SPEC.NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.M4-134-102

TITLE

1.0

SCOPE

UNDERGRO
UND PROTECTION FOR PIPING

SECTION: D2
SHEET 1 OF 5
OF 4

The purpose of this specification is to describe the technical requirements for the
application of hot coal-tar enamel and fibre glass wrapping or pipeline wrapping
tapes for the protection of external surface of underground carbon steel piping.
2.0

GENERAL

2.1

The coating shall consist of coal-tar enamel, inner wrap of fibre glass, final outer
wrap of enamel-impregnated fibre or enamel-impregnated kraft paper. The primer
and the enamel shall be from the same supplier.

2.2

Alternatively, if specified in Data Sheet-A, ready-made tapes available for

underground protection shall be used. Tape shall be of approved make. The
CONTRACTOR shall furnish all the technical information, experience details etc.
of the tapes proposed to be used for review.

2.3

The two ends of each length of pipe shall be left bare of primer coating and
wrapping for a distance of 150 mm from the end to facilitate field welding and
subsequent field coating or wrapping.

2.4

The supply, application, characteristics of materials and testing requirements shall

be strictly as per IS 10221.

2.5

Type of coating system based upon the soil resistivity may be selected on the
following basis :
SOIL RESISTIVITY

CORROSIVITY

COAL TAR
COATINGS

WRAPPING
TAPES

(a)

1000 ohm-cm

Extremely
corrosive

3 coats
and 3 wraps

3 layers
of tape

(b)

> 1000 ohm-cm

Corrosive &
non-corrosive

2 coats
and 2 wraps

2 layers
of tape

2.6

If no specific choice is indicated in Data Sheet-A, system 2.5(b) using coal tar
coating shall be used.

3.0

SURFACE PREPARATION
Pipe surfaces to be provided with underground protection shall be cleaned by shot
or sand blasting. The cleaning shall be so carried out that the piping surface is free
from mill scale, rust, oil, welding scale and other foreign materials. Primer shall be
applied immediately after shot or sand blasting to prevent rust forming. Superficial
rust formed shall be removed by wire brushing or by the use of emery paper. If the
ISSUE
R5

FILE NAME : M4134102R5.DOC

TCE FORM NO. 329 R3

SPEC.NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.M4-134-102

TITLE

UNDERGRO
UND PROTECTION FOR PIPING

SECTION: D2
SHEET 2 OF 5
OF 4

rust formation is heavy, re-blasting may be necessary. Around field joints, the pipe
surfaces may be cleaned by wire brushing prior to the application of anti-corrosive
protection.
4.0

PRIMER COAT

4.1

The primer shall be compatible with the grade of enamel used. It shall be
thoroughly mixed before using by stirring or by rocking the drum to provide
uniformity of material. The primer coat shall be applied over a thoroughly clean
and dry surface within three (3) hours of the cleaning operation, and shall be
applied preferably immediately with a uniform thickness on the entire surface of
the piping using appropriate quantity per unit area of surface as recommended by
the manufacturer. The primer coating shall be free of bubbles, globules, drips and
runs. Pipes having a longitudinal seam shall be carefully examined to determine
that all excess primer has been brushed out of each side of the welding seam. The
primer shall be thoroughly dry before the enamel is applied. If ready-made tapes
are used, then primer, as suggested by the manufacturer, shall be used.

4.2

Freshly-primed pipe shall be handled carefully to prevent damage. The damaged

area shall be re-primed before applying enamel/wrapping tapes.

5.0

ENAMEL AND WRAPPING MATERIALS FOR COAL TAR ENAMEL

APPLICATION

5.1

The material to be used for coating and wrapping shall be coal-tar enamel, fibre
glass inner wrap, fibre glass or kraft paper outer wrap, all as per IS 10221.

5.2

Well-experienced personnel shall be placed in charge of coating and wrapping

operations. They shall strictly follow the manufacturer's instructions regarding
recommended temperature in the heating kettles and the temperature at which the
hot coating is applied to the pipe. Clean dry enamel in lumps not exceeding 35 kg
in weight shall be heated slowly in clean kettles to the recommended temperature,
and after reaching the required temperature, the heating flame shall be controlled
to prevent over-heating. Any enamel heated in excess of manufacturer's
specifications shall be discarded. Only batch heating of enamel shall be permitted.

5.3

Kettles shall be completely emptied of one batch and cleaned, if necessary, before
preparing the next batch of enamel. The enamel shall be stirred continuously with
metal agitators. Enamel kettles shall be equipped with indicating or recording
thermometers having temperature range from 100 to 350C. Enamel withdrawn
from the kettles shall be strained through a 1.5 mm strainer.

