› STEEL PIPE PILES Mill-Pro

FABRICATION & COATING

Australia – AS 1579

www.mill-pro.com.au

› 2014 Revision 1
› www.mill-pro.com.au

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

CO N T E N T S
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 1579 | 03

› INT R O D U C T I O N

Mill-Pro is a highly specialised Mill-Pro’s business model differs

engineering solutions business with from typical trading models:
offices in Australia, New Zealand &
• We are technical specialists in our fields of; Steel pipe,
Hong Kong. Welding, Fabrication & Coatings

• We do not ‘shop’ for the cheapest suppliers; We have our own

The business has spent many years and significant resources
exclusive source.
developing a small number of highly reliable and exclusive
sources within each of our product segments. These sources are • We use Mill-Pro expatriate inspection staff on site throughout
best in class, generally located in emerging markets and have production & shipping operations
been developed to meet the international quality, safety &
• Our team are highly experienced project managers, quality
environmental audit demands from large-scale construction
inspectors and manufacturers
projects in developed markets.
• We deliver complete end to end solutions with full traceability
Mill-Pro is 50% owned by GS Global Corporation, a large
and quality documentation
Korean publicly listed trading company. Our shareholder
Whilst many construction firms have developed their own sourcing
partnership gives us the balance sheet to deliver large scale
teams based in low cost countries, the Mill-Pro offer is a complete
projects in the region.
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 1579 | 05

› www.mill-pro.com.au

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.

› W E L DE D P IP E

Mill-Pro Steel Pipe Piles – Australia AS 1579 | 07

› W EL D E D P I P E

DIMENSION TABLE DIMENSION TABLE

External Thickness / Gross Area Second Elastic External Thickness / Gross Area Second Elastic
Inside Meters Surface Diameter of Cross Moment of Section Radius of Inside Meters Surface Diameter of Cross Moment of Section Radius of
Diameter Diameter Thickness Diameter Mass per Tonne Area Ratio Section Area ‘I’ Modulus ‘S’ Gyration ‘rg’ Diameter Diameter Thickness Diameter Mass per Tonne Area Ratio Section Area ‘I’ Modulus ‘S’ Gyration ‘rg’
D mm Inches t mm d mm kg / m m / mt m² / m D/t mm2 x106 mm4 x103 mm3 rg = mm D mm Inches t mm d mm kg / m m / mt m² / m D/t mm2 x106 mm4 x103 mm3 rg = mm

457 18 6.0 445.2 66.8 14.98 1.44 76.2 8504.9 216.5 946.9 159.5 800 Ref Note 1 10.0 780.0 194.8 5.13 2.51 80.0 24818.6 1936.5 4841.2 279.3
457 18 8.0 441.2 88.6 11.28 1.44 57.2 11289.6 284.8 1246.0 158.8 800 Ref Note 1 12.0 776.0 233.2 4.29 2.51 66.7 29706.9 2306.3 5765.8 278.6
457 18 10.0 437.2 110.3 9.07 1.44 45.7 14049.2 351.4 1537.1 158.1 800 Ref Note 1 16.0 768.0 309.4 3.23 2.51 50.0 39408.1 3029.1 7572.7 277.2
457 18 12.0 433.2 131.8 7.59 1.44 38.1 16783.6 416.1 1820.3 157.5 800 Ref Note 1 20.0 760.0 384.7 2.60 2.51 40.0 49008.8 3729.6 9323.9 275.9
457 18 16.0 425.2 174.1 5.74 1.44 28.6 22177.1 540.3 2363.6 156.1 800 Ref Note 1 22.0 756.0 422.1 2.37 2.51 36.4 53771.5 4071.6 10179.1 275.2

