Mill-Pro STEEL PIPE PILES FABRICATION & COATING Revision 1. Australia AS

Transcription

1 STEEL PIPE PILES FABRICATION & COATING Australia AS 1579 Mill-Pro Revision 1

2 Welded Pipe WELDED PIPE 6 / 7 DIMENSIONS 8 / 11 Manufacturing Process SPIRAL WELDED PIPE 14 UOE / JCOE PIPE 15 MANUFACTURING SIZE TABLES 16 / 17 Manufacturing Standards CONTENTS MANUFACTURING STANDARDS 18 / 19 Combined Walls COMBINED WALLS 20 / 21 CLUTCHES 22 TYPICAL APPLICATIONS 23 Coatings ULTRA HIGH BUILD COATINGS 24 / 29 Accessories ACCESSORIES 30 / 33 Certification CERTIFICATION 34 / 35 Mill-Pro Steel Pipe Piles Australia AS

3 INTRODUCTION Mill-Pro is a highly specialised engineering solutions business with offices in Australia, New Zealand & Hong Kong. The business has spent many years and significant resources developing a small number of highly reliable and exclusive sources within each of our product segments. These sources are best in class, generally located in emerging markets and have been developed to meet the international quality, safety & environmental audit demands from large-scale construction projects in developed markets. Mill-Pro is 50% owned by GS Global Corporation, a large Korean publicly listed trading company. Our shareholder partnership gives us the balance sheet to deliver large scale projects in the region. Mill-Pro s business model differs from typical trading models: We are technical specialists in our fields of; Steel pipe, Welding, Fabrication & Coatings We do not shop for the cheapest suppliers; We have our own exclusive source. We use Mill-Pro expatriate inspection staff on site throughout production & shipping operations Our team are highly experienced project managers, quality inspectors and manufacturers We deliver complete end to end solutions with full traceability and quality documentation Whilst many construction firms have developed their own sourcing teams based in low cost countries, the Mill-Pro offer is a complete packaged solution including shipping and logistics. Mill-Pro was created from a merger between Millmerran Pty Ltd and SsangYong Australia Pty Ltd and has established a strong track record in supplying major engineering projects for more than 20 years. With our sourcing skills and proprietary coating systems developed over the last 5 years Mill-Pro has assembled a world leading marine piling product with unmatched benefits to product quality, coating performance and schedule. Mill-Pro has achieved significant deliveries with exacting quality requirements to major Australian Resource companies such as FMG, Rio Tinto, Citic Pacific and QCG on large resource projects such as CLB, AP3, 4, 5, and QCLNG. Mill-Pro Steel Pipe Piles Australia AS

4 Welded Pipe DIMENSIONS 8 / 11 Mill-Pro specialises in manufacturing long marine piles, coated in single lengths up to 100m long. Piles are shipped pre slung with certified slings ready for discharge into waiting barges for pitching & driving on site. WELDED PIPE Mill-Pro Steel Pipe Piles Australia AS

5 WELDED PIPE DIMENSION TABLE Diameter Diameter Thickness Inside Diameter Mass Meters per Tonne External Surface Area Thickness / Diameter Ratio Gross Area of Cross Section Second Moment of Area I Elastic Section Modulus S Radius of Gyration r g D mm Inches t mm d mm kg / m m / mt m² / m D / t mm 2 x10 6 mm 4 x10 3 mm 3 r g = mm Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note DIMENSION TABLE Diameter Diameter Thickness Inside Diameter Mass Meters per Tonne External Surface Area Thickness / Diameter Ratio Gross Area of Cross Section Second Moment of Area I Elastic Section Modulus S Radius of Gyration r g D mm Inches t mm d mm kg / m m / mt m² / m D / t mm 2 x10 6 mm 4 x10 3 mm 3 r g = mm 800 Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note Ref Note UOE Mill-Pro Steel Pipe Piles Australia AS

