External Three Layer Extruded

Polyethylene Based Coatings for OnShore and Off-Shore Steel Linepipes

Revision 0
An Uncontrolled Copy

DATA Steel Pipe Industries

Date: June 30, 2000

Written by:

Reviewed by:

Approved by:

Table of Contents

SCOPE .................................................................................................................................... 1

REFERENCES ....................................................................................................................... 1

SUMMARY OF PHYSICAL PROPERTIES OF THE COATING SYSTEM (AS PER

DIN30670) ............................................................................................................................... 1

APPLICATION PROCEDURE............................................................................................ 2

CUT-BACK ............................................................................................................................ 3

INSPECTION & TESTING .................................................................................................. 3

MARKING OF COATED PIPE ........................................................................................... 4

ii

EXTERNAL THREE LAYER EXTRUDED POLYETHYLENE BASED COATINGS

ISO 4287-1: Surface roughness-Part 1: Surface and its

parameters

Scope

This specification defines the application of factory

applied external three layer extruded polyethylene based
coatings for the corrosion protection of pipes and pipeline
components.
External extruded polyethylene coating can be used for
the protection of buried or submerged pipes service at
o
temperatures up to +50 C when supplied with normal
type coatings (N). Higher temperature and/or higher
mechanical requirements may demand special types of
PE.
The coating in this specification can be applied to
longitudinally or spirally welded and to seamless steel
tubes and components used for the construction of
pipelines for conveying liquids or gases
1.1

Definitions

Applicator - The contractor who applies the coating to the

pipe.
Company - The purchaser of the coated pipe or the entity
for whom the Applicator coats the pipe.
DSPIL - DATA Steel Pipe Industries (Pvt.) LTD.

ISO 8501-1: Preparation of steel substrates before

application of paints and related products
ISO/CD 11420: Plastic pipes and fittings-Method of test
for carbon black dispersion in polyethylene pipes and
fittings.
ISO R.1183: Methods for determining the density and
relative density of non-cellular plastics

Summary of physical properties of the

coating system (as per DIN30670)

Property
Min. thickness
D < 114.3
114.3 < D < 273
273 < D < 508
508 < D < 762
D< 762
Continuity
Peeling resistance

SSPC - The Steel Structures Painting Council.

NACE - NACE International.
NAPCA: National Association of Pipe Coating Applicators.

Impact resistance

Manufacturer - The company that makes the coating

materials which are applied to the pipe.

REFERENCES

This specification makes reference to the latest additions

of the following standards. In case of conflict, the
requirements of this specification shall have precedence.

Indentation
resistance

ASTM G 8-90: Test method for cathodic disbonding of

pipeline coatings
ASTM D638: Standard test method for tensile properties
of plastics

Elongation
Coating resistivity

DIN 30670: Polyethylene coatings for steel pipes and

fittings.
ISO 306: Plastics-determination
temperature

of

Vicat

softening

ISO 527: Plastics-Determination of tensile properties

ISO 1133: Plastics-Determination of the melt mass-flow
rate and the melt volume-flow rate of thermoplastics.
ISO 1515: Paints and varnishes-Determination of volatile
and non-volatile matter
ISO 2555: Plastics-Determination of apparent viscosity by
the Brookfield Test Method

Thermal stability
Stability against
U.V.
Resistance to
cathodic
disbondment

Requirements
Normal type (n) Reinforced (v)
1.8 mm
2,5 mm
2.0 mm
2,7 mm
2.2 mm
2,9 mm
2.5 mm
3,2 mm
3.0 mm
3,7 mm
Free from holidays, the test voltage
shall be 25 kV
o
At 23 5 C: at least 35 N/10 mm
o
At 50 5 C: at least 15 N/10 mm
for type N coatings, at least 25
N/10 mm for type S coatings
Impact energy shall be equal to 5
J per mm coating thickness.
The test temperature shall be
232? C
Nominal size:
D > 219.1
1,00
o
At 232 C, shall not exceed 0.2
mm for type N coatings
o
At 502 C, shall not exceed 0.3
mm for type N coatings
o
At 702 C, shall not exceed 0.3
mm for type S coatings
At least 200%
RS value after 100 days shall be
8
2
greater than 10 O.m
The ratio of resistivity after 100
days to that after 70 days shall
not be less than 0.8, provided the
resistivity is only one power of 10
above that specified for 100 days
of conditioning
Deviation not more than 35% of
original value
Deviation not more than 35% of
original value.
o
At 232 C maximum 10 mm

Table 3-1

ISO 2808: Paints and varnishes-Determination of film

thickness
ISO 2811: Paints and varnishes-Determination of density.
ISO 3001: Plastics-Determination of epoxy equivalent

