be stored away from contaminating agents
such as: vegetation, solid and liquid waste.

[Link] Reinforcement Screen

The reinforcement screens must be piled on wooden pallets up to a height

maximum of 2 m above the platform.

[Link] Concrete pipes:

a) the pipes with concrete coatings must be supported, at a minimum, by

2 supports with at least 30 cm in width, spaced such that the
efforts are equally distributed among them;
b) the supports must ensure a minimum height of 30 cm between the lower generatrix
from the first layer and the floor, as well as a longitudinal slope of the pipes
of 1%;
c) the maximum number of concreted tube layers must be determined from
way to ensure safety and avoid damage to the pipes.

5.2 Handling and Transportation

5.2.1 In the transportation of tubes, the loads must be arranged in a way that allows for securing.
be careful not to damage the tube or its coating. Before untieing the stack to
download, a visual inspection must be carried out to verify if the pipes are
conveniently supported, without the risk of rolling.

5.2.2 For handling concrete tubes, straps with resistance must be used.
appropriate, protected with abrasion-resistant material. Special hooks for lifting
tubes at the ends (pads) can be used, provided they support, at a minimum,
1/8 of the circumference of the tube should be covered with soft material to adapt to its
internal curvature and that do not cause deformations, which would hinder usability
rear of the tubes.

5.2.3 For the unloading of uncoated pipe bundles, the following must be used
nylon straps. Such straps must be adjusted to the bundle in order to prevent movement.
relatives between the tubes.

5.2.4 The equipment used for handling the tubes must have their booms
coated with rubber, felt, or similar material.

5.2.5 The handling of coated tubes must be done in a way that avoids mechanical damage to them.
bisel of the pipe and to the anticorrosive and concrete coatings.

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5.2.6 In the case of using a type of loader equipped with forks, these
Equipment must be protected so as not to damage the concrete surface.

5.2.7 The handling of concrete pipes produced by the conventional process, intended for ducts
terrestrial, should only be carried out 72 hours after concreting. The reduction of this
time can be accepted, as long as it is proven, through tests or certification, that the
The adopted time does not incur losses in the properties of the concrete coating.

5.2.8 The handling of the concrete tubes by projection or compression processes,

after the start of curing, it should only be carried out after the concrete reaches the strength to
minimum compression of 20 MPa for the case of underwater pipelines and 15 MPa for pipelines
terrestrial.

5.2.9 The transportation of concrete pipes for application at the construction site should only occur after the
concrete reaching a minimum strength of 34 MPa, in the case of pipes for underwater ducts
is 15 MPa, in the case of pipes for land ducts.

6 APPLICATION OF CONCRETE

6.1 Concrete Dosage

6.1.1 The concrete dosage must be carried out in accordance with the standards ABNT NBR 6118
the ABNT NBR 12655, in order to meet the properties required by the project.
Meanwhile, the maximum acceptable water-cement ratio for pipes intended for land pipelines.
It must be 0.65.

6.1.2 The use of additives is allowed for the purpose of reducing the setting time,
as long as the chloride ion content does not exceed the limits of the ABNT NBR 6118 standard.

6.2 Armor

The type of screen should be defined based on the concrete application process accordingly.
with TABLE 2. In the case of submarine ducts, it should be verified whether the screen section
meets the launch efforts.

TABLE 2 - TYPES OF REINFORCEMENTS BASED ON THE PROCESS OF

APPLICATION OF CONCRETE

Application Process of
Type of Armor
Concrete
Conventional Cage
Projection Cage or Continuous
Compression Continuous

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6.2.1 Cage Type Armor (Conventional Process)

[Link] Before its installation, the reinforcement screen must be calendered in order to obtain
a cylindrical cage with a diameter that allows for its installation according to
provided for in the project.

[Link] The longitudinal and circumferential overlaps of the calendered sheets must be
at least 100 mm, in order to achieve the closure of the cage.

[Link] The screens must be positioned using non-metallic spacers in such a way as to
ensure the distance from the tube and the specified covering, including in
extremities where the covering must be at least 25 mm.

[Link] In the case of simple armor (one layer of screen), applicable to underground ducts, the
Fabrics must be positioned at half the thickness of concrete.

6.2.2 Continuous Armor (Projection and Compression Process)

[Link] In the case of simple reinforcement (1 layer of mesh), applicable to concretes with
thickness less than 50.8 mm (2”), the screens must be positioned in the middle of the
concrete thickness.

