pile technical specification

7/29/2019 Pile Technical Specification

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ICTSI Berth 6 Redevelopment

Pile Procurement Technical Specification

Table of Contents1.0 General 12.0 Deliverables 13.0 Materials 14.0 Fabrication 2

4.1 1,500dia Tubular Pile Tolerances 24.2 900dia Tubular Pile Tolerances 34.3 800dia Tubular Pile Tolerances 34.4 700dia Tubular Pile Tolerances 34.5 Sheet Piling Tolerances 4

5.0 Piling Shoes 46.0 Clutches 47.0 Corrosion Protection 4

7.1 Surface Preparation 47.2 Painting 57.3 Handling 57.4 Testing 67.5 Reinstatement of Painted Surfaces 6

8.0 Testing and Inspection 68.1 Material 68.2 Pile Weld Testing 68.3 Corrosion Protection 78.4 Defects and Damage 88.5 Inspection Access 8

9.0 Package, Storage, Handling and Delivery 8

9.1 General 89.2 Marking 89.3 Handling 89.4 Damage and Repairs 89.5 Additional Storage 89.6 Delivery Packages 9

10.0 Handover of Piles from the Supplier to the Buyer 911.0 Shipping of Materials and Equipment 912.0 Acceptable Standards 1013.0 Pile Supply Schedule 1014.0 Pile Delivery Orders 12

10


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1.0 GeneralThis Technical Specification covers the requirements for the manufacture, supply and delivery of 1,500diameter, 900 diameter, 800 diameter and 700 diameter tubular steel piles and sheet piles for theconstruction of the ICTSI Berth 6 development.

The scope of work shall include the following:

1. Supply of all materials, labour, equipment, supervision and management necessary to fabricate

steel piles to the quantity, dimensions and quality specified on the contract drawings and the

specifications.

2. Supply, fabrication and fitting to the steel piles of all accessories such as piling shoes and clutches,

along with any other items detailed on the drawings.

3. Supply and application of surface corrosion protection as specified.

4. Transportation and delivery of the steel piles and accessories to the project site.

5. Testing and provision of all documentation to the Buyers Representative as specified.

6. When requested, provide assistance to the Buyers Representative for inspection and testing of the

work under the Contract.

The Supplier shall comply with this Specification and Drawing Nos. 51052607-2013(B) and 2014(E) that setout the minimum technical requirements for the supply, fabrication, surface treatment, storage, handling anddelivery of steel piles under this Contract.

2.0 DeliverablesThe Supplier shall include the preparation and submission of Contract deliverables as per the specifiedschedules.

3.0 MaterialsThe Supplier shall arrange for and supply all pile sections as required under the Contract.

Piles shall be rolled or formed from steel with a minimum yield strength of 350 MPa. Steel composition andperformance shall conform to the requirements of BS EN 10025: 2004 or an equivalent approvedInternational Standard. Tubular piles shall be fabricated as either spirally or longitudinally seam weldedsteel and shall comply with the BS EN 10219-1:2006 or other approved international standards except asvaried in the specification. Sheet piles shall comply with BS EN 10248-1:1996. Inspection of metallicproducts shall comply with BS EN 10204:2004. The type of Certificates to be issued shall be Type B.

Pile steel material properties shall be:

Minimum Yield Strength/Minimum Tensile Strength : 350 MPa / 490 MPaSteel Grade : Steel type S355Material elongation at yield : Min 18%

The Supplier shall not vary the place of manufacture of the steel plate used in the pile fabrication withoutthe written approval of the Buyers Representative. The Supplier shall obtain Manufacturers Certificatesand mill inspection reports, or certified reports of tests made by a certified testing laboratory, or if by anoverseas facility, must be acceptable to the Buyer for all steel plate, demonstrating compliance in allrespects with the specified standards. The manufacturers certificates and mill inspection reports orcertified material reports shall be submitted, and written approval of the Buyers Representative is requiredbefore fabrication work commences.

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All such plates shall have clear and distinct manufacturers markings indicating the grade of steel.