6 WELDED PIPE DIMENSION TABLE Diameter Diameter Thickness Inside Diameter Mass Meters per Tonne External Surface Area Thickness / Diameter Ratio Gross Area of Cross Section Second Moment of Area I Elastic Section Modulus S Radius of Gyration r g D mm Inches t mm d mm kg / m m / mt m² / m D / t mm 2 x10 6 mm 4 x10 3 mm 3 r g = mm UOE LIMIT Ref Note Ref Note Ref Note Ref Note DIMENSION TABLE Diameter Diameter Thickness Inside Diameter Mass Meters per Tonne External Surface Area Thickness / Diameter Ratio Gross Area of Cross Section Second Moment of Area I Elastic Section Modulus S Radius of Gyration r g D mm Inches t mm d mm kg / m m / mt m² / m D / t mm 2 x10 6 mm 4 x10 3 mm 3 r g = mm Note 1 Common Non ISO, hard metric pile sizes are shown for reference. This is not a complete list, any diameter and thickness combination within the capacity table for spiral pipe can be manufactured to order. Assume a minimum quantity of m for custom sizes. Note 2 Typical ISO soft metric / Imperial piling sizes are shown with common stock thickness for reference. The diameter & thickness tables are not exclusive, any diameter and thickness increment within the capacity table for spiral pipe (Diameter mm, thickness mm) can be manufactured to order. Assume a minimum quantity of m for setup viability. Note 3 Some indicative heavy gauge LSAW sizes outside Spital capacity (t >25.4mm) are shown for reference, these are limited to 12m long JCOE Limit UOE JCOE PRESS Mill-Pro Steel Pipe Piles Australia AS

7 Manufacturing Process SAW PIPE 14 JCOE PIPE 15 MANUFACTURING SIZE TABLES 16 / 17 For pipe piles there are two main methods of manufacture. For simplicity we have only shown the main forming processes excluding hydrostatic testing as this is not required in pipe piles. We are not showing end preparation or final inspection. MANUFACTURING PROCESS Mill-Pro Steel Pipe Piles Australia AS