EXTERNAL THREE LAYER EXTRUDED POLYETHYLENE BASED COATINGS

4.1.2 Prior to abrasive blast cleaning, the steel surface

shall be dry and free from contamination (oil, grease,
temporary corrosion protection, etc.) and surface defects
(slivers, laminations, etc....) detrimental to the surface or
to the adhesion of the coating. The blast-cleaned surface
shall have a roughness Rz between 40 m and 90 m, as
measured in accordance with ISO 4287-1.
4.1.3 After blast cleaning, the surface of the pipe shall be
inspected. All slivers, laminations, weld spatter and other
surface imperfections made visible by the blast cleaning
process shall be removed.
After removal of these
defects, the residual thickness of pipe and components
shall satisfy the minimum tolerance requirements
specified by the relevant standard. All treated areas
greater than 10 cm shall be prepared to provide a profile
to satisfy the provisions of 4.1.
4.1.4 Pipe and components shall be maintained at least
3 C above the dew point temperature prior to coating.
4.1.5 Contaminants (e.g. residual abrasive dust) shall be
removed prior to coating. Chemical treatment of the steel
may be used in addition to abrasive blast cleaning, by
agreement.
4.1.6 The temperature holding time of the pipe shall not
result in oxidation of its surface, detrimental to the good
quality and adhesion of the coating. At the time of
application, the temperature range at the surface of the
pipe to be coated shall be determined in agreement with
the manufactures of the products. The temperature of the
pipe shall be monitored using suitable means in order to
make sure that the application conditions are fully
satisfied.
4.2

External Coating Application

The principle of this coating shall consist of three layers.

The coating in the factory shall be applied in accordance
with the established procedure.
The data sheets of the used materials shall contain the
items required in table 2.
Prior to the application the pipe shall be heated according
to the material specification of the manufacturer.
4.2.1 Layer 1
Immediately after abrasive blast cleaning the layer shall
be formed by a film of liquid epoxy or resin of powder.
The minimum dry thickness shall be between 20 and 60
microns checked in accordance with method 5 of ISO
2808 depending on the primer used. The thickness may
be subject to agreement by the customer, and to the
conform manufacturers recommendations.
4.2.2 Layer 2
A polymer intended to provide adhesion between layers 1
and 3 and be compatible with those layers shall form this
layer. The minimum thickness shall be between 140 and
200 microns depending on the type of adhesive and the

4.2.3 Layer 3
Polyethylene coating shall form this layer. The thickness
shall be uniform and the minimum total thickness shall
satisfy the requirements in table 3-1.
Pigments and additives may be added to the basic
polyethylene, provided that all the required properties of
the coating are obtained. The pigments shall be dispersed
uniformly.
When the coater adds pigments and additives to the
basic polyethylene, the required properties must be
certified by a documented quality programme. The
following tests shall be undertaken as a minimum:

quantitative analysis of the raw-material

components immediately before coating;

determination of dispersion of pigments and

additives in accordance with ISO/CD 11420

Content of data sheets and certificates

+ Technical data sheet
o Test certificate
Layer 1
Items

Standard
test
reference

Layer 3

4.1.1 Pipe and components shall be abrasive blast

cleaned. The degree of cleanliness shall be Sa 2 in
accordance with ISO 8501-1.

Layer 2

Surface preparation

application. The thickness may be subject to agreement

by the customer, and conform to manufacturers
recommendations. The thickness shall be uniform and
the minimum thickness shall make it possible to satisfy
the tests specified in Section 8.

Liquid

4.1

Application procedure

Powder

Date of issue

+o

+o

+o

+o

Name of
manufacturer

+o

+o

+o

+o

Name and type

of product

+o

+o

+o

+o

Factory of
origin

Batch for
production lot
number

+o

+o

Shelf life
Epoxy
equivalent

ISO 3001

+o

Physical state
delivered
product

Packaging

Storage
conditions

Sieve analysis
or viscosity

+o

+o

+o

+o

+o

+o

Density

ISO 2811
primer
ISO R. 1183
adhesive and

+o

EXTERNAL THREE LAYER EXTRUDED POLYETHYLENE BASED COATINGS

PE
Melt index

ISO 1133

Processing
temperature

+o

Content of
pigment

ISO/CD
11420

+o

+o

Dispersion of
pigment

ISO/CD
11420

+o

+o

Temperature
range of
coating

Tube service
temperature

Elongation at
break

ISO 527

Maximum
moisture
content

+o

Infra red

+o

Gel time

+o

Cure
characteristics

+o

Viscosity of
base and
hardener

ISO 2555

Volume solids
base and
hardener

ISO 1515

Softening point

ISO 306

+o

5.1

6.2.5 The coated system shall be electrically tested for

flaws in the coating with a suitable holiday detector as
approved by the Approved Manufacturer.