[Link] In the case of double reinforcement (2 layers of mesh), applicable to concretes with
thicknesses greater than or equal to 50.8 mm (2”), the screens must be positioned in such a way as to
guarantee a minimum of 15 mm for both coverage and for the distance between the
anti-corrosive coating of the pipe and the screen.

[Link] The screen must be applied continuously, in order to provide a

minimum overlap of 25 mm between 2 consecutive turns.

6.3 Forms

6.3.1 Conventional Process

[Link] The shapes must have a circular cross-section, concentric with the axis of the tube.
forming an annular space with a width equal to the thickness of the coating defined in
project, with a tolerance of (0 ± 10) %.

[Link] The ends of the molds must be set back 350 mm from the ends of the
tube, to form the collars (“cut backs”), when processes are not anticipated.
machining of welding or testing of field welds. When there is a forecast of
use of mechanized processes in the execution of field welds or testing
non-destructive, the length of the collars must be 450 mm.

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[Link] The molds must be watertight and have sufficient support to prevent their
deformation.

[Link] The internal surface of the molds must be greased with release agent.
take care not to contaminate the armor or leave excess.

[Link] The reinforcement and the surface of the tube must be cleaned before the installation of the formwork.

[Link] The removal of the forms must be carried out at least 24 hours after the
concreting.

6.3.2 Processes by Compression and Projection

[Link] In these processes, the waterproof film itself also serves as a mold.

[Link] The film should only be removed after the curing time determined by the type of
cement according to the PETROBRAS standardN-1644.

6.4 Concrete pouring

6.4.1 The preparation of concrete must be executed mechanically. After its

Loading, the materials must be mixed for a minimum of 5 minutes.

6.4.2 The containers used for the preparation, transportation, and pouring of concrete must
be ponds, in such a way that there is no loss of materials.

6.4.3 The time elapsed between the start of preparation and the end of concrete pouring does not
it must exceed 1 hour, unless the start times for cement setting exceed 1 hour
be confirmed through previously conducted tests.

The transport of the mixed material to the application site must be carried out in such a way as to
do not provoke segregation among the components of the mortar.

6.4.5 The average thickness of the concrete coating must be that established in
project with a tolerance of 0% for less and 10% for more, as long as it does not alter the
negative buoyancy condition. The average thickness should be determined through the
measurement of the circumference perimeter of the tube in 5 sections distributed evenly.

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6.5 Methods of Concrete Application

6.5.1 Conventional Process

[Link] This process is applicable only to land pipelines.

[Link] The concrete must be poured in a way that prevents segregation of its constituents.

[Link] The concrete must be compacted using wall vibrators, fixed on both sides
the sides of the mold in quantity and spacing compatible with the power of the
vibrators. The vibrators can alternatively be attached to the ends of the tube,
through claws sized and manufactured in such a way as not to damage them
extremities.

[Link] The tubes must be supported on supports that do not damage them.
extremities.

[Link] In the case of a stoppage of the concrete pouring (cold joint), observe the following sequence:

a) remove the molds at least 24 hours after the stop;

b) to expose the coarse aggregate by removing all the surface of the joint;
c) remove all loose material;
d) saturate the surface with water;
e) to continue with the concreting.

6.5.2 Processes by Compression and by Projection of Concrete

[Link] In the compression process, the concrete is applied to the surface of the tube.
together with the continuous screen and simultaneously compressed by a polyethylene film.

[Link] In the projection process, the screen is applied during the projection of concrete on the
tube, with the assembly later surrounded by a polyethylene film.

[Link] Before the start of concreting, the pipes must be tested for continuity.
of its anti-corrosive coating.

[Link] Before the start of concreting, the pipes must be moistened.

[Link] The position of the screen must comply with item 6.2.2.

[Link] Application of concrete coating:

a) the tubes released for concreting move in the plan through

simultaneous rotation and translation movements, made with the help of
rubber rollers, in order not to damage the anti-corrosive coating;

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b) the aggregates and the cement, stored in separate deposits, must be

cleared over the main conveyor belt, with the dosage
this material is carried out through flow control and whose adjustment is
function of the dash in weight;
c) the homogenization of the dry mixture of aggregates and the cement must be
carried out on the main conveyor belt itself, which must have
cross palettes to serve this purpose;
d) water must be added immediately before the concrete falls on the
applicator layer, injected through spray nozzles controlled in
system panel of the plant operation;
e) at the beginning of the coating, the polyethylene film and the framework must be fixed
at the end of the tube, with the concrete being poured over the film, making it
that the concrete/set/reinforcement/film be compressed around the tube,
helical shape, ensuring a longitudinal overlap of 2.5 cm of the frame and
of the film;
f) tests must be carried out to ensure the minimum coverage of the framework
(reinforcement fabric), defined in the project, as well as the uniformity of the layer
which must have a uniform and compact thickness.