4.0 FabricationThe details of the type of processes to be used in the fabrication of the piling tube and shoes proposed shallbe submitted to the Buyers Representative for formal approval prior to the work commencing.

Hold Point: The Supplier shall not fabricate the piles to the required lengths, until the lengths are

confirmed in writing by the Buyer.

The Supplier shall submit details of all proposed welding procedures to the Buyers Representative, andreceive written approval from the Buyers Representative, prior to the commencement of welding work. Alllongitudinal, spiral and circumferential welds shall be qualified complete penetration butt welds to BS EN15614:2004 Parts 1 to 3 or an approved equivalent international standard. The welds shall be made by anautomatic or semi automatic process. Longitudinal welds shall be staggered by a minimum of 90 degrees.

All piles and pile shoes shall be finished free of surface flaws, cracks, laminations and any other defects.Repairs to minor defects can be made at the discretion of the Buyers Representative. Proposed repair

procedures shall be submitted to the Buyers Representative for review and approval prior to commencingrepairs.

Pile sections shall be supplied in the lengths shown on the drawings and schedule. The Supplier shall notvary the pile preparation lengths without first obtaining written approval of the Buyers Representative.

The ends of all pile segments shall be accurately cut square to the longitudinal pile axis and prepared asshown in the drawings.

The finished surface profile of all welding shall be smooth and free from sharp edges or crevices that wouldbe detrimental to the performance of the structure or to the protective treatment. All slag and weld splattershall be thoroughly removed, and the weld surface shall be replaced, repaired and ground as directed bythe Buyers Representative until a satisfactory surface finish has been achieved.

Arc strikes outside the area of permanent welds shall be avoided. Cracks or blemishes resulting from arcstrikes shall be ground to ensure that metallurgical notch is removed and the wall thickness has to be re-checked after grinding.

The tolerance on straightness of individual completed tubular piles shall not exceed L/1000 over the lengthof the pile. Plate thickness of tubular piles shall not exceed -0.75mm / +1mm of that specified.

Pile manufacture shall conform to the tolerance requirements in the following sections. All shape anddimensional tolerances not given in the tables below should conform to the relevant standards, includingthose listed in this specification.

4.1 1,500dia Tubular Pile Tolerances

Item Tolerance

Circumference +/- 0.5%

Overall length +100 / -0 mm

Out-of-roundness +/- 15 mm

Alignment of splices between sections.


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Item Tolerance

Internal diameter pile wall measured across any particular crosssection of the pile.

1460 mm +/- 10 mm

Internal diameter of pile shoes measured across any particularcross section of the pile.

1450 mm +/- 8 mm

4.2 900dia Tubular Pile Tolerances

Item Tolerance

Circumference +/- 0.5%


Out-of-roundness +/- 9 mm

Alignment of splices between sections.


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4.5 Sheet Piling Tolerances

Item Tolerance


Wall height +/- 4.0 mm

Wall thickness +1.5 / -0.3 mm

Width along the full length of the pile +/- 5 mm

Straightness of completed piles L / 500Ends out of square 2% width

5.0 Piling ShoesThe Supplier shall fabricate and splice piling shoes to all tubular pile ends, as shown on the drawings andindicated in the pile schedule, in accordance with the fabrication requirements.

6.0 ClutchesAll 1,500dia piles, not including the top 0.5m, shall be fitted with clutches as shown on the drawings. It isbrought to the Suppliers attention that piles B1 and R21 have different clutch arrangements to the otherpiles.

7.0 Corrosion ProtectionProtective coating shall be applied to the piles as indicated in this Specification.

7.1 Surface Preparation

The surfaces of piles that are to have protective coating applied shall receive treatment as follows:

1. Removal of grease, oil or dirt, by degreasing or blasting. Surfaces shall then be dry abrasive blast

cleaned Class Sa 2 finish to BS EN 8503-2:1995 to remove all traces of rust, mill scale or oxide

deposits.

2. During blast cleaning, particular attention shall be paid to joints, angles, pits and weld areas to

ensure that their surfaces are brought to the standard required.