508 20 6.0 496.0 74.3 13.46 1.60 84.7 9462.5 298.1 1173.7 177.5 813 32 10.0 793.0 198.0 5.05 2.55 81.3 25227.0 2033.6 5002.8 283.9
508 20 8.0 492.0 98.6 10.14 1.60 63.5 12566.4 392.8 1546.5 176.8 813 32 12.0 789.0 237.0 4.22 2.55 67.8 30197.0 2422.3 5959.0 283.2
508 20 10.0 488.0 122.8 8.14 1.60 50.8 15645.1 485.2 1910.2 176.1 813 32 14.0 785.0 275.9 3.62 - 58.1 35141.9 2805.2 6900.8 282.5
508 20 12.0 484.0 146.8 6.81 1.60 42.3 18698.8 575.4 2265.2 175.4 813 32 16.0 781.0 314.5 3.18 2.55 50.8 40061.6 3182.2 7828.3 281.8
508 20 16.0 476.0 194.1 5.15 1.60 31.8 24730.6 749.1 2949.2 174.0 813 32 18.0 777.0 352.9 2.83 2.55 45.2 44956.2 3553.5 8741.7 281.1
813 32 20.0 773.0 391.1 2.56 2.55 40.7 49825.7 3919.1 9641.1 280.5
600 Ref Note 1 8.0 584.0 116.8 8.56 1.88 75.0 14878.6 651.9 2173.1 209.3
600 Ref Note 1 10.0 580.0 145.5 6.87 1.88 60.0 18535.4 806.8 2689.2 208.6
813 32 22.0 769.0 429.2 2.33 2.55 37.0 54670.0 4279.1 10526.6 279.8

600 Ref Note 1 12.0 576.0 174.0 5.75 1.88 50.0 22167.1 958.4 3194.7 207.9 900 Ref Note 1 10.0 880.0 219.5 4.56 2.83 90.0 27960.2 2768.8 6152.8 314.7
600 Ref Note 1 16.0 568.0 230.4 4.34 1.88 37.5 29355.0 1252.4 4174.7 206.6 900 Ref Note 1 12.0 876.0 262.8 3.81 2.83 75.0 33476.8 3300.3 7334.1 314.0
600 Ref Note 1 18.0 564.0 258.4 3.87 1.88 33.3 32911.3 1394.8 4649.4 205.9 900 Ref Note 1 16.0 868.0 348.8 2.87 2.83 56.3 44434.7 4341.9 9648.6 312.6

610 24 8.0 594.0 118.8 8.42 1.92 76.3 15129.9 685.5 2247.6 212.9 900 Ref Note 1 20.0 860.0 434.0 2.30 2.83 45.0 55292.0 5355.0 11900.1 311.2

610 24 10.0 590.0 148.0 6.76 1.92 61.0 18849.6 848.5 2781.9 212.2 900 Ref Note 1 25.0 850.0 539.5 1.85 2.83 36.0 68722.3 6582.3 14627.4 309.5