[Link] Tube Ends

The edges of the concrete coatings must be set back from the edges of the
tube as described below:

a) the removal of concrete to form the collar ('cut back') must be carried out
while the concrete is fresh, using cutting saws with limiters
and/or cutting pliers;
b) to preserve the concrete, filament tape should be applied
circumferentially, at the cut locations;
c) the collar ('cut back') of the concrete coating must be 300 mm in
manual welding case and 400 mm in the case of welding or mechanized inspection; in
In the case of tubes intended for land pipelines, the following must be complied with:
collar dimensions established in item [Link];
d) the end of the concrete covering must form a 90° angle with
the axis of the tube;
e) the edges and the part not covered with concrete must be cleaned of residues
concrete;
f) the edges of the concrete at the cut locations must be protected with
1 coat of coal tar epoxy paint, according to PETROBRAS standard
N-1265.

[Link] Reuse of Rebound Material

The reuse of rebound material is permitted, provided that the reuse is

done immediately and that does not compromise the final strength of the concrete.

6.5.3 Concrete Projection Process

[Link] Jet Incidence

The application spray must strike the surface perpendicularly.

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[Link] Application of the Jet

a) concrete should be applied in such a way as to avoid the need for a layer
complementary;
b) the achievement of final thickness is allowed with the application of more than 1 layer,
since this supplementation is done immediately after the application of the
previous layer. [Recommended Practice]

[Link] Uniformity of the Layer

The application should run continuously, aiming to achieve a layer of

uniform and compact thickness.

6.6 Cure

6.6.1 In the conventional process, after the molds are removed, the coating must be
kept moist for the time required by the type of cement according to the standards
PETROBRASN-1644through one of the following methods:

a) wetting of the surface by sprinkling water at intervals of 30 minutes,

whenever the surface feels warm to the touch;
the coating temperature should be maintained between 25 °C and 32 °C;
b) keeping bags of cement, cloths, or rags, damp on the
surface of the coating, also seeking to meet the limits of
temperature established in item a);
c) by the application of a waterproof film over the coating.

6.6.2 In the processes of projection and compression, the waterproof film must be maintained.
during the necessary curing period, according to the time required by the type of cement
according to the standardPETROBRASN-1644.

6.7 Identification

6.7.1 In addition to the original information, the pipes coated by the processes of
compression and projection must contain the following information:

a) type of concrete (light, normal, or heavy);

b) specific weight of concrete;
c) thickness of the concrete;
d) date of concrete application.

6.7.2 In addition to the original information, the tubes coated by the conventional process
they must contain the following information:

a) date of concrete application;

b) information on the bending of the tube (when applicable);
c) thickness of the concrete.

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7 INSTALLATION OF ANODES

7.1 The sacrificial anodes must be installed according to PETROBRAS standards.

N-1989, consideringthat the electrical connection between the anode and the tube must be as per
procedure specified in the PETROBRAS standardN-1643 or throughelectric cable. A
The oversight must approve the final proposal of the contractor.

7.2 The concrete tubes with anode assembly must be prepared according to
established in FIGURE 3. There must be a 1" annular space between the anode and the concrete and
fill the gaps with mastic or similar.

GO TO
MONTAGE
OF ANODE CL

ANODE

SPACE TO BE
FILLED WITH
Mastic

COATING OF
CONCRETE

FIGURE 3 - CONCRETE TUBES WITH ANODE MOUNTING

7.3 The specification of the anode, the quantity of anodes related to the thickness of
concrete and the quantity of anodes related to the span length for the
the assembly of the anode must be provided by a specific data sheet for each project.

7.4 The contractor must check the length of the anode according to the detailed project of
manufacturer to confirm or restore a value of 'L', in order to allow that the span
have enough space for the assembly of the anodes.

8 INSPECTION AND TESTS

The inspections and tests defined in this Chapter must be carried out at the beginning of each project.
and periodically according to the frequency established in this Standard.