3. After blast cleaning and prior to painting, all surfaces to be coated shall be free of dust and grit.

Between cleaning and priming, the steel shall not be allowed to be contaminated in any way. The supplierspersonnel shall wear clean gloves when handling the steel after blast cleaning.

The Supplier shall take necessary measures to ensure possible weather variations, windborne dust or non-availability of labour, equipment or paint do not affect the application and curing of coatings.

7.2 Painting

The external circumference of tubular piles and both sides of sheet piles is to be coated with Interzone 485or approved equivalent in accordance with the manufacturers recommendations.

The paint shall be applied to the 1,500 diameter piles in two separate and distinct coats. The first shall beapplied over the top 21 metres of the pile in order to achieve a total minimum dry film thickness of 1,000microns. The second shall be applied over the top 6 metres of the pile in order to achieve a total minimumdry film thickness of 2,000 microns.



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For all other piles the paint shall be applied in two separate and distinct coats in order to achieve a totalminimum dry film thickness of 1,500 microns in order to minimise dry film formation of pinhole defects in thecured coating film.

The portions of pile length that are to be painted are nominated in the table below.

Pile Type Pile Mark Coating thicknessmicrons

Pile Length Sections to be Painted

1500dia x 20mm

Tubular Pile

B1 B285 2,000

1,000

Top 6 metres

15 metres below top 6 metres

1500dia x 20mm

Tubular Pile

R1 R21 2,000

1,000

Top 6 metres

15 metres below top 6 metres

900dia x 16mm Tubular

Pile

C1 C30 1,500 Top 6 metres


Pile

A1 A14 1,500 Top 6 metres


Pile

T1 T60 1,500 Top 6 metres


Pile

M1 M4 1,500 Top 25 metres

SP1 SP14 1,500 Top 12 metres




FSP VL Sheet Piles


Painting shall be carried out before surface discolouration takes place, or within a maximum time of fourhours.

The finished surface shall be free from sagging, streaking, running, cracks, imperfections or damage undernormal vision.

A margin of 50 mm of unpainted steel surface shall be allowed from the edges to be welded.

7.3 Handling

All steelwork that has been surface treated shall be handled with care in order to preserve the coating in thebest practical condition.

Steelwork shall not be handled until the coating has completely cured and dried hard.

Slings used for the handling of finished coated steelwork shall be covered with rubber hose or similar soft

material. Pipe bolsters or cradles may be used to aid in transport.

Supports in contact with coated steel during transport and storage shall be covered with a soft material suchas rubber to minimise damage to the coating.

Similarly soft material shall be used between coated steelwork and holding down chains to prevent damageto the coating during transportation.

7.4 Testing

Testing shall be carried out by the Supplier in accordance with Section 8.0.



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7.5 Reinstatement of Painted Surfaces

The procedure for reinstatement of painted coatings shall be:

1. Pre-clean the damaged or unpainted areas in accordance with this Specification.

2. Abrasive blast clean damaged or unpainted areas in accordance with surface preparation

requirements of this Specification. All damaged and unsound paint must be removed back to

sound coating.

3. Edges of sound coating must be feathered back to a minimum distance of 50 mm.

4. The new coatings shall overlap the existing coating by a minimum distance of 50 mm.

Unless otherwise specified or approved by the Buyers Representative in writing, the repair coatings willbe the same as the existing coating by taking into account the environmental conditions, which should bemonitored and reported.

8.0 Testing and Inspection

8.1 MaterialThe Supplier shall be responsible for maintaining quality control over the chemical analysis and mechanicalproperties of all steel for use in the Works. The Supplier will provide an inspection and testing (ITP) plan.Chemical analysis and mechanical testing, including tension, bend, flattening and impact tests, shall beperformed for each batch of steel. Testing shall be performed by the steel manufacturer or by an approvedlaboratory. Results shall be presented in a manner, which demonstrates compliance to the requirements ofBS EN 10025:2004 (or an approved equivalent International Standard), and shall be submitted to theBuyers Representative when available.

