Concrete Coated Pipe

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What’s Concrete Coated Pipe?

Concrete Coated Pipe, or Concrete Weight Coating (CWC), is a specialized system where a layer of heavy concrete is applied over a pre-existing anti-corrosion coating (like 3PE or FBE). This is primarily used for underwater and offshore pipelines.

Types of Concrete Coating

  • Lightweight CWC: For basic physical protection.
  • Heavyweight CWC: Using iron ore or heavy aggregates in the concrete mix to achieve specific high-density requirements for buoyancy control.

Advantages of Using Concrete Coated Pipe

  • Negative Buoyancy: In offshore or swamp environments, the weight of the concrete keeps the pipe firmly on the seabed, preventing it from floating.
  • Mechanical Protection: Acts as a “shield” against impact from ship anchors, fishing nets, or rocky seafloors.
  • Stability: Increases the stability of the pipe against underwater currents.

Specifications of Concrete Coated Pipes

  • Standards: ISO 21809-5, DNV-OS-F101.
  • Concrete Thickness: 25mm to 150mm.
  • Concrete Density: Usually ranges from 2200 kg/m³ to 3450 kg/m³.

Concrete Coating Manufacturing Process

  1. Anti-Corrosion Base: The pipe must first be coated with FBE or 3PE.
  2. Reinforcement: A wire mesh or rebar cage is wrapped around the pipe to give the concrete tensile strength.
  3. Application: The concrete is applied using either the “Impingement Method” (sprayed at high speed) or the “Compression Method” (wrapped/extruded).
  4. Curing: The pipes are stored in a controlled environment to allow the concrete to reach its full design strength before being moved to the dock.