610 24 12.0 586.0 177.0 5.65 1.92 50.8 22544.1 1008.1 3305.4 211.5 914 36 10.0 894.0 222.9 4.49 2.87 91.4 28400.0 2901.5 6349.0 319.6
610 24 16.0 578.0 234.4 4.27 1.92 38.1 29857.7 1317.8 4320.7 210.1 914 36 12.0 890.0 266.9 3.75 2.87 76.2 34004.6 3458.9 7568.7 318.9
610 24 18.0 574.0 262.8 3.81 1.92 33.9 33476.8 1467.9 4812.8 209.4 914 36 16.0 882.0 354.3 2.82 2.87 57.1 45138.4 4551.4 9959.3 317.5
711 28 8.0 695.0 138.7 7.21 2.23 88.9 17668.3 1091.6 3070.7 248.6 914 36 18.0 878.0 397.7 2.51 2.87 50.8 50667.6 5086.6 11130.5 316.8
711 28 10.0 691.0 172.9 5.78 2.23 71.1 22022.6 1353.0 3805.9 247.9 914 36 20.0 874.0 440.9 2.27 2.87 45.7 56171.7 5614.6 12285.8 316.2
711 28 12.0 687.0 206.9 4.83 2.23 59.3 26351.7 1609.9 4528.6 247.2 914 36 22.0 870.0 484.0 2.07 2.87 41.5 61650.6 6135.4 13425.3 315.5
711 28 14.0 683.0 240.6 4.16 2.23 50.8 30655.7 1862.4 5238.7 246.5 914 36 25.0 864.0 548.1 1.82 2.87 36.6 69821.9 6903.2 15105.4 314.4
711 28 16.0 679.0 274.2 3.65 2.23 44.4 34934.5 2110.4 5936.4 245.8 914 36 26.0 862.0 569.4 1.76 2.87 35.2 72533.1 7155.6 15657.7 314.1
711 28 18.0 675.0 307.6 3.25 2.23 39.5 39188.2 2354.1 6621.9 245.1
965 38 10.0 945.0 235.5 4.25 3.03 96.5 30002.2 3420.7 7089.6 337.7
750 Ref Note 1 8.0 734.0 146.4 6.83 2.36 93.8 18648.5 1283.5 3422.8 262.4 965 38 12.0 941.0 282.0 3.55 3.03 80.4 35927.3 4079.3 8454.6 337.0
750 Ref Note 1 10.0 730.0 182.5 5.48 2.36 75.0 23247.8 1591.6 4244.3 261.7
965 38 14.0 937.0 328.3 3.05 3.03 68.9 41827.2 4729.6 9802.3 336.3
750 Ref Note 1 12.0 726.0 218.4 4.58 2.36 62.5 27821.9 1894.6 5052.4 261.0
965 38 16.0 933.0 374.5 2.67 3.03 60.3 47701.9 5371.6 11132.8 335.6
750 Ref Note 1 14.0 722.0 254.1 3.94 2.36 53.6 32371.0 2192.7 5847.2 260.3
965 38 18.0 929.0 420.4 2.38 3.03 53.6 53551.6 6005.4 12446.3 334.9
750 Ref Note 1 16.0 718.0 289.6 3.45 2.36 46.9 36894.9 2485.8 6628.9 259.6
965 38 20.0 925.0 466.1 2.15 3.03 48.3 59376.1 6631.0 13743.0 334.2
750 Ref Note 1 18.0 714.0 324.9 3.08 2.36 41.7 41393.6 2774.1 7397.7 258.9
965 38 22.0 921.0 511.6 1.95 3.03 43.9 65175.5 7248.6 15023.0 333.5
750 Ref Note 1 20.0 710.0 360.1 2.78 2.36 37.5 45867.3 3057.6 8153.7 258.2
965 38 24.0 917.0 557.0 1.80 3.03 40.2 70949.7 7858.2 16286.4 332.8
762 30 8.0 746.0 148.8 6.72 2.39 95.3 18950.1 1346.8 3535.0 266.6 965 38 26.0 913.0 602.1 1.66 3.03 37.1 76698.8 8459.9 17533.4 332.1
762 30 10.0 742.0 185.5 5.39 2.39 76.2 23624.8 1670.3 4383.9 265.9
762 30 12.0 738.0 222.0 4.51 2.39 63.5 28274.3 1988.5 5219.3 265.2 1000 Ref Note 1 10.0 980.0 244.1 4.10 3.14 100.0 31101.8 3810.7 7621.5 350.0

762 30 14.0 734.0 258.3 3.87 2.39 54.4 32898.8 2301.7 6041.2 264.5 1000 Ref Note 1 12.0 976.0 292.4 3.42 3.14 83.3 37246.7 4545.4 9090.9 349.3

762 30 16.0 730.0 294.4 3.40 2.39 47.6 37498.0 2609.7 6849.7 263.8 1000 Ref Note 1 16.0 968.0 388.3 2.58 3.14 62.5 49461.2 5988.0 11975.9 347.9

762 30 18.0 726.0 330.3 3.03 2.39 42.3 42072.2 2912.8 7645.1 263.1 1000 Ref Note 1 20.0 960.0 483.4 2.07 3.14 50.0 61575.2 7395.2 14790.4 346.6

