EN ISO 21809-5:2010

SLOVENSKI STANDARD
01-julij-2010
Naftna industrija in industrija zemeljskega plina - Zunanje prevleke za cevovode,
zakopane v zemljo ali potopljene v vodo, v sistemih cevovodnega transporta - 5.
del: Zunanje betonske prevleke (ISO 21809-5:2010)
Petroleum and natural gas industries - External coatings for buried or submerged
pipelines used in pipeline transportation systems - Part 5: External concrete coatings
(ISO 21809- 5:2010)
Erdöl- und Erdgasindustrie - Umhüllungen für erd- und wasserverlegte Rohrleitungen in
Transportsystemen - Teil 5: Betonummantelungen (ISO 21809-5:2010)
Industries du pétrole et du gaz naturel - Revêtements externes des conduites enterrées
ou immergées utilisées dans les systèmes de transport par conduites - Partie 5:
Revêtements extérieurs en béton (ISO 21809-5:2010)
Ta slovenski standard je istoveten z: EN ISO 21809-5:2010
ICS:
25.220.99 Druge obdelave in prevleke Other treatments and
coatings
75.200 2SUHPD]DVNODGLãþHQMH Petroleum products and
QDIWHQDIWQLKSURL]YRGRYLQ natural gas handling
]HPHOMVNHJDSOLQD equipment
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

EUROPEAN STANDARD
EN ISO 21809-5
NORME EUROPÉENNE
EUROPÄISCHE NORM
April 2010
ICS 75.200
English Version
Petroleum and natural gas industries - External coatings for
buried or submerged pipelines used in pipeline transportation
systems - Part 5: External concrete coatings (ISO 21809-
5:2010)
Industries du pétrole et du gaz naturel - Revêtements Erdöl- und Erdgasindustrie - Umhüllungen für erd- und
externes des conduites enterrées ou immergées utilisées
wasserverlegte Rohrleitungen in Transportsystemen - Teil
dans les systèmes de transport par conduites - Partie 5: 5: Betonummantelungen (ISO 21809-5:2010)
Revêtements extérieurs en béton (ISO 21809-5:2010)
This European Standard was approved by CEN on 25 March 2010.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the CEN Management Centre or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the
official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland,
Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2010 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN ISO 21809-5:2010: E
worldwide for CEN national Members.

Contents Page
Foreword .3

Foreword
This document (EN ISO 21809-5:2010) has been prepared by Technical Committee ISO/TC 67 "Materials,
equipment and offshore structures for petroleum, petrochemical and natural gas industries" in collaboration
with Technical Committee ECISS/TC 110 “Steel tubes, and iron and steel fittings” the secretariat of which is
held by UNI.
This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by October 2010, and conflicting national standards shall be withdrawn at
the latest by October 2010.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and the United Kingdom.
Endorsement notice
The text of ISO 21809-5:2010 has been approved by CEN as a EN ISO 21809-5:2010 without any
modification.
INTERNATIONAL ISO
STANDARD 21809-5
First edition
2010-04-01
Petroleum and natural gas industries —
External coatings for buried or
submerged pipelines used in pipeline
transportation systems —
Part 5:
External concrete coatings
Industries du pétrole et du gaz naturel — Revêtements externes des
conduites enterrées ou immergées utilisées dans les systèmes de
transport par conduites —
Partie 5: Revêtements extérieurs en béton

Reference number
ISO 21809-5:2010(E)
©
ISO 2010
ISO 21809-5:2010(E)
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ii © ISO 2010 – All rights reserved