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8.1 Visual Inspection of the Tubes

The tubes must be visually inspected in order to detect dents,

damage to the coating and residues of grease, oil, and other materials that may
to compromise the adhesion of the concrete or contaminate it.

8.2 Anti-Corrosive Coating

8.2.1 The pipes must be inspected using a 'Holliday Detector' with the aim of
check for the existence of discontinuities in the anticorrosive coating before application
of the concrete coating. If discontinuities are detected, they must be
repairs were made according to the specific procedure.

8.2.2 The 'Holliday Detector' must be calibrated daily, at least once, and the
frequency should be determined in specific procedures.

8.2.3 In all tubes, the external surface must be inspected. In this inspection, it must
It should be checked if the corrugated anti-corrosion coating is in good condition. The
Application procedures must anticipate the control of roughness.

8.3 Reinforcement Screen

8.3.1 The screens must be visually inspected with the aim of detecting
dents, grease residues, oil and other materials that may compromise the
adhesion of the concrete or contaminate it. Dents and residues must be removed.

8.3.2 The screens showing widespread corrosion with losses exceeding 3% of

nominal diameter must be rejected.

8.3.3 The galvanized screens, applicable to underwater ducts, containing damage in the
coating must be rejected. In these screens, it must be verified whether the rates of
armor were met, according to TABLE 1. The application procedures
they must foresee the control of the armor rate.

8.4 Aggregates

8.4.1 The aggregates must be previously subjected to qualification tests.

defined in the ABNT NBR 12654 standard, with the samplings provided for in the standard
ABNT NBR NM26. The acceptance criteria must comply with the ABNT NBR 7211 standard.

8.4.2 Upon receipt, the aggregates must be subjected to visual inspection,

with the aim of detecting the presence of contaminants or changes in the characteristics of
previously qualified material. If contaminants are detected, their levels must
are measured according to the ABNT NBR 7211 standard.

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8.4.3 Before the mixing process, the moisture content of the aggregates must be checked.
with the aim of adjusting the necessary amount of water in the mixture. The moisture content
It must be determined according to ABNT NBR 9775 and ABNT NBR 9939 standards.

8.5 Form and Armor

Before concreting, the information described in items 8.5.1 to 8.5.3 must be checked.

8.5.1 The formwork and the reinforcement must be inspected to verify if they are
free from materials harmful to concrete.

8.5.2 The fixing, overlap, and positioning of the reinforcement must comply with item 6.2.

8.5.3 The dimensions, watertightness, application of the releasing agent, and support of the molds
they must comply with item 6.3.

8.6 Concrete Pouring Inspection

8.6.1 The tests must be carried out:

a) discount for the cone trunk according to the ABNT NBR NM67 standard
(only in the conventional process);
b) compressive strength, according to item 8.9.

8.6.2 In the case of concrete pouring by conventional process, in addition to the mentioned tests
No item 8.6.1, the following must be checked:

a) if the time elapsed between the start of preparation and the end of the launch is
compatible with the cement set time established in
execution procedure;
b) the homogeneity of the mixture.

8.6.3 In the conventional process, the concrete coating must be inspected

visually to check for the presence of defects after the removal of the molds.

8.6.4 In the processes of compression and projection, the concrete coating must be
visually inspected to check for the presence of defects immediately after the
concreting and after the removal of the waterproof film.

8.6.5 Tubes with a total defective area of more than 3% of the total area must be
totally reprocessed.

8.6.6 Perform visual inspection during the handling and storage of pipes, in order to
check for the presence of cracks.

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8.6.7 Cracks with openings of up to 0.5 mm and extending for less than 180° in
tube return or when they are longitudinal will present a length less than
300 mm should be accepted. The other cracks should be repaired.

8.6.8 If any defect in the coating is detected, it must be repaired accordingly.

described in Chapter 9 of this Standard.

8.7 Weight of the Concrete Pipe

8.7.1 The weight of each concrete tube must be measured using a calibrated scale.
minimum resolution of 1%. For land ducts, when flotation is not required
negative of the concreted tube, weighing the tube is not necessary.

Notes: 1) For an analog scale, the resolution is the smallest difference between the
indications of the display that can be significantly perceived.
2) For a digital scale, it is the variation in the display reading when the
the least significant digit varies by one unit.

8.7.2 A certificate must be provided to PETROBRAS before the weighing services.

calibration issued by a recognized entity proving that the minimum resolution of the
weighing equipment is 1%.