8 MANUFACTURING PROCESS SPIRAL FORMED PIPE Also known as spirally Formed Pipe, Helical Wound Pipe, Spiral Arc Welded Pipe (SAW) or Double Submerged Arc Welded Pipe (DSAW). It should be noted the term DSAW is not exclusive to helically formed pipe, but using this term does exclude Seamless & ERW pipes. The Spiral method uses Hot Rolled Coil (HRC) feed stock to continuously form pipe by helically winding the steel strip into a circular pipe. The coil edges (seams) are then welded internally and externally with complete penetration welds from opposing sides. The seam weld is performed as the pipe is being formed in the mill (typically) or on high speed mills the seams are tack welded as the pipe is formed and full penetration welds are made off line using multiple welding stations to increase output. The key features of Spiral formed pipe for piling are: The pipe is manufactured circular (it s not possible to helically wind pipe out of round) The pipe is manufactured straight (it s not possible to helically wind bent pipe) Any diameter from 100mm (in 1mm increments) to over 3000mm can be formed using any coil thickness within the size range of the equipment (typically 5-25mm). Spiral pipe is formed continuously with length only limited by handling restrictions (either inside the factory or by transportation.) In heavy gauges minimum diameter restrictions apply, maximum gauge is 25.4mm The Spiral manufacturing method provides great benefits for piling projects where long piles >50m are required in single lengths. For marine piling projects piles can be formed in a single length coated and shipped ready to pitch and drive from the water, thereby eliminating length restrictions imposed by land transportation. PRESS BENDING OR ROLL FORMING PIPE Also known as UOE, JCOE, Brake Pressed Pipe and Roll Formed Pipe. All are referred to as Longitudinal Submerged Arc Welded (LSAW) pipe as they have one (or more) longitudinal weld seams parallel with the pipe axis. This pipe is also referred to as Double Submerged Arc Welded (DSAW) pipe, as like Spiral pipe, it has a full penetration welds made from opposing sides. Regardless of the forming method employed, all methods use fixed size steel plates as the feedstock cut to the width & length of the finished pipe. UOE: The plate is prepared along its length and then pressed longitudinally in a large hydraulic press to form a U shape. It is then closed in a fixed size die to an O shape, the pipe is then tack welded, and welded internally and externally with complete penetration longitudinal welds (the E is for Electrically welded in UOE). Typically, diameters are fixed standard sizes ranging from 508mm OD to 1118mm OD. Full Penetration Internal & External Submerged Arc Welds Weld Testing by Ultrasonic NDT JCOE: As the name suggests, is where the plate is either pressed or rolled longitudinally into a J shape first then repeated to form a C shape, then closed to an O by hydraulic pressing. The pipe is then tack welded and fully welded in the same manner as UOE pipe. Typically available diameters range from 508mm OD to 1829mm OD and any diameter and combination thickness can be made within the equipment s capacity (refer attached charts). ROLL FORMING: Large rollers roll flat plate to form a circular O shape, which is then welded in a similar manner to UOE pipe. Roll forming can accommodate gauges up to 230mm thick in large diameters however lengths are limited to 2-3m wide, making it impractical for creating long piles, but ideal for heavy gauge accessories such as pile shoes. Both UOE & JCOE forming methods require mechanical rounding to expand the finished pipe circular. After welding the pipe may also require straightening as a single side weld input creates bending on along the pipe axis. Both forming methods are limited to 12m lengths, so multiple pipe-to-pipe splices are required to achieve a long finished piles. The key features of Longitudinal formed pipe for piling are: Heavy gauges (>25mm) can be formed by pressing Typically up to 60mm thick Heavy gauges can be formed into smaller diameters such as 406 OD x 30mm thick Ultra heavy gauges in narrow sections can be rolled such as 2000 OD x 210mm thick Steel Plate feedstock sized for finished pipe size and inspected for laminations Plates are edge milled and edges are set Plate is formed to a semi circular shape U or J by press (UOE / JCOE) U shape is closed by fixed die to O shape for UOE pipe J shape is break pressed to C and then O shape for JCOE O shape is externally tack welded Full Penetration Internal submerged Arc welds longitudinally Full Penetration Opposing external Submerged Arc weld Coil Flattening Edge Milling Pipe expanding to eliminate asymmetry Weld testing by Ultrasonic or X-Ray De-Coiler Outside Diameter Rolling Cage Coil Joining Main Drive Rolls Edge Setting End Preparation & Shipment Mill-Pro Steel Pipe Piles Australia AS

9 MANUFACTURING PROCESS The following charts provide typical diameter and thickness ratios, minimum and maximum diameters for various pipe-forming methods. The limits may vary by manufacturer, however these give a good indication of the capacity of each forming method. SPIRAL PIPE OD Thickness UOE PIPE Grade 450 Mpa Grade 350 Mpa OD Thickness Grade 450 Mpa Grade 350 Mpa Notes: Length min 6.0m / max 100m Thickness min 5.0mm / max 25.4mm Grade 350 Diameter 1mm increments from 406 to 3048 mm OD max Notes: Length min 6.0m / max 12m Thickness min 5.0mm / max 27.0mm Grade 350 Diameter Fixed standard sizes only ROLL FORMED PIPE (JCOE) OD Thickness Grade 450 Mpa PRESS FORMED PIPE (JCOE) Grade 350 Mpa OD Thickness Grade 450 Mpa Grade 350 Mpa Notes: Length min 6.0m / max 12m Thickness min 5.0mm / max 27.0mm Grade 350 Diameter 1mm increments from 406 to 1829mm OD max Notes: Length min 6.0m / max 12m Thickness min 5.0mm / max 63.0mm Grade 350 Diameter 1mm increments from 406 to 1626mm OD max Mill-Pro Steel Pipe Piles Australia AS