ISO 21809-5:2010(E)
Contents Page
Foreword .v
Introduction.vi
1 Scope.1
2 Normative references.1
3 Terms and definitions .4
4 Symbols and abbreviated terms .7
4.1 Symbols.7
4.2 Abbreviated terms .7
5 General requirements .7
5.1 Rounding.7
5.2 Compliance with this part of ISO 21809 .7
6 Information supplied by the purchaser.7
6.1 General information .7
6.2 Additional information .8
7 Materials .8
7.1 Pipe .8
7.2 Cement.9
7.3 Supplementary cementitious materials .9
7.4 Aggregate — Fine and coarse.10
7.5 Heavyweight aggregate .10
7.6 Lightweight aggregate .11
7.7 Recycled concrete as aggregate .11
7.8 Water.11
7.9 Steel reinforcement .12
7.10 Concrete admixtures.12
7.11 Reclaimed concrete.12
8 Concrete mix.12
9 Coating application .13
9.1 Qualification.13
9.2 Application of concrete coating.15
9.3 Environmental conditions .15
9.4 Pipe .15
9.5 Steel reinforcement .15
9.6 Concrete cutback .17
9.7 Anode installation .17
10 Curing methods .17
11 Inspection and testing .17
11.1 General .17
11.2 Test procedures.19
11.3 Retesting .21
11.4 Test results .22
12 Repair of concrete coated pipe.22
12.1 General .22
12.2 Damaged areas .23
12.3 Cracks.23
12.4 Gaps.23
ISO 21809-5:2010(E)
12.5 Stripping .23
13 Markings .23
14 Handling and storage .23
15 Test reports and certificate of compliance .24
Annex A (normative) Water absorption test.25
Annex B (normative) Shear resistance test.28
Bibliography .29

iv © ISO 2010 – All rights reserved

ISO 21809-5:2010(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.
ISO 21809-5 was prepared by Technical Committee ISO/TC 67, Materials, equipment and offshore structures
for petroleum, petrochemical and natural gas industries, Subcommittee SC 2, Pipeline transportation systems.
ISO 21809 consists of the following parts, under the general title Petroleum and natural gas industries —
External coatings for buried or submerged pipelines used in pipeline transportation systems:
⎯ Part 1: Polyolefin coatings (3- layer PE and 3- layer PP)
⎯ Part 2: Fusion-bonded epoxy coatings
⎯ Part 3: Field joint coatings
⎯ Part 4: Polyethylene coatings (2-layer PE)
⎯ Part 5: External concrete coatings
ISO 21809-5:2010(E)
Introduction
It is necessary that users of this part of ISO 21809 be aware that further or differing requirements might be
needed for individual applications. This part of ISO 21809 is not intended to inhibit a vendor from offering, or
the purchaser from accepting, alternative equipment or engineering solutions for the individual application.
This can be particularly applicable if there is innovative or developing technology. If an alternative is offered, it
is the responsibility of the vendor to identify any variations from this part of ISO 21809 and provide details.

vi © ISO 2010 – All rights reserved

INTERNATIONAL STANDARD ISO 21809-5:2010(E)

Petroleum and natural gas industries — External coatings for
buried or submerged pipelines used in pipeline transportation
systems —
Part 5:
External concrete coatings
1 Scope
This part of ISO 21809 specifies the requirements for qualification, application, testing and handling of
materials required for the application of reinforced concrete coating externally to either bare pipe or pre-coated
pipe for use in pipeline transportation systems for the petroleum and natural gas industries as defined in
ISO 13623.
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 part of ISO 21809 is applicable to concrete thicknesses of 25 mm or greater.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
ISO 31-0:1992, Quantities and units — Part 0: General principles
ISO 1920-5: 2004, Testing of concrete — Part 5: Properties of hardened concrete other than strength
ISO 10474, Steel and steel products — Inspection documents
1)
EN 197-1, Cement — Part 1: Composition, specifications and conformity criteria for common cements
EN 206-1, Concrete — Part 1: Specification, performance, production and conformity
EN 450-1, Fly ash for concrete — Part 1: Definition, specifications and conformity criteria
EN 450-2, Fly ash for concrete — Part 2: Conformity evaluation
EN 934-2, Admixtures for concrete, mortar and grout — Part 2: Concrete admixtures — Definitions,
requirements conformity, marking and labelling
EN 1008, Mixing water for concrete — Specification for sampling, testing and assessing the suitability of water,
including water recovered from processes in the concrete industry, as mixing water for concrete