5.4

Enamel shall be moisture - and dirt-free at all times prior to and at the time of
heating and application. The primed surface shall be dry and clean at all times and
the enamel shall be applied not later than three (3) days after the application of
primer. Along with the first coat of enamel, a single spiral inner wrap of fibre glass
ISSUE
R5

FILE NAME : M4134102R5.DOC

TCE FORM NO. 329 R3

SPEC.NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.M4-134-102

TITLE

UNDERGRO
UND PROTECTION FOR PIPING

SECTION: D2
SHEET 3 OF 5
OF 4

shall be applied overlapping at least 20 mm on pipes upto 250 mm diameter and 25

mm on larger diameter pipes. It shall be ensured that fibre glass impregnates in the
first coat. The second coat of enamel and the second outer wrap of enamelimpregnated fibre glass or enamel-impregnated kraft paper shall be applied in the
same way and shall conform to Table-10 or 12 of IS 10221. The total thickness of
the coating shall not be less than 2.5 mm.
5.5

A third coat of enamel and wrapping shall be applied wherever soil resistivity is
below 1000 ohm-cm (extremely corrosive).

5.6

During cold weather, when the pipe surface temperature is below 7C or during
rainy and foggy weather when moisture tends to collect on the cold pipe,
enamelling shall be preceded by warming of the primed pipe. Warming shall be
done by any method that will heat the pipe uniformly to the recommended
temperature without damage to the primer. Temperature of the pipe shall not
exceed 70C.

5.7

Each end of the pipe left bare for welding purpose shall be hand-coated and
wrapped after completion of field welding and satisfactory hydrotesting of pipe.

6.0

APPLICATIONN OF WRAPPING TAPES

6.1

After the surface preparation as per para 3.0, the primer shall be applied by brush
or spay so as to give a coating thickness is between 2 and 4 mils when wet. The
primer shall be allowed to dry to the touch prior to tape application. Primer and
tape shall be furnished by the same manufacturer. If application is done in cold
weather, the surface of the pipe shall be preheated until it is warm to the touch, and
until all traces of moisture are removed and then the primer shall be applied and
allowed to dry.

6.2

The tape shall be wrapped strictly in accordance with the manufacturer's

recommendations in a manner that shall meet the adhesion and holiday detection
requirements of IS 10221. There shall be a minimum overlap of 12 mm per single
wrap. Each layer of tape shall be of 2 mm thickness.

7.0

TESTING

7.1

THICKNESS

The thickness of the pipe coating shall be measured either by elcometer or by

coating thickness gauge.
7.2

BOND

7.2.1

Bond test shall be carried out by cutting 25 mm square at three locations of the
coating on a sample test specimen to qualify the procedure. Coating shall be pulled
ISSUE
R5

FILE NAME : M4134102R5.DOC

TCE FORM NO. 329 R3

SPEC.NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.M4-134-102

TITLE

UNDERGRO
UND PROTECTION FOR PIPING

SECTION: D2
SHEET 4 OF 5
OF 4

out by lifting one corner of the square. For a good coating, the section shall not
peel off easily.
7.2.2

The coating on the pipe shall be carried out only after satisfactory completion of
the qualifying test.

7.2.3

In case of doubt regarding the quality of coating, bond test shall be carried out on
any location of the pipe to the satisfaction of the PURCHASER. The tests
indicated under clauses 7.1 and 7.2 are applicable for coal tar enamel applications
only.

7.3

FIELD ADHESION TEST FOR WRAPPING TAPES

7.3.1

Adhesion test shall be made to determine the proper bond between the tape and
primed pipe. The temperature of the tape and pipe to be tested shall be between 10
and 27 C. If the temperature is outside this range, hot or cold water shall be
poured over the test area until this temperature range is attained. A test area shall
be selected by the inspector where the tape is smooth for 15 cm in the longitudinal
direction of the tape. Two knife cuts that are 15 cm long and 5 cm apart shall be
made through the tape. A flat blade shall be used to pry up 5 cm of the fabric. This
5 cm flap of fabric shall be grasped firmly in one hand and shall be pulled with a
quick motion in the direction of the remaining 10 cm of the 15 cm knife cut.

7.3.2

The adhesion is satisfactory if the tape tears at the point of stripping or the fabric
strips from the underlying coal tar component, leaving exposed not more than 10%
of the primer or metal.

7.4

HOLIDAY TEST

7.4.1

On completion of coating/wrapping, the quality of the coating shall be tested using

efficient high voltage holiday detectors, operating at a voltage high enough to jump
an air gap, the length of which is equal to the thickness of the coating/wrapping.
All holidays found shall be repaired and the repairs shall be retested with the
holiday detector to ensure that adequate repairs have been made.

7.4.2

The suggested test voltage shall be as follows :

V

1250 (t) where

voltage, in volts

coating thickness in mils (1 mil = 0.001 in.)

ISSUE
R5

FILE NAME : M4134102R5.DOC

TCE FORM NO. 329 R3

SPEC.NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.M4-134-102

8.0

TITLE

UNDERGRO
UND PROTECTION FOR PIPING

SECTION: D2
SHEET 5 OF 5
OF 4

CERTIFICATES
The CONTRACTOR shall furnish certificates of all the materials purchased by
him and also complete instructions from the manufacturer regarding the storage,
preparation and application of the coating materials.

ISSUE
R5

FILE NAME : M4134102R5.DOC

TCE FORM NO. 329 R3