10 Manufacturing Standards MANUFACTURING STANDARDS 19 For Pacific markets Mill-Pro offers pipe in compliance with AS 1579 and produced in mills certified to AS/NZS/ISO9001 and API 5L PSL 1 & 2. The use of non-standard sizes for structural piles has become common in the Australian and Pacific markets, unlike pipelines which are required to be standardised for future connection. MINIMUM REQUIREMENTS MANUFACTURING STANDARDS FEEDSTOCK: Hot rolled Coil AS/NZS Grades 250 / 350 / 450* Mpa Specified Min Yield Strength Plate AS/NZS 3678 Grades 250 / 350 / 450* Mpa Specified Min Yield Strength Carbon Equivalent 0.40% Feedstock Testing In accordance with AS1594 & 3678 WELDING: Welding & Repairs AS/NZS Category SP Welders must be certified Weld Reinforcement <3mm maximum height at any point Plate misalignment 1.5mm where t <12mm, 3.0mm where t 12mm Weld Testing AS/NZS SP PIPE MANUFACTURE: Diameter +/- 0.50% of circumference at any point Ovalness +/ 1% of the specified Outside Diameter at the pipe ends Straightness 0.2% of pipe length Length +/-75mm End Square Gap <3.0mm (for joining ends) NON-DESTRUCTIVE TESTING: Ultrasonic / X-Ray In accordance with AS 1710 (UT), AS 2314 (RT), Client specifies frequency MPI & Dye Pen In accordance with AS 1710 (UT), AS 2314 (RT), Client specifies frequency Mill-Pro Steel Pipe Piles Australia AS

11 Combined Walls CLUTCHES 22 TYPICAL APPLICATIONS 23 Mill-Pro in concert with STEELWALL has developed a coated clutched pile product line, providing both clutch-to-clutch joints for tubular pipe walls and Clutch-to-sheet joints for combining pipes with Larssen U or Z type sheets. Along with providing superior engineering efficiency & performance, these connectors eliminate the problems encountered with L&T or Split pipe clutch arrangements such as tidal infiltration and inability to achieve envelope protective coatings. COMBINED SteelWall Clutches comply with BS EN / BS EN WALLS Mill-Pro Steel Pipe Piles Australia AS

12 COMBINED WALLS L8 CLUTCH SECTION The L8 is the latest design improvement in the Larssen hook family. It can be used as a direct replacement for C9 type applications and is independently rated for 1000Kn/m in tensile strength. Typical applications include sheet to pile connections. It provides joint articulation and can accommodate both Larssen U & Z type sheets for combination walls. FD180 ULTRA HEAVY CLUTCH SECTION The FD180 is an Ultra Heavy Duty ball & socket connector. Available in grade 350 Mpa this section is rated for 3400Kn/m and is designed for pile-to-pile connections where extreme conditions exist. TYPICAL APPLICATIONS LPB180 HEAVY CLUTCH SECTION SteelWall manufactures an entire range of LPBs with layout space ranging from 247.8mm to 100 mm. The LPB is the most popular connector for use with Pipe-Pipe Walls. All LPB series are available in grade 350 Mpa or high tensile Grade 430 Mpa yield. This section is 60% stronger than the L8 Clutch line and is specifically designed for withstanding hard driving conditions and lateral side forces experienced on long piles. It is attached to the pipe using full penetration welds from opposing sides. The clutch is a 12mm section with a mass of 15.4kg/m, it has been certified by TUV as rated for 1600kn maximum tensile strength and has an installed base of 5000mt / 325,000 lineal meters. This connector requires orientation, which needs to be accommodated in design & fabrication. COATING Mill-Pro has developed a post coating clutch application method to bring the benefits of automated ultra-high build coatings to clutched piles. Mill-Pro Steel Pipe Piles Australia AS