1) CEN, European Committee for Standardization, Central Secretariat, Rue de Stassart 36, B-1050, Brussels, Belgium.
ISO 21809-5:2010(E)
EN 10080, Steel for the reinforcement of concrete — Weldable reinforcing steel — General
EN 10016-2, Non-alloy steel rods for drawing and/or cold rolling — Part 2: Specific requirements for general
purpose rod
EN 10204, Metallic products — Types of inspection documents
EN 10244-2, Steel wire and wire products — Non-ferrous metallic coatings on steel wire — Part 2: Zinc or zinc
alloy coatings
EN 12390-2, Testing hardened concrete — Part 2: Making and curing specimens for strength tests
EN 12390-3, Testing hardened concrete — Part 3: Compressive strength of test specimens
EN 12390-7, Testing hardened concrete — Part 7: Density of hardened concrete
EN 12504-1, Testing concrete in structures — Cored specimens — Taking, examining and testing in
compression
EN 12620, Aggregates for concrete
EN 13055-1, Lightweight aggregates — Part 1: Lightweight aggregates for concrete, mortar and grout
EN 13263-1, Silica fume for concrete — Part 1: Definitions, requirements and conformity criteria
2)
ACI 308.1-98, Standard Specification for Curing Concrete
3)
ASTM A82/A82M, Standard Specification for Steel Wire, Plain, for Concrete Reinforcement
ASTM A185, Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete
ASTM A641, Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire
ASTM A810, Standard Specification for Zinc-Coated (Galvanized) Steel Pipe Winding Mesh
ASTM C31/C31M, Standard Practice for Making and Curing Concrete Test Specimens in the Field
ASTM C33, Standard Specification for Concrete Aggregates
ASTM C39, Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens
ASTM C40, Standard Test Method for Organic Impurities in Fine Aggregates for Concrete
ASTM C42/C42M, Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of
Concrete
ASTM C128, Standard Test Method for Density, Relative Density (Specific Gravity) and Absorption of Fine
Aggregate
ASTM C150, Standard Specification for Portland Cement
ASTM C171, Standard Specification for Sheet Materials for Curing Concrete
ASTM C172, Standard Practice for Sampling Freshly Mixed Concrete

2) American Concrete Institute, 38800 Country Club Drive, Farmington Hills, MI 48331, USA.
3) American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, USA.
2 © ISO 2010 – All rights reserved