8.7.3 The concrete pipes must meet, at a minimum, the floating conditions.
negative forecasts in the project.

8.7.4 In the case of pipes intended for land pipelines, the specific weight of the concrete may
to be verified by weighing the compression test specimens, in place of
weighing of the concrete pipes defined in item 8.7.1. The specific weight of the concrete must
be equal to or greater than the specific weight defined by the project.

8.8 Water Absorption

8.8.1 Water absorption tests are required only for submarine pipelines.

8.8.2 The water absorption of the concrete coated pipes must follow the specifications
from the standard BSI BS 8010 Part 3.

8.8.3 Absorption tests must be carried out on the concreted tubes at the frequency of
1 tube for every 50 concrete tubes. The tests must be carried out after a period has elapsed.
minimum period of 24 hours, after concreting, by complete immersion of a tube
concreted in a freshwater tank for 24 hours.

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8.8.4 After being removed from the tank and immediately after draining the stored water
inside the tube, the tube is heavy. The maximum water absorption allowed in the concrete,
expressed with 1 decimal place, it should be 5.0%, with absorption defined by the following
formula:

WPsat− W c
Absorption [%]= x 1,025 x 100
W c− W

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 N-2432 REV. A SET / 2004

Where:
WPsat = weight of the concrete tube saturated in fresh water, in kgf;
Wc weight of the coated pipe immediately after concreting, in kgf;
W weight of each tube without concrete coating, in kgf.

8.9 Compressive Strength

8.9.1 For the verification of compressive strength, the following must be observed
minimum samples:

TABLE 3 - COMPRESSION RESISTANCE - MINIMUM SAMPLES

Sample
Process
7 days 28 days
1 copy (2 CPs) for each 1 copy (2 CPs) for each
concrete mixer truck or each concrete mixer truck or each
Conventional
4 hours of concreting, when 4 hours of concreting, when
used stationary concrete mixer. used stationary concrete mixer.
3 each a CPs 20 tubes 3 CPs a every 20 tubes
concluded. After the tests concluded. After the tests
Projection or initials, at the discretion of PETROBRAS, initials, at the discretion of PETROBRAS,
Compression
3 CPs can be rehearsed each
50 concrete tubes. 50 concrete tubes.

8.9.2 The compressive strength of concrete must meet the minimum values described
in TABLE 4.

TABLE 4 - MINIMUM COMPRESSION RESISTANCE VALUES OF

CONCRETE

Application of the Tube

Age of the Sample
Submarine Pipelines Land Pipelines
7 days 24 MPa 14 MPa
28 days 34 MPa 20 MPa

8.9.3 For the execution of the tests, 3 cylindrical test specimens must be shaped.
Ø 150 mm x 300 mm, for each age considered. The modeling of the test specimens.
must comply with the ABNT NBR 5738 standard, however in the case of processes by projection and
compression, the densification must be carried out mechanically in 4 layers.

8.9.4 Compression resistance tests must be carried out in accordance with the standard.
ABNT NBR 5739. The control of concrete strength must comply with the standard.
ABNT NBR 12655.

8.9.5 The mechanical resistance of concrete must be, at a minimum, equal to 90% of the resistance
provided for in the project.

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8.10 Negative Flotation

This procedure applies to submarine pipelines and to land pipelines (only for
crossing rivers, flooded areas, and lagoons.

8.10.1 The negative fluctuation must be based on the conditions of the freshly applied concrete and
not under saturation conditions.

8.10.2 The time period between casting and weighing must be constant for
all tubes. The negative fluctuation tolerance must follow what is specified in the standard
BSI BS 8010 Part 3.

8.10.3 The negative fluctuation per meter of the tube immersed in seawater must be
determined for each tube, being defined by the following formula:

negative buoyancy = weight concrete per meter - buoyancy per meter

[Link] The thrust per meter is given by:

π
E= (DA)2x1025 (kgf/m )
3
4

Where:
thrust
DA = arithmetic mean of the external diameter of the concrete coating, referred to
5 measurements taken with a tape measure, in equally distributed spaces along the
pipe, in m.

[Link] The weight of the concreted tube (Wtcper meter, for freshly applied concrete, must
to be calculated by the formula:

(W c max −
Wtc= (kgf/m)
(L− 2e)

Where:
Wc weight of the coated tube immediately after concreting, in kgf;
w weight per meter of pipe = W/L, in kgf/m;
L length of each pipe, in m;
e length of each end of the unpoured tube, in m.