13 Coatings COATINGS 26 / 29 Mill-Pro partnered with coating applicator LONG KEY and the leading coating suppliers to develop a unique automatically applied ultra high build epoxy coating system for marine piles. With over five years supply to major resource projects in Australia, the system is well proven in meeting schedule regardless of climatic conditions and delivering a significantly superior coating compared to manual application. COATINGS Ultra high build coatings can be manually applied, however when combined with the automatic application process significant additional benefits are achieved; Unaffected by Climate Year round coating regardless of temperature & humidity High Application Rates Reliable Schedule Holiday Free Coating Performance improvements >2500m2/day up to 1500um thick coating from a continuous process Piles exit the coating line hard cured ready to ship Four to eight wet-on-wet coats ensure 100% holiday free coatings Significant Improvements in the major coating performance criteria Environmentally Responsible Large reductions in, waste, VOC, overspray, unnecessary application Mill-Pro Steel Pipe Piles Australia AS

14 COATINGS INTRODUCTION RELIABLE SCHEDULE ENVIRONMENTALLY RESPONSIBLE Ultra High Build coatings have a solids content approaching 100% (~98%) vs. high build epoxies at ~85%. The increase in solids is achieved through elimination of the solvents required to apply the coating. Instead each component is supplied in refillable jacketed & heated 1000 litre holding tanks and then hot applied and hot cured (HAHC) to the pipe surface in a continuous operation. Automatic application eliminates the issues associated with manual application of high build epoxies to long piles. Typically these are sagging, mud cracking, uneven application (DFTs), the need for multiple coats and manually rotating pipes until cured all contribute to reduce the available daily output. By eliminating climatic conditions and increasing application rates, coating is no longer the largest schedule risk in pile supply. Hot Applied Hot Cured coating offers significant Environmental, Health & Safety (EH&S) benefits during application including: No open air blasting No manual coating application (reduced operator exposure) Limited solvent release to the atmosphere No contaminated paint can disposal 88% reduction in VOC (Volatile Organic Content) emissions 50% reduction in application losses (overspray) 25% reduction in actual paint applied to achieve minimum dry film thickness UNAFFECTED BY CLIMATE There are few manufacturers globally with the ability to control the environment during coating application especially for large quantities of long piles. Temperatures below 10 0 C significantly impact the cure time for polyamine adduct cured coatings and application when humidity is above 85% impacts long-term performance. The Longkey process takes place in a fully enclosed, heated environment eliminating the issues surrounding climatic conditions, thus allowing year-round coating. HIGH APPLICATION RATES The Longkey process can apply >2500m2/shift of 1500 micron DFT ultra high build coating to pipe piles. Typically this is 10 times faster than manual application rates with the added advantage of uniform DFTs. 1 Raw steel pipe is lifted onto the continuous rotators and washed to remove sodium chlorides HOLIDAY FREE COATINGS Depending on the traverse vs rotation speed, wet-onwet coating overlap is between four to eight times or % coating overlap. This eliminates requirements for stripe coating of weld seams, wet on dry recoats and different colours to differentiate multiple coats. PERFORMANCE IMPROVEMENTS Significant improvements are gained in adhesion, impact resistance, abrasion resistance, cathodic disbondment, salt spray and sea water immersion performance compared to equivalent high build epoxies. 2 The rotating pipe is air blasted and wire brushed if necessary to remove scale COATING REPAIRS Repairs are effected in the same manner as with standard high build epoxies. Cold Applied Cold Cured (CACC) high build epoxies are used for coating repairs as the coatings are fully compatible. 3 The pipe is blasted in a rotary wheel abrader to achieve SA2.5 blast with 100-micron surface profile 5 Regular checks are made for surface profile and cleanliness 4 The blasted surface is mechanically brushed and vacuumed to remove blasting dust from the substrate profile (Post blast dust residue acts as a barrier between the coating and the surface reducing adhesion) Mill-Pro Steel Pipe Piles Australia AS