ISO 21809-5:2010(E)
ASTM C309, Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete
ASTM C330, Standard Specification for Lightweight Aggregates for Structural Concrete
ASTM C331, Standard Specification for Lightweight Aggregates for Concrete Masonry Units
ASTM C332, Standard Specification for Lightweight Aggregates for Insulating Concrete
ASTM C494, Standard Specification for Chemical Admixtures for Concrete
ASTM C595, Standard Specification for Blended Hydraulic Cements
ASTM C617, Standard Practice for Capping Cylindrical Concrete Specimens
ASTM C618, Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in
Concrete
ASTM C637, Standard Specification for Aggregates for Radiation-Shielding Concrete
ASTM C642, Standard Test Method for Density, Absorption, and Voids in Hardened Concrete
ASTM C989, Standard Specification for Slag Cement for Use in Concrete and Mortars
ASTM C1157, Standard Performance Specification for Hydraulic Cement
ASTM C1176, Standard Practice for Making Roller-Compacted Concrete in Cylinder Molds using a Vibrating
Table
ASTM C1240, Standard Specification for Silica Fume Used in Cementitious Mixtures
ASTM C1435, Standard Practice for Molding Roller-Compacted Concrete in Cylinder Molds Using a Vibrating
Hammer
ASTM C1602, Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete
ASTM C1604/C1604M, Standard Test Method for Obtaining and Testing Drilled Cores of Shotcrete
ASTM D2216, Standard Test Methods for Laboratory Determination of Water (Moisture) Content of Soil and
Rock by Mass
ASTM D4643, Standard Test Method for Determination of Water (Moisture) Content of Soil by Microwave
Oven Heating
ASTM D4959, Standard Test Method for Determination of Water (Moisture) Content of Soil by Direct Heating
ASTM D6176, Standard Practice for Measuring Surface Atmospheric Temperature with Electrical Resistance
Temperature Sensors
ISO 21809-5:2010(E)
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
aggregate
〈fine and coarse〉 granular material such as sand, crushed stone, iron blast furnace slag, magnetite, ilmenite,
or hematite used with a cement medium to form concrete or mortar
3.2
anode
sacrificial metallic attachment that is electrically connected to the steel pipe
3.3
applicator
company which undertakes the coating application in compliance with the provisions of this part of ISO 21809
3.4
cementitious material
inorganic material or a mixture of inorganic materials that sets and develops strength by chemical reaction
with water by formation of hydrates and is capable of doing so under water
3.5
certificate of compliance
document issued in accordance with ISO 10474 or EN 10204, stating compliance with the purchase order for
concrete coated pipes, but without mention of any test results, issued in accordance with the purchasing
requirements
3.6
compression wrap process
process by which the concrete mix is discharged into a coating head and applied in a continuous helical strip
with pressure onto rotating pipe
3.7
compressive strength
maximum compressive stress at the point of failure
3.8
concrete admixture
material, other than aggregate, water, cement or supplementary cementitious material, or fibre reinforcement,
that is added as an ingredient to the concrete mix or one of its components, to enhance or modify the
properties of the concrete or application process
3.9
concrete coated pipe weight
weight of the concrete coated pipe in air after the concrete cutback has been completed
3.10
core
cylindrical specimen of a specific or designated diameter drilled from hardened concrete coating to be tested
in compression or examined petrographically
3.11
cover
distance between the surface of the reinforcement and the outer surface of the concrete
3.12
cube
specimen of specific dimensions prepared from fresh concrete to be tested in compression
4 © ISO 2010 – All rights reserved

ISO 21809-5:2010(E)
3.13
curing
action taken to maintain moisture and temperature conditions in a freshly placed cementitious mixture to allow
hydraulic cement hydration and (if applicable) pozzolanic reactions to occur so that the required properties of
the mix can develop
3.14
cutback
length of pipe left without concrete coating at each end
3.15
cylinder
cylindrical specimen prepared from fresh concrete to be tested in compression
3.16
electrical isolation
absence of electrical continuity between the steel pipe and reinforcement
3.17
field specimen
cores, cubes, cylinders, prisms or in situ specimens taken from the hardened concrete coating
3.18
form process
pour process
process by which the concrete mix is poured into a mould on a stationary pipe
3.19
gap
annular separation between the concrete coating and the underlying substrate
3.20
holiday
pre-coating discontinuity that exhibits electrical conductivity when exposed to a specific voltage
3.21
impact resistance
resistance of concrete coating against interference and accidental loads
3.22
impingement process
process by which the concrete is discharged at high velocity onto a rotating pipe
3.23
mix design
unique blend of aggregates, cement, water, and supplementary cementitious materials and/or admixtures that
will result in a concrete mix
3.24
negative buoyancy
weight of the concrete coated pipe less the positive buoyancy of the concrete coated pipe when considered as
a closed cylinder immersed in the service environment
3.25
NPS
nominal pipe size in USC units (inches)
ISO 21809-5:2010(E)
3.26
phi tape
pi tape
tape used to measure the diameter of the concrete coated pipe
3.27
pre-coating
any coating or coating system applied to the external surface of the steel pipe prior to the application of the
concrete coating
3.28
purchaser
company responsible for providing the product order requirements
3.29
reclaimed concrete
concrete that is reintroduced into the mix and does not require processing before reuse
3.30
recycled concrete as aggregate
concrete that has been reprocessed for use as aggregate
3.31
shear resistance
resistance against relative displacement (movement) along the interface between the concrete coating and
the underlying pre-coating
3.32
slip form process
process whereby the concrete is applied to a vertical pipe by means of a slip form mould
3.33
specific gravity
ratio of mass of a volume of material to the mass of an equal volume of distilled water at a stated temperature
3.34
steel reinforcement
bars, wires, fibres, or strands, which are embedded in the concrete coating in such a manner that the
reinforcement and the concrete act together in resisting forces
3.35
supplementary cementitious material
SCM
natural or man-made siliceous or siliceous and aluminous materials that can be used to either partially
substitute Portland cement or increase the total content of cementitious material in concrete mixes to improve
the strength and durability of concrete
EXAMPLE Fly ash, ground granulated blast furnace slag, silica fume, calcined shale or metakaolin.
3.36
supplier
provider or manufacturer of supplies or materials used in the application of concrete coating
3.37
test report
document that provides the quantitative test results for tests conducted in accordance with the requirements of
this part of ISO 21809
6 © ISO 2010 – All rights reserved