+o

6.3
+o

+o

Cut-Back
Cut back at the ends

Inspection & Testing

Material Inspection

6.1.1
Independent laboratory test certificates for the
coating system shall be provided by the applicator. The
certificates shall include adhesion testing, water
absorption, water vapour transmission, insulation
resistance, tensile strength, elongation, impact resistance
and penetration resistance.
6.2

6.2.4 Coated
pipe
not
complying
with
these
specifications shall be rejected and re-coated at the
expense of the applicator.

6.2.7 All holidays electrically detected shall be repaired.

The affected area shall be repaired to an approved
procedure and retested.

angle of 30 unless otherwise specified by the

purchaser.
When removing the coating, the tube surface shall not be
damaged.

6.1

6.2.3 All inspections shall be made at the application

plant prior to shipment of coated pipe and shall be
conducted as not to interfere unnecessarily with the
operation of the coating plant. If required, the company
inspector shall be present at all times when work is in
progress.

+o

+o

The length of the cut back shall be 150 mm 20 mm and

the coating shall be bevelled at the back forming a bevel

6.2.2 The company coating inspectors shall have

access, while the application of the coating system is
being performed, to all parts of the application plant
concerned with the storage, application, inspection,
testing and training of coated pipe and material.

6.2.6 The holiday inspection shall be performed on the

total coating system. The total coating system shall be
electrically inspected on the kick-out racks after water
quenching. The voltage setting for the total system shall
be based on DIN 30670.

Table 4-1

performed by coating inspectors qualified either by

experience or certified training.

Plant Inspection

6.2.1 The company may employ the service of inspectors

as it shall deem appropriate to undertake the required
inspection and test of the coating applied under the
specifications. The inspection of the coated pipe shall be

Quality Plan

6.3.1 The applicator shall prepare a detailed quality plan

for Company approval. The plan shall include all activities
of the coating process in a chronological manner showing
the frequency of control, the acceptance limit, the
governing code and whether document or report is
produced for that activity.
6.3.2 As a minimum, the following quality aspects must
be endorsed:
Properties
Surface condition
before blasting

Method
of Test

Minimum
Production Control

Visual

every pipe
twice per shift

Dimensions, shape
and properties of
blast cleaning
products and
checking of the blast
cleaning process
Roughness of the
blast cleaned
surface
Surface preparation

one per shift

Visual

100% inspection

Temperature of
heating before
coating
Appearance and
continuity

continuously

Visual

every pipe

EXTERNAL THREE LAYER EXTRUDED POLYETHYLENE BASED COATINGS

Thickness testing

DIN
30670

on one pipe every 25

coated pipes

Cut back

Visual

every pipe

Holiday inspection

DIN
30670

100% of all pipes

incl. mill pipes

Impact resistance

DIN
30670

one per order

Adhesion test

DIN
30670

on one pipe each

100 coated pipes

Indentation test

DIN
30670

1)

to be conducted
three times, one at
production start, at
end of the job and
when the order is
50% completed

DIN
30670

Once per order

ISO 527

once at the start of

the work

Stability against U.V.

DIN
30670

once per order

Thermal stability

DIN
30670

once per order

ASTM G
8-90

by agreement

Electric resistance

2)

Elongation test

2)

Resistance to
cathodic resistance

Process of manufacture (seamless: SMLS - electric

resistance welder: ERW - submerged arc welding:
SAW).

Table 6-1
The system and applicator approval may be combined
with a coating production run.

a)

Any pipe from the beginning to the end of the

production may be used for this test.

b)

The delivery of pipes can be undertaken prior to

the completion of the test.

Marking of coated pipe

Each joint of coated pipe shall be marked by the coating

applicator on the outside surface of the coating starting a
minimum of twelve (12) inches from the bevelled end of
the pipe.
Marking shall be stencilled on the coated pipe utilizing a
waterproof permanent type paint or ink, which will not rub
off when the coated pipe is handled.
The marking shall be legible from a distance of five (5) to
six (6) feet with letters no less than one quarter (1/4)
inches high.
Marking shall be in English and in the following sequence,
regardless of previous markings on the inside or outside
surface of the bare steel pipe.

Pipe manufacturers name

Pipe identification number
Outside diameter measured in inches
Wall thickness measured in inches
Grade of pipe

HEAD OFFICE

STEEL PIPE
INDUSTRIES

IBRAHIM BUILDING
20, WEST WHARF ROAD
KARACHI 74000, PAKISTAN
TEL:
+92 (21) 231 3685
FAX:
+92 (21) 231 0422
E-MAIL: sales@datasteel.com

An Uncontrolled Copy

Factory
7 K.M.S. KLP Road
Sadiqabad, Dist. Rahim Yar Khan
Pakistan

Phone: +92 (702) 74406

Fax: +92 (702) 74405
Email: factory@datasteel.com