762 30 20.0 722.0 366.0 2.73 2.39 38.1 46621.2 3210.8 8427.4 262.4 1000 Ref Note 1 25.0 950.0 601.1 1.66 3.14 40.0 76576.3 9105.4 18210.8 344.8

UOE

Mill-Pro Steel Pipe Piles – Australia AS 1579 | 09

› W EL D E D P I P E

DIMENSION TABLE DIMENSION TABLE

External Thickness / Gross Area Second Elastic External Thickness / Gross Area Second Elastic
Inside Meters Surface Diameter of Cross Moment of Section Radius of Inside Meters Surface Diameter of Cross Moment of Section Radius of
Diameter Diameter Thickness Diameter Mass per Tonne Area Ratio Section Area ‘I’ Modulus ‘S’ Gyration ‘rg’ Diameter Diameter Thickness Diameter Mass per Tonne Area Ratio Section Area ‘I’ Modulus ‘S’ Gyration ‘rg’
D mm Inches t mm d mm kg / m m / mt m² / m D/t mm2 x106 mm4 x103 mm3 rg = mm D mm Inches t mm d mm kg / m m / mt m² / m D/t mm2 x106 mm4 x103 mm3 rg = mm

1016 40 10.0 996.0 248.1 4.03 3.19 101.6 31604.4 3998.5 7871.1 355.7 1829 72 16.0 1797.0 715.4 1.40 5.75 114.3 91131.3 37446.1 40947.1 641.0
1016 40 12.0 992.0 297.1 3.37 3.19 84.7 37849.9 4769.8 9389.5 355.0 1829 72 20.0 1789.0 892.3 1.12 5.75 91.5 113662.8 46500.6 50848.1 639.6
1016 40 16.0 984.0 394.6 2.53 3.19 63.5 50265.5 6284.8 12371.6 353.6 1829 72 25.0 1779.0 1112.2 0.90 5.75 73.2 141685.8 57649.1 63039.0 637.9
1016 40 20.0 976.0 491.3 2.04 3.19 50.8 62580.5 7763.2 15282.0 352.2
2032 80 16.0 2000.0 795.5 1.26 6.38 127.0 101335.2 51484.8 50674.0 712.8
1016 40 25.0 966.0 611.0 1.64 3.19 40.6 77833.0 9560.9 18820.6 350.5
2032 80 20.0 1992.0 992.4 1.01 6.38 101.6 126417.7 63975.9 62968.5 711.4
1016 40 26.0 964.0 634.8 1.58 3.19 39.1 80864.6 9913.8 19515.3 350.1
2032 80 25.0 1982.0 1237.4 0.81 6.38 81.3 157629.4 79379.7 78129.6 709.6
1016 40 27.0 962.0 658.5 1.52 3.19 37.6 83889.9 10264.5 20205.6 349.8
2235 88 20.0 2195.0 1092.5 0.92 7.02 111.8 139172.6 85358.4 76383.4 783.2
UOE LIMIT 2235 88 25.0 2185.0 1362.5 0.73 7.02 89.4 173573.0 105982.0 94838.5 781.4

1016 40 32.0 952.0 776.5 1.29 3.19 31.8 98922.5 11985.4 23593.4 348.1 3048 120 20.0 3008.0 1493.5 0.67 9.58 152.4 190254.9 218060.2 143084.1 1070.6
1016 40 40.0 936.0 962.8 1.04 3.19 25.4 122647.8 14628.4 28796.2 345.4 3048 120 25.0 2998.0 1863.8 0.54 9.58 121.9 237425.9 271233.9 177975.0 1068.8