8.11 Eccentricity between the Concrete Coating and the Steel Pipe

8.11.1 The eccentricity is characterized by the distance between the geometric center.
of the medium circle adjusted to the external diameter of the duct and the geometric center of the medium circle
fitted to the outer diameter of the concrete casing.

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 N-2432 REV. A SET / 2004

8.11.2 The eccentricity must be assessed by measuring the coating thickness of

concrete at 8 points offset by 45° along the circumference of the coating. The
measurement must be taken at both ends of the concrete tube. The measurement of
excentricity should be performed for every 50 tubes.

8.11.3 Depending on the performance of the process, at the discretion of PETROBRAS, the frequency of
measurements can be reduced. [Recommended Practice]

8.11.4 The maximum eccentricity for each tube is defined as the difference between the
the greatest thickness and the smallest thickness of the concrete coating. The maximum
excentricity must be equal to 12 mm.

8.12 Adhesion of Concrete to the Tube

8.12.1 The adhesion of the concrete to the corrosion-resistant coating must be tested as follows
way

a) an axial load must be applied to a segment of concrete tubing whose

the edge of the concrete coating should be supported in such a way as to produce
shear stress between the anti-corrosive coating and the concrete;
b) the load to be applied must be 9.17 tons per meter in length
of the tested evidence body.

The test must be conducted in 3 concreted tubes at the beginning of each work and must be
repeated, at least, for every 1,000 tubes produced. Depending on the results, at the discretion of
PETROBRAS, the frequency of tests can be reduced. [Recommended Practice]

9 REPAIRS ON CONCRETE

Repairs to the concrete must ensure the maintenance of geometric and physical properties.
and the chemicals of the finished product. The materials to be used for the execution of the
repairs must have the same characteristics as the materials used for concreting
in the plant. The procedures described in item 9.1 are used for subsea ducts and
for land products see item 9.2.

9.1 Process by Compression and Projection

9.1.1 Before the Healing

[Link] If the damaged area is less than 0.10 m2:

a) isolation of the coating surface in good condition through the

fixation of adhesive tape around the entire perimeter of the damaged area;
b) cut of the polyethylene film in the damaged area;
c) removal of all damaged concrete until surpassing the mesh, for anchoring of the
concrete, taking care not to damage it;
d) before applying the mixture, wet the area and make repairs;

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 N-2432 REV. A SET / 2004

e) after manual repairs, the tubes must be covered on the surface

repaired with polyethylene film fixed with filament tape.

[Link] If the damaged area is greater than 0.10 m2length up to 1 m:

a) isolation of the surface of the coating in good condition through the

fixing the adhesive tape around the entire perimeter of the damaged area;
b) cutting of the polyethylene film in the damaged area;
c) removal of all damaged concrete, including below the reinforcement mesh,
taking care not to damage it;
d) before applying the mixture, moisten the area and repair;
e) repair care: identical to tube care, that is, at least 7 days.

Note: After being manually repaired, the tubes should be wrapped on the surface
repaired with polyethylene film fixed with filament tape.

[Link] If the area is greater than 1 m2all the cladding must be redone.

9.1.2 After the Healing

[Link] With a loss of, at most, 25% of the total thickness in an area smaller than 0.10 m2, and
where the remaining concrete is firm, it is not repaired.

[Link] With a loss of no more than 25% of the total thickness in areas greater than 0.10 m2,
less than 0.3 m2remove all concrete until the screen is exposed, in order to provide the
embedding of the repair material.

[Link] If the damaged area is greater than 0.3 m2, the coating must be removed in
the entire perimeter of the tube along the affected area should be restored.

9.2 Conventional Process

9.2.1 Before the Cure

[Link] Manual repairs must be made to the coating before curing, if the area
damaged for less than 0.10 m2These repairs must be made by removing the
coating affected up to the height of the reinforcement screen, taking care not to damage it
in the removal process and properly moistening the area of the concrete to be
repaired.

[Link] If the damaged area exceeds 0.10 m2, but do not extend more than 1 m to the
Along the length of the pipe, the repair must be done by removing all the concrete from the affected area,
including below the reinforcement screen and completing the repair manually. If the area is
extend for more than 1 m along the tube, this tube must be re-coated.

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 N-2432 REV. A SET / 2004

9.2.2 After the Healing

Dents and crushes caused by impact during handling and storage

they must be repaired or not, according to the criteria established in items [Link] to [Link].