ISO 21809-5:2010(E)
4 Symbols and abbreviated terms
4.1 Symbols
D bare pipe diameter (mm)
b
D average concrete coated pipe diameter (mm)
c
t concrete thickness (mm)
c
t pre-coating minimum thickness (mm)
p
4.2 Abbreviated terms
AWG American wire gauge
h. hour(s)
min minute(s)
5 General requirements
5.1 Rounding
Unless otherwise stated in this part of ISO 21809, to determine conformance with the specified requirements,
observed or calculated values shall be rounded to the nearest unit in the last right-hand place of figures used
in expressing the limiting value, in compliance with ISO 31-0:1992, Annex B, Rule A.
NOTE For the purposes of this provision, the rounding method of ASTM E29 is equivalent to ISO 31-0:1992, Annex B,
Rule A.
5.2 Compliance with this part of ISO 21809
A quality system and an environmental management system should be applied to assist compliance with the
requirements of this part of ISO 21809.
NOTE ISO/TS 29001 gives sector-specific guidance on quality management systems and ISO 14001 gives guidance
on the selection and use of an environmental management system.
The applicator shall be responsible for complying with all of the applicable requirements of this part of
ISO 21809. It shall be permissible for the purchaser to make any investigation necessary in order to be
assured of compliance by the applicator and to reject any material and/or concrete coating that does not
comply.
6 Information supplied by the purchaser
6.1 General information
The purchase order shall include the following information:
a) number of this part of ISO 21809 and year of publication (ISO 21809-5:2010);
b) pipe quantity, outside diameter, wall thickness, minimum and maximum individual pipe lengths, type and
thickness of pre-coating;
c) bare pipe standard or specification designation, e.g. ISO 3183, or pre-coated pipe standard or
specification designation, e.g. ISO 21809-2;
ISO 21809-5:2010(E)
d) concrete coating thickness, density or specific gravity or negative buoyancy, and compressive strength;
e) applicable project specifications;
f) reinforcement type, standard and cross-sectional area percentages;
g) concrete coating cutback length and tolerances for each pipe end;
h) pre-coating inspection and repair requirements;
i) markings to be applied to the concrete coated pipe;
j) frequency of concrete coating density test during coating production (see Table 2).
6.2 Additional information
The purchase order shall indicate which of the following provisions apply for the specific order item:
a) plant inspection by the purchaser;
b) additional tests, types and frequency;
c) handling procedures;
d) storage procedures;
e) requirement for applicator to submit details of the facilities and the methods to be used for yard storage;
f) waiver of test reports;
g) other special requirements, e.g. impact resistance, shear resistance for tension transfer on the pipe lay
vessel;
h) anode location area.
7 Materials
7.1 Pipe
The supply of bare or pre-coated pipe to be concrete coated shall conform to the pipe and pre-coating
standards or specifications that are specified in the purchase order.
IMPORTANT — Pre-coated steel pipe might not necessarily have a surface condition that is
appropriate for the application of concrete coating. Remediation of the bare steel pipe or pre-coating
may therefore be required.
8 © ISO 2010 – All rights reserved