The Supplier may be required to prepare and submit for testing, specimens of material intended to be usedin pile fabrication if requested by the Buyers Representative.

The Supplier may also be required to prepare and submit test specimens cut from a fabricated pile

segment. The entire cost of preparing test specimens and carrying out tests on materials shall be borne bythe Supplier. In the event of a failed test the Buyers Representative may request additional tests todemonstrate that the piles supplied are to the specified standard. The costs of the additional testing shallalso be borne by the Supplier.

In the event that materials tests supplied do not comply with the minimum specified standards and that ifsubsequent inspection and testing of the same materials meets the required specification, the Buyer makesno guarantees to the Supplier that these same materials will be accepted under the Contract.

8.2 Pile Weld Testing

All non-destructive testing for which the Supplier is responsible shall be performed by a testing authority,which has been approved by the Buyer. In the event of materials being rejected as a result of non-

destructive testing, all costs of replacement, repair and the cost of further non-destructive tests shall beentirely at the Suppliers expense.

Longitudinally Seam Welded Piles:

1. Pile welds shall be 100% ultrasonically tested on the first five pile segments fabricated.

2. Pile welds shall be 100% ultrasonically tested where a change to material thickness or grade

occurs at a joint.

3. Pile welds shall be 100% ultrasonically tested for every one in four pile segments fabricated.

4. Where piles are made up of two or more lengths of pile the longitudinal welds shall be tested over a

length of 300mm either side of the splice weld.



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Spirally Welded Piles:

a. Pile spiral welds shall be ultrasonically tested on 10% of the spiral weld length for one in four

piles manufactured.

b. Pile welds shall be 100% ultrasonically tested where a change to material thickness or grade

occurs at a joint.c. Pile welds shall be 100% ultrasonically tested at pile section joints.

Where piles are made up of two or more lengths of pile the longitudinal spiral welds shall be tested over alength of 300mm either side of the splice weld.

8.3 Corrosion Protection

The Supplier shall be responsible for conducting the supervision and inspection as per the following testrequirements of surface preparation and coating operations. The Supplier shall conduct as a minimum thefollowing testing program:

Property

Tested

Test

Description

Test Standard Pass/Fail

Criteria

Test Frequency Remedial

Act ion i f NonConforming

Surface

preparation

As per

manufacturers

requirements.

As per

manufacturers

requirements.

As per

manufacturers

requirements.

As per

manufacturers

requirements.

As per

manufacturers

requirements.

Dry Film

thickness

Testing of

Coating

Thickness

SSPC-PA2

Method of

Measurement for

Dry Paint

Thicknesses with

Magnetic

Gauges.

Coating

thickness as

per section 14.3

Minimum every 1

m2Preparation of

coating surface

and application

coating defect

area. (additional

50% of original

thickness)

Visual Inspection for

Defects

N/A Defects in

Coating

100% of Coated

Surface Area.

Surface

Preparation toReinstate Profile,

Reapply Coating

Pinholes Electrical

Continuity

Testing using

High Voltage

Brush Method

ASTM G62-87

Test Methods

for Holiday

Detection in

Pipeline

Coatings

As per test

method

100% of Coated

Surface Area.

Preparation of

coating surface

and application

of an additional

50% of original

thickness

8.4 Defects and Damage

If any defects or damage are found before the Buyer takes possession of the piles, the Buyers

Representative shall, at their absolute discretion, decide whether piles will be rejected, repaired or thedamaged portions returned to a workshop. The full cost of repairs or replacement of sections damagedshall be borne by the Supplier.

8.5 Inspection Access

During this Contract, the Supplier shall permit the Buyer or its Representatives free access to the Works atall times for the purpose of carrying out inspection and additional testing, and shall afford all necessaryfacilities for the carrying out of such inspections. Pile sections shall be laid out and fabricated as necessaryso that all parts are accessible for inspection before loading onto the Suppliers transport. Any inspectionby the Buyers Representative shall not prevent the rejection of any work or materials in which defects havebeen found at any time prior to the piles and accessories being loaded onto ships.ICTSI Berth 6 RedevelopmentPile Procurement Technical SpecificationC:\Documents and Settings\fcabuang\Desktop\08-02-13 Pile P rocurement Technical Specification Rev 2_3.docRevision 2 13 February 2008 Page 7


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The Buyers Representativemay elect to pass a clearance template through the piles to confirm that thepiles meet the minimum internal clearances for the equipment required to operate inside the piles. Pileswhich do not meet the minimum clearance requirement will be rejected.