1200 Ref Note 1 12.0 1176.0 351.6 2.84 3.77 100.0 44786.5 7902.0 13169.9 420.0
1200 Ref Note 1 16.0 1168.0 467.2 2.14 3.77 75.0 59514.3 10430.7 17384.5 418.6 Note 1
Common Non ISO, hard metric pile sizes are shown for reference.
1200 Ref Note 1 20.0 1160.0 582.0 1.72 3.77 60.0 74141.6 12908.1 21513.4 417.3 This is not a complete list, any diameter and thickness combination within the
1200 Ref Note 1 25.0 1150.0 724.4 1.38 3.77 48.0 92284.3 15933.5 26555.8 415.5 capacity table for spiral pipe can be manufactured to order. Assume a minimum
quantity of 150-200m for custom sizes.
1219 48 12.0 1195.2 357.3 2.80 3.83 101.6 45510.4 8291.3 13601.2 426.8
Note 2
1219 48 16.0 1187.2 474.8 2.11 3.83 76.2 60479.4 10946.4 17956.6 425.4 Typical ISO soft metric / Imperial piling sizes are shown with common stock
1219 48 20.0 1179.2 591.5 1.69 3.83 61.0 75348.0 13548.3 22224.9 424.0 thickness for reference.
The diameter & thickness tables are not exclusive, any diameter and thickness
1219 48 25.0 1169.2 736.3 1.36 3.83 48.8 93792.2 16727.1 27439.5 422.3 increment within the capacity table for spiral pipe (Diameter 406-3048mm,
1219 48 32.0 1155.2 936.9 1.07 3.83 38.1 119350.4 21042.5 34518.5 419.9 thickness 5-25.4mm) can be manufactured to order.
Assume a minimum quantity of 150-200m for setup viability.
1219 48 40.0 1139.2 1163.2 0.86 3.83 30.5 148182.6 25785.9 42299.6 417.1
Note 3
1422 56 12.0 1398.0 417.3 2.40 4.47 118.5 53155.7 13210.8 18580.6 498.5 Some indicative heavy gauge LSAW sizes outside Spital capacity (t >25.4mm) are
1422 56 16.0 1390.0 554.8 1.80 4.47 88.9 70673.3 17465.9 24565.3 497.1 shown for reference, these are limited to 12m long.
1422 56 20.0 1382.0 691.5 1.45 4.47 71.1 88090.3 21648.2 30447.6 495.7
1422 56 25.0 1372.0 861.3 1.16 4.47 56.9 109720.1 26774.9 37658.1 494.0
1422 48 32.0 1358.0 1096.9 0.91 4.47 44.4 139738.0 33766.4 47491.4 491.6
1422 48 40.0 1342.0 1363.3 0.73 4.47 35.6 173667.2 41496.1 58363.1 488.8

1626 64 12.0 1602.0 477.6 2.09 5.11 135.5 60846.4 19814.2 24371.7 570.7
1626 64 16.0 1594.0 635.3 1.57 5.11 101.6 80927.4 26224.1 32256.0 569.2
1626 64 20.0 1586.0 792.1 1.26 5.11 81.3 100908.0 32538.2 40022.4 567.9
1626 64 25.0 1576.0 987.1 1.01 5.11 65.0 125742.2 40297.7 49566.6 566.1
1626 48 32.0 1562.0 1257.9 0.79 5.11 50.8 160246.4 50915.5 62626.7 563.7
1626 48 40.0 1546.0 1564.5 0.64 5.11 40.7 199302.6 62705.5 77128.5 560.9

JCOE Limit

UOE JCOE PRESS

Mill-Pro Steel Pipe Piles – Australia AS 1579 | 11

› www.mill-pro.com.au

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.