ISO 21809-5:2010(E)
7.2 Cement
The applicator shall use cement that is:
a) certified by the supplier to be in compliance with the requirements of ASTM C150, ASTM C595,
ASTM C1157 or EN 197-1;
b) identified with the following information on the certification and/or delivery documents for each shipment
of cement:
⎯ cement producer's name and location,
⎯ product description including type and classification of cement,
⎯ year and month of production;
c) handled, transported and stored prior to use, in compliance with the cement manufacturer's
recommendations and in compliance with the applicable standards;
d) no more than six months from the date of manufacture, unless it is retested and proven to be in
compliance with the original standard.
NOTE Cement stored in a warm, humid environment for an extended period of time could possibly lose significant
properties.
For submarine service conditions using concrete mixes containing Portland cement as the only cementitious
material, the tricalcium aluminate (C A) content of the cement shall be less than or equal to 10,0 %. For all
other service conditions the tricalcium aluminate content limit is not applicable.
For submarine service conditions using concrete mixes containing Portland cement as the only cementitious
material, the alkali content shall not exceed 0,6 %, if potentially reactive aggregates are used.
7.3 Supplementary cementitious materials
If approved by the purchaser, the applicator shall use SCMs that are:
a) certified by the supplier to be in compliance with the requirements of ASTM C618, ASTM C989,
ASTM C1240, EN 450-1 or EN 13263-1;
b) identified with the following information on the certification and/or delivery documents for each shipment
of SCMs:
1) SCM producer's name and location;
2) product description including type and classification of SCM;
3) year and month of production;
c) handled, transported and stored prior to use, in compliance with the SCM supplier's recommendations
and in compliance with the applicable standard;
d) within time limits stated in the applicable standard, unless it is retested and proven to be in compliance
with the original standard.
NOTE SCMs stored in a warm, humid environment for an extended period of time could possibly lose significant
properties.
ISO 21809-5:2010(E)
7.4 Aggregate — Fine and coarse
The applicator shall use fine or a combination of fine and coarse aggregates that are:
a) certified by the supplier to be in compliance with the requirements of ASTM C33 or EN 12620;
b) identified with the following on the certification and/or delivery documents for each source of aggregate:
1) aggregate supplier's name and location;
2) product description including gradation;
3) qualification standard or specification;
c) stored in such a condition as to prevent contamination and shall remain in compliance with the applicable
standard.
The applicator shall verify that the aggregate received meets the above requirements.
7.5 Heavyweight aggregate
If required, the applicator shall use heavyweight aggregate with an oven-dried density higher than 3 000 kg/m ,
such as iron ore or other dense material, that is:
a) certified by the supplier to be in compliance with the requirements of ASTM C637 or EN 12620;
b) identified with the following on the certification and/or delivery documents for each shipment of
heavyweight aggregate:
1) heavyweight aggregate supplier's name and location;
2) product description including gradation;
3) chemical composition;
4) density;
c) suitable in size for the application process, and achieves the required concrete coating properties;
d) stored in such a condition as to prevent contamination and shall remain in compliance with the applicable
standard.
The applicator shall verify that the aggregate received meets the above requirements.
10 © ISO 2010 – All rights reserved

