Concrete weight pipe coating machine: stability for offshore pipelines
Bauhuis designs and delivers turnkey concrete weight coating (CWC) plants that add weight and mechanical protection to pre-coated steel pipes, keeping pipelines stable in offshore conditions. Bauhuis CWC coating plant come in many different shapes:
Either with impingement or compression or wrap coating technology
Integrated batch plant with continuous or batch mixers
(Steam) curing rooms adapted to local climate for accelerated curing of the concrete coating
Turnkey concrete weight pipe coating plants
Bauhuis supplies turn-key concrete weight pipe coating equipment plants. Each plant is engineered based on the required output, pipe dimensions, coating thickness and other specifications.
A complete CWC coating plant includes the following equipment:
All Pipe handling equipment to route the bare and coated pipes through the plant
Concrete batching plant for weighing and mixing iron ore, sand, water and cement in the right mix
Impingement or wrap/compression coating application unit
Wiremesh or cage reinforcement application
Anode installation station
Pipe end treatment stations
Foil wrapping station
Steam curing room
Reclaim systems for re-use of spilled coating materials
Impingement or wrap coating
Bauhuis supplies two main types of concrete weight pipe coating systems:
Impingement coating: high-speed rubber rollers apply the concrete mix onto the rotating pipe
Compression wrap coating: the pipe moves helically past an applicator belt that presses concrete and wire mesh layers onto the pipe surface
Each concrete weight pipe coating machine is engineered based on the applicable pipe dimensions, coating thickness and output.
Concrete batch plant
The concrete mix is prepared in a dedicated batch plant, where iron ore, sand, cement and water are mixed to achieve the required density and coating performance before the mix is fed to the CWC application unit.
The batch plant can include:
Cement silos with loading system
Discharge bunkers with sieves for iron ore and sand
Aggregate storage bins with weighing conveyors
Batching plant
Transport belts to transport coating materials between the discharge bunkers, storage bins, mixer and application unit.
Heavy-duty continuous or batch type twin shaft mixers with automatic high pressure water cleaning systems
Reclaim systems to collect spilled materials and transport these either to a dump location or feed it back into the system for re-use. and improve process efficiency
Reinforcement and anode installation
Concrete weight pipe coating requires reinforcement. Depending on the coating system and project specification, Bauhuis equipment can apply steel cages, steel wire mesh, or a combination of both.
In case of cages special machines to produce the cages from rebar are part of the plant. After manufacturing of the cages the pipes are inserted into the cage. Next on a pegging conveyor, pegs or spacers are placed in between the cage and the steel pipe.
For the installation of sacrificing anodes, Bauhuis supplies complete installation stations with rotators, jib cranes, welding units and backfill equipment.
Curing systems
Curing is a key step in concrete weight pipe coating and depends on the local climate and project conditions:
In hot regions, coated pipes can be wrapped and cured outdoors
In colder environments, steam-heated curing cabins can be used to control the curing process
Bauhuis designs curing systems around the output of the concrete weight pipe coating machine, the available space and environmental conditions.
Key features
Turnkey concrete weight pipe coating equipment engineered based on pipe specification, coating thickness and production output
Impingement or compression/wrap coating application
Dedicated concrete batch plant
Reclaim system for re-use of wasted coating materials
Reinforcement with steel cages, wire mesh or a combination of both
Complete anode installation stations with rotators, jib cranes and welding units
Curing systems outdoor natural curing or accelerated steam-heated cabins
Your concrete weight coating setup
Frequently asked questions about concrete weight coating
What is concrete weight coating?
Concrete weight coating (CWC) is a reinforced concrete layer on pre-coated steel pipes that adds weight and mechanical protection. The extra weight keeps offshore pipelines stable. The concrete mix consists of iron ore, sand, cement and water.
Who builds complete concrete weight coating plants?
Bauhuis designs and delivers turnkey concrete weight coating plants, from pipe handling and the concrete batch plant to the coating application unit and the curing system. A complete plant also includes reinforcement application, anode installation, pipe end treatment, foil wrapping and reclaim systems. Bauhuis engineers each plant based on the required output, pipe dimensions and coating thickness.
Impingement or compression wrap: which concrete weight coating technology fits my project?
Bauhuis supplies both technologies and engineers each machine based on the pipe dimensions, coating thickness and output of your project. With impingement coating, high-speed rubber rollers apply the concrete mix onto the rotating pipe. With compression wrap coating, the pipe moves helically past an applicator belt that presses concrete and wire mesh layers onto the pipe surface.
Can concrete weight coated pipes cure in a cold climate?
Yes, steam-heated curing cabins control the curing process in colder environments. In hot regions, coated pipes can be wrapped and cured outdoors. Bauhuis designs the curing system around the output of the coating machine, the available space and the environmental conditions.
What happens to spilled coating material in a CWC plant?
Reclaim systems collect spilled material and either transport it to a dump location or feed it back into the system for re-use. Re-use of spilled material improves process efficiency.