› MAN UFA C T UR IN G
P R O CE S S

Mill-Pro Steel Pipe Piles – Australia AS 1579 | 13

› MANU FA CT U R I NG PR OCE SS
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
Coil Flattening
Edge Milling
De-Coiler
Coil Joining
Main Drive Rolls
Steel Plate feedstock
sized for finished pipe
size and inspected for
The Spiral manufacturing method provides great JCOE: As the name suggests, is where the plate is laminations
benefits for piling projects where long piles >50m are either pressed or rolled longitudinally into a ‘J’ shape
required in single lengths. For marine piling projects first then repeated to form a ‘C’ shape, then closed
piles can be formed in a single length coated and to an ‘O’ by hydraulic pressing. The pipe is then tack
shipped ready to pitch and drive from the water, welded and fully welded in the same manner as UOE Plates are edge milled
thereby eliminating length restrictions imposed by land pipe. Typically available diameters range from 508mm and edges are set
transportation. OD to 1829mm OD and any diameter and combination
thickness can be made within the equipment’s capacity
PRESS BENDING OR ROLL (refer attached charts).
Plate is formed to a
semi circular shape U
FORMING PIPE ROLL FORMING: Large rollers roll flat plate to form
a circular ‘O’ shape, which is then welded in a similar
or J by press
(UOE / JCOE)
Also known as UOE, JCOE, Brake Pressed Pipe and manner to UOE pipe. Roll forming can accommodate
Roll Formed Pipe. All are referred to as Longitudinal gauges up to 230mm thick in large diameters however
Submerged Arc Welded (LSAW) pipe as they have lengths are limited to 2-3m wide, making it impractical
U shape is closed by
one (or more) longitudinal weld seams parallel with for creating long piles, but ideal for heavy gauge fixed die to O shape for
the pipe axis. This pipe is also referred to as Double accessories such as pile shoes. UOE pipe
J shape is break
Submerged Arc Welded (DSAW) pipe, as like Spiral pressed to C and then
Both UOE & JCOE forming methods require mechanical
pipe, it has a full penetration welds made from opposing O shape for JCOE
sides. Regardless of the forming method employed, all rounding to expand the finished pipe circular. After
methods use fixed size steel plates as the feedstock cut welding the pipe may also require straightening as a
to the width & length of the finished pipe. single side weld input creates bending on along the pipe
axis. Both forming methods are limited to 12m lengths,
UOE: The plate is prepared along its length and then so multiple pipe-to-pipe splices are required to achieve O shape is externally
pressed longitudinally in a large hydraulic press to form tack welded
a long finished piles.
a ‘U’ shape. It is then closed in a fixed size die to an
‘O’ shape, the pipe is then tack welded, and welded The key features of Longitudinal formed pipe for piling are:
internally and externally with complete penetration
• Heavy gauges (>25mm) can be formed by pressing
longitudinal welds (the ‘E’ is for ‘Electrically welded’ Full Penetration Internal
– Typically up to 60mm thick submerged Arc welds
in UOE). Typically, diameters are fixed standard sizes
longitudinally
ranging from 508mm OD to 1118mm OD. • Heavy gauges can be formed into smaller diameters
such as 406 OD x 30mm thick
• Ultra heavy gauges in narrow sections can be rolled
Full Penetration Weld Testing by – such as 2000 OD x 210mm thick Full Penetration
Internal & External Ultrasonic NDT Opposing external
Submerged Arc Welds Submerged Arc weld
Pipe expanding to
eliminate asymmetry
Weld testing by
Ultrasonic or X-Ray
Outside Diameter Rolling Cage
End Preparation
& Shipment
Edge Setting
Mill-Pro Steel Pipe Piles – Australia AS 1579 | 15
› MANU FA CT U R I NG PR OCE SS

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 ROLL FORMED PIPE (JCOE)

OD OD
Thickness 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Thickness 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

406 406
457 457
508 508
610 610
711 711
762 762
812 812
864 864
914 914
965 965
1016 1016
1118 1118
1219 1220
Notes:
1422 1422
Length min 6.0m / max 12m
1626 1626 Thickness min 5.0mm / max 27.0mm Grade 350
1829 Diameter 1mm increments
1829 from 406 to 1829mm OD max
1920 Grade ≤450 Mpa Grade ≤350 Mpa
2032
2286
2338 Notes:
PRESS FORMED PIPE (JCOE)
2540 Length min 6.0m / max 100m OD
Thickness min 5.0mm / max 25.4mm Grade 350 Thickness 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 32 34 36 38 40 41 43 46 48 51 54 56 60 62 63
2845
Diameter 1mm increments 406
3048 from 406 to 3048 mm OD max
457
Grade ≤450 Mpa Grade ≤350 Mpa
508
610