9.0 Package, Storage, Handling and Delivery9.1 General

Before, during and after fabrication, all pile sections shall be handled, stacked and stored so that they arenot damaged, bent or twisted. Prior to delivery to the site, piles shall be temporarily stored by the Supplier,clear of the ground on non-metallic suitable supports to prevent distortion or damage to the piles and pilecoatings.

9.2 Marking

Piles shall be clearly marked with their pile number as specified in the schedule to allow identification duringtransit and upon delivery to the construction Site.

9.3 Handling

The Supplier shall be responsible for transporting the piles to site and arranging for the unloading andstacking of the piles on site, as directed by the Buyers Representative.

9.4 Damage and Repairs

Any damage to the protective coating of piles which occurs during transport to site or unloading andstacking, shall be repaired by the Supplier in accordance with this specification as soon as practical afterthe damage has occurred, and the cost for such repairs shall be borne by the Supplier.

All repairs made to the protective coating of piles shall be subject to inspection and approval by

the BuyersRepresentative.

9.5 Additional Storage

Should the Buyer deem it necessary to defer the date for the receipt of the piles by the Port Contractor,beyond the Contract date nominated in the Contract, the Supplier will be required to extend the time forstorage of the piles for this period, at the rates tendered in the schedule.

9.6 Delivery Packages

The pile supply order is to be divided into two (2) separate delivery packages, so that overall delivery isstaged throughout the wharf construction contract.

The order is to be divided into two packages as stipulated by the Buyer.

10.0 Handover of Piles from the Supplier to the BuyerThe Buyer or its Representativeshall inspect the condition of the piles delivered as soon as possible andwithin 72 hours of the piles being available for inspection. The Buyer or its Representative will formallyreport to the Supplier in writing, the findings of the inspection. The condition of the pile segments shall beclassified as either acceptable or unacceptable to the Buyer.



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For all piles classified as unacceptable the Supplier shall advise the proposed remedial actions and anestimate of the impacts of the proposed remedial actions. The Supplier shall not carry out remedial workwithout prior written authorisation by the Buyers Representative. The BuyersRepresentative may elect toinstruct the Supplier on further actions as necessary including the extent of any remedial work required andthe party required to carry out the work.

Upon the completion of any remedial work authorised by the Buyers Representative, the Buyers

Representative

shall re-inspect and classify the piles that have had remedial work carried out.

11.0 Shipping of Materials and EquipmentThe Supplier shall provide written notice to the Buyers representative giving details of the delivery date forthe piles a minimum of 28 days prior to delivery of piles to the nominated port. The Supplier shall not beentitled to compensation for delays resulting from any failure by the Supplier to provide adequate notice tothe Buyers Representative the for pile delivery dates.



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12.0 Acceptable StandardsThe International Standards to be conformed to include, but are not limited to, the following;

Specification Number Rev Title

BS EN 8503-2:1995 NA Preparation of steel substrate before applicationof paints and related products.BS EN 10025: 2004 NA Hot rolled products of non-alloy structural steel

Technical delivery conditions.BS EN 10204: 2004 NA Metallic Products. Types of inspection documents.BS EN 10219-1:2000 NA Cold formed structural hollow sections of non-

alloy and fine grained structural steels. Technicaldelivery requirements.

BS EN 10219-2:2000 NA Cold formed structural hollow sections of non-alloy and fine grained structural steels.Tolerances, dimensions and sectional properties.

BS EN 10248-1:1996 NA Hot rolled sheet piling of non alloy steels.Technical delivery conditions

BS EN 10248-2:1996 NA Hot rolled sheet piling of non alloy steels.Tolerances on shape and dimensions

BS EN 15614-1:2004 NA Specification and qualification of weldingprocedures for metallic materials.