ISO 21809-5:2010(E)
7.6 Lightweight aggregate
If required, the applicator shall use lightweight aggregate with an oven-dried density lower than 2 000 kg/m ,
such as expanded or sintered clay, shale, slate, perlite, slag, sintered fly ash, natural pumice, volcanic cinders
or industrial cinders, that is:
a) certified by the supplier to be in compliance with the requirements of ASTM C330, ASTM C331,
ASTM C332 or EN 13055-1;
b) identified with the following on the certification and/or delivery documents for each shipment of lightweight
aggregate:
1) lightweight aggregate supplier's name and location;
2) product description including gradation;
3) chemical composition;
4) density;
c) suitable in size for the application process, and achieves the required coating properties;
d) stored in such a condition as to prevent contamination and shall remain in compliance with the applicable
standard.
The applicator shall verify that the aggregate received meets the above requirements.
7.7 Recycled concrete as aggregate
The use of recycled concrete is acceptable if processed from current or previous concrete coating projects to
achieve an aggregate suitable in size for the application process. The use of this aggregate in combination
with new aggregates shall achieve the required concrete coating properties stated in Tables 1 and 2.
Every 100 m of processed recycled concrete shall be tested for:
a) moisture in compliance with ASTM D4643;
b) cleanliness in compliance with ASTM C40;
c) particle size in compliance with ASTM C33 or EN 12620;
d) density in compliance with ASTM C128.
The percentage of recycled concrete used as aggregate shall not exceed 10 % by weight unless agreed on
with the purchaser.
NOTE Percent mass fraction is commonly called “weight percent” in USC units.
7.8 Water
Water used in the production of concrete shall comply with ASTM C1602 or EN 1008. Water that is potable
does not require testing for compliance.
ISO 21809-5:2010(E)
7.9 Steel reinforcement
The concrete coating shall be reinforced by steel bars tied or welded to form cages or by wire mesh steel.
Steel bars shall comply with ASTM A82 or EN 10080. Wire mesh reinforcement shall comply with ASTM A185
or EN 10016-2. Zinc coated wire mesh shall comply with ASTM A810 or EN 10244-2.
The applicator shall request and retain certificates for each shipment. The certificates shall contain the
information required in the aforementioned standards.
7.10 Concrete admixtures
The use and types of concrete admixtures shall be agreed on with the purchaser and shall comply with
ASTM C494 or EN 934-2. Concrete admixtures containing added chlorides shall not be used.
7.11 Reclaimed concrete
The use of reclaimed concrete is acceptable only when the material is reintroduced via a conveyance system
into the process within 30 min of initial mixing with water.
8 Concrete mix
The concrete ingredients shall be homogeneously mixed according to the applicator's mix design to
predetermined proportions based on the concrete density and compressive strength necessary to achieve the
requirements of the purchase order.
Each time the source of aggregate, water or cement changes, and that change necessitates a modification of
the mix design, the applicator shall verify by testing that the new mix design results in a concrete coating that
meets the purchase order requirements.
The applicator shall have a documented process control system to assure continuity of the produced mix.
For submarine service conditions using concrete mixes containing Portland cement as the only cementitious
material, the water to cement ratio in the concrete mix shall be equal to or less than 0,40 and the minimum
cement content shall be 400 kg/m of the concrete mix.
For all other service conditions using concrete mixes containing Portland cement as the only cementitious
material, the water to cement ratio in the concrete mix shall be equal to or less than 0,45 and the minimum
cement content shall be 350 kg/m of the concrete mix.
For all service conditions using concrete mixes containing SCMs, the water to cement ratio in the concrete mix
may be equal to or lower than concrete mixes containing only Portland cement to achieve equivalent or higher
compressive strengths.
12 © ISO 2010 – All rights reserved

ISO 21809-5:2010(E)
9 Coating application
9.1 Qualification
A qualification test in accordance with Table 1 shall be performed prior to the start of concrete coating
production. Three 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.
If a result for density, compressive strength or water absorption does not meet the requirements of Table 1,
retesting shall be carried out in accordance with 11.3.
If a result for other test parameters does not meet the requirements of Table 1, retesting may be done in
agreement with the purchaser.
NOTE This qualification test represents one pipe diameter coated with one thickness and one density of concrete.
If existing documentation from previous projects using the same application process, application equipment
and materials d
...