[Link] With a loss of no more than 25% of the total thickness in an area smaller than 0.10 m2e
where the remaining concrete is solid, it should be accepted without repairs.

[Link] With a loss of no more than 25% of the total thickness in an area greater than 0.10 m2e
less than 0.3 m2the concrete that remains in this area must be removed until the exposure of the
fabric, in order to provide for the embedding of the repair material.

[Link] If the damaged area is greater than 0.30 m2, the coating must be removed in
the entire perimeter of the tube along the affected area must have its coating repaired.

The resulting coating must be equal in weight, density, uniformity,

resistance and must have the same characteristics as the originally applied concrete.

10 QUALIFICATION OF THE CONCRETE COATING CARRIED OUT IN

PLANT

10.1 At PETROBRAS's discretion, the qualification tests, as defined in item 10.1

At 10.6, they can be witnessed by their technicians or professionals accredited by them.
Recommended Practice

10.2 Before the start of the concrete coating application work, the materials
employees involved in concrete coating must undergo all inspections or
tests defined in this Standard to ensure that they meet the respective
specifications.

5 tubes must be coated in accordance with the application procedure.

numbered and approved, and all tests, verifications and must be carried out on them
inspections defined in this Standard.

10.4 The dimensions and quantity of test specimens, the acceptance criteria, the location and the
The schedule for the execution of qualification tests must be defined in advance and
informed to PETROBRAS.

10.5 The qualification tests must be repeated whenever there is a change in, for at least
less, one of the parameters below:

a) material of the anti-corrosive coating or its anchoring profile;

b) thickness of the concrete coating (with a thickness less than
50.8 mm for another greater than or equal to 50.8 mm and vice versa;
c) specification of any aggregate or the steel reinforcement;

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 N-2432 REV. A SET / 2004

d) tube diameter (change of at least 10" in the nominal diameter for

less or more).

10.6 Upon completion of the qualification work of the procedure, the implementing company of the
concrete must issue a Qualification Report, containing at least the following
information:

a) type of anti-corrosive coating;

b) characteristics and suppliers of the aggregates;
c) anchoring profile of the anticorrosive coating;
d) thickness of the concrete coating;
e) application procedure;
f) specification and certificate of the screen;
g) entity that conducted the tests.

_____________

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 N-2432 REV. A SET / 2004

INDEX OF REVIEWS

REV. A
Affected Parts Description of the Change

All Reviewed

_____________

IR 1/1
 N-2432 REV. A SET / 2004

8.6.7 Cracks with an opening of up to 0.5 mm that extend for less than 180° in
tube return or when they are longitudinal will have a shorter length than
300 mm must be accepted. The other cracks must be repaired.

8.6.8 If any defect in the coating is detected, it must be repaired according to

described in Chapter 9 of this Standard.

8.7 Weight of the Concreted Pipe

8.7.1 The weight of each concrete tube must be measured using a calibrated scale.
minimum resolution of 1%. For terrestrial ducts, when flotation is not required.
negative of the concrete tube, weighing the tube is not necessary.

8.7.2 A certificate must be provided to PETROBRAS before the weighing services.

certification issued by a recognized entity proving the resolution of the equipment
weighing that should be a maximum of 1%.

8.7.3 The concrete pipes must present, at minimum, the flotation conditions
anticipated negatives in the project.

8.7.4 In the case of pipes intended for underground ducts, the specific weight of the concrete may
to be verified by weighing the compression test specimens, in place of
weighing of the concrete pipes defined in item 8.7.1. The specific weight of the concrete must
be equal to or greater than the specific weight defined by the project.

8.8 Water Absorption

8.8.1 Water absorption tests are required only for underwater ducts.

8.8.2 The water absorption of the concrete coated pipes must follow the specifications.
from standard BSI BS 8010 Part 3.

8.8.3 Absorption tests must be performed on the concreted tubes at the frequency of
1 tube for every 50 concrete tubes. Tests should be conducted after a period has elapsed.
minimum period of 24 hours, after concreting, by complete immersion of a tube
concreted in a freshwater tank for 24 hours.

8.8.4 After being removed from the tank and immediately after draining the stored water
inside the pipe, the pipe is heavy. The maximum water absorption permitted in the concrete,
expressed with 1 decimal place, it should be 5.0%, with absorption defined by the following
formula:

WPsat− W c
Absorption [%]= x 1,025 x 100
W c− W

20