Other equivalent standards can be used with prior approval from the Buyers Representative.

13.0 Pile Supply Schedule

Nominal 1,500mm Outer Diameter Piles

Pile Mark Wall Thickness

(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

B1 20 24.0 1 24

B2 B208 20 24.0 207 4968

B209 B285 20 25.0 77 1925

R1 R7 20 24.0 7 168

R9, R11, R13,R15, R17, R19

20 24.0 6 144

R8, R10 20 23.0 2 44

R12 20 22.0 1 63

R14, R16 20 21.0 2 42

R18 20 20.0 1 20

R20 R21 20 19.0 2 38Total 306 7436



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Nominal 900mm Outer Diameter Piles



Nominal 1,500mm Outer Diameter Pile Shoes

Nominal 900mm Outer Diameter Pile Shoes



Sheet Pile type FSP VL or Similar Approved


(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

C1 C30 16 26.0 30 780

A1 A15 16 14.5 15 217.5

Total 45 997.5


(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

M1 M4 12 27.0 4 108

Total 4 108

Pile Mark Wall thickness

(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

T1 T60 12 25.0 60 1500

Total 60 1500

Wall Thickness

(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

25 0.9 306 275.4

Wall Thickness

(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

25 0.9 30 27.0

Wall Thickness

(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

20 0.9 4 3.6

Wall Thickness

(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

20 0.9 60 54.0

Pile Mark Length (m) No. of

Piles

Total Length Supply

(m)

S1 20.0 14 280

S2 18.0 16 288

S3 16.0 16 256

S4 14.0 16 224

S5 12.0 15 180

Total 77 1228



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14.0 Pile Delivery Orders

Pile Delivery Order 1 No Later Than October 31, 2008

All tubular piles to include pile shoes and, where necessary, clutches. Pile lengths indicated in these tablesare exclusive of pile shoes.

All piles are to be painted in accordance with the specification.


Nominal 900 Outer Diameter Piles


Pile Delivery Order 2 No Later Than December 12, 2008

All tubular piles to include pile shoes and, where necessary, clutches. Pile lengths indicated in these tablesare exclusive of pile shoes.

All piles are to be painted in accordance with the Specification.


(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

B1 20 24.0 1 24

B2 B143 20 24.0 142 3408Total 143 3432


(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

C1 C18 16 26.0 18 468

Total 18 468


(mm)

Length (m) No. of

Piles

Total Length Supply

(m)T1 T30 12 25.0 30 750

Total 30 750

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* Piles A1-A15 to be supplied without shoes



Sheet Pile type FSP VL or Similar Approved


(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

B144 B208 20 24.0 65 1560

B209 B285 20 25.0 77 1925

R1 R7 20 24.0 7 168

R9, R11, R13,R15, R17, R19

20 20.0 6 120

R8, R10 20 23.0 2 46

R12 20 22.0 1 22

R14, R16 20 21.0 2 42

R18 20 20.0 1 20

R20, R21 20 19.0 2 38

Total 163 4006


(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

C19 C30 16 26.0 12 312

A1 A15 * 16 14.5 15 217.5

Total 27 529.5


(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

T31 T60 12 25.0 30 750

Total 30 750


(mm)

Length (m) No. of

Piles

Total Length Supply

(m)

M1 M4 12 27.0 4 108

Total 4 108

Pile Mark Length (m) No. of

Piles

Total Length Supply

(m)

SP1-SP14 20.0 14 280

SP15-SP30 18.0 16 288SP31-SP46 16.0 16 256

SP47-SP62 14.0 16 224

SP63-SP77 12.0 15 180

Total 77 1228



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CONFORME:

I have read and fully understood the contents of the Pile Procurement Technical

Specification for the Berth 6 project, and therefore comply with all the provisions stated above.

________________________ ________________________Signature over Printed Name Company Name

________________________ ________________________Position in the Company Date

ICTSI Berth 6 RedevelopmentPil P t T h i l S ifi ti