15 COATINGS 6 The pipe then enters a pre-heat oven to standardise the temperature to 50 0 C, this eliminates both humidity and the climatic effects of winter 7 The two coating components are held in 1000L heated tanks at 60 0 C and constantly agitated. The components are pumped to the nozzle in the correct ratios and applied via airless spray 8 The spray fan is approximately 400mm wide, in this case with 350mm overlap, it provides eight wet-on-wet coats ensuring a completely uniform and holiday free coating 9 The coated pipe enters the curing over where the surface temperature reaches C. This combination of pre-heated pipe and hot applied coating cures the coating to touch-dry in 12 minutes 10 After the curing oven, heat is reduced using water sprays. Within 16 minutes the coating is cured and the pipe can be handled and stacked (equivalent manual application of a high build epoxy can take 3 to 5 days to cure sufficiently to be handleable depending on ambient climatic conditions) 11 Inspections for dry film thickness, holiday testing and adhesion are conducted and any necessary repairs applied 12 Finished pipes are lifted off the rotators and can be slung, marked and loaded out 13 The increased toughness and impact resistance of HAHC coatings results in minimal (if any) coating damage during transit Mill-Pro Steel Pipe Piles Australia AS

16 Accessories ACCESSORIES 30 / 31 Mill-Pro has significant experience in supplying a wide range of fabricated accessories related to tubular piling including: STEEL FABRICATION Pre fabricated & coated assemblies for modular construction, including Pile Caps, Dolphins, Headstocks, and Beacons. PILE SHOES ACCESSORIES Rolled & fabricated piles shoes of any configuration with tapered interfaces, fitted to piles with complete penetration welds, 100% NDT inspected to AS SP CONTINUOUS HELICAL WELD BEAD SHEAR RINGS As an alternative to welded in shear rings, Mill-Pro supplies complete penetration helical weld bead - 12mm wide by 8mm high at any nominated pitch applied to internal pile walls or external pin or tube anchors for creating composite piles. PIN PILES / TUBE ANCHORS Solid pins and tube anchors supplied with external helical weld bead TIE RODS For sheet to pile connections, including supply of fitted connecting lugs CERTIFIED SPREADERS & LIFTING BEAMS Supply of certified custom made spreader beams and soft slings to AS 4497 CONVEYOR MODULES WALER BEAMS BRIDGE ACCESSORIES Mill-Pro Steel Pipe Piles Australia AS

17 ACCESSORIES ACCESSORIES The Mill-Pro team has spent more than 15 years advising local authorities, consultants and Government bodies throughout the Asia Pacific region on Polyethylene specifications, helping to create robust specifications & recommending appropriate testing criteria. This team has been supplying major projects all across Asia and has built relationships with global leaders such as FRIATEC of Germany, giving Mill-Pro the ability to deliver a complete solutions approach to pipeline systems. Mill-Pro Steel Pipe Piles Australia AS

18 Certification In today s market with numerous manufacturers and suppliers providing polyethylene pipe systems, the challenge for end users is to ensure that not only the product complies with and has been tested to the required standards and specifications, but the correct and true documentation is available for every product supplied. Mill-Pro s polyethylene product offering is manufactured to the highest quality in our partners factories operating to ISO9001 certified operating procedures and systems. CERTIFICATION Our polyethylene pressure pipe has been third party reviewed under a product certification scheme as compliant to AS/NZS Our polyethylene fittings are manufactured to AS/NZS In addition to the Australian and New Zealand standards above, Mill-Pro supplied polyethylene pipe and fittings complying to the following standards in other markets: BS EN BS EN ISO ISO Mill-Pro polyethylene pipe has also undertaken and passed testing for the following standards; Mill-Pipe Extreme 3,300 hour ACT to PAS1075 Mill-Pipe / Mill-Pipe extreme JIS 6762, BS6920 Mill-Pro provides as part of our quality system, full batch reports with traceability for all of our polyethylene products via our unique QR code system. Mill-Pro Steel Pipe Piles Australia AS

19 Mill-Pro HONG KONG phone office Level 43, AIA Tower, 183 Electric Road, North Point, HK SAR AUSTRALIA phone fax office Suite 3801, Northpoint Bldg, 100 Miller St. Sydney, NSW 2060 phone fax office Lot 16, 146 St Andrews Drive, Yanchep, Perth, WA 6035 NEW ZEALAND info@mill-pro.co.nz phone post PO Box 7014 Taradale, Napier Steel Pipe Piles Australia AS 1579