UOE PIPE 711

762
OD
Thickness 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 812
864
406
914
457
965
508
1016
610
1118
711
1219
762
1422
812
1626
864
914 Grade ≤450 Mpa Grade ≤350 Mpa
965 Notes:
1016 Length min 6.0m / max 12m Notes:
Thickness min 5.0mm / max 27.0mm Grade 350 Length min 6.0m / max 12m
1118 Diameter Fixed standard sizes only Thickness min 5.0mm / max 63.0mm Grade 350
Diameter 1mm increments
Grade ≤450 Mpa Grade ≤350 Mpa
from 406 to 1626mm OD max

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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

FEEDSTOCK:

› MAN UFA C T UR IN G Hot rolled Coil AS/NZS 1594 - 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

S TA N DA R DS WELDING:

Welding & Repairs AS/NZS 1554.1 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 1554.1 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

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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.

CO M B IN E D
SteelWall Clutches comply with BS EN 10248 / BS EN 10249.

WA L L S

Mill-Pro Steel Pipe Piles – Australia AS 1579 | 21

› C O M BI NE D WAL L S

L8 CLUTCH SECTION FD180 ULTRA HEAVY CLUTCH SECTION TYPICAL APPLICATIONS

The L8 is the latest design improvement in the Larssen The FD180 is an Ultra Heavy Duty ball & socket
“hook” family. It can be used as a direct replacement connector. Available in grade 350 Mpa this section
for C9 type applications and is independently rated is rated for 3400Kn/m and is designed for pile-to-pile
for 1000Kn/m in tensile strength. Typical applications connections where extreme conditions exist.
include sheet to pile connections. It provides 22.50 joint
articulation and can accommodate both Larssen U & Z
type sheets for combination walls.

LPB180 HEAVY CLUTCH SECTION This connector requires orientation, which needs to be
accommodated in design & fabrication.
SteelWall manufactures an entire range of LPBs with
layout space ranging from 247.8mm to 100 mm.

The LPB180-12 is the most popular connector for use COATING

with Pipe-Pipe Walls. All LPB series are available in
Mill-Pro has developed a post coating clutch
grade 350 Mpa or high tensile Grade 430 Mpa yield.
application method to bring the benefits of automated
This section is 60% stronger than the L8 Clutch line
ultra-high build coatings to clutched piles.
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.

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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.

Ultra high build coatings can be manually applied, however when combined
with the automatic application process significant additional benefits are

C O AT IN G S
achieved;

› Unaffected by Climate

Year round coating regardless of
temperature & humidity

High Application Rates >2500m2/day up to 1500um thick coating

from a continuous process

Reliable Schedule Piles exit the coating line hard cured

ready to ship

Holiday Free Coating Four to eight wet-on-wet coats ensure

100% holiday free coatings

Performance improvements 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 1579 | 25

› C O AT I NG S
INTRODUCTION
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.
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 100 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 2
Raw steel pipe is lifted onto the continuous rotators
and washed to remove sodium chlorides
RELIABLE SCHEDULE
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.
HOLIDAY FREE COATINGS
Depending on the traverse vs rotation speed, wet-on-
wet coating overlap is between four to eight times or
400-800% 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.
The rotating pipe is air blasted
and wire brushed if necessary to remove scale
ENVIRONMENTALLY RESPONSIBLE
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
COATING REPAIRS 5
Regular checks are made for
Repairs are effected in the same manner as with surface profile and cleanliness
standard high build epoxies. Cold Applied Cold Cured
(CACC) high build epoxies are used for coating repairs
as the coatings are fully compatible.
4
The blasted surface is mechanically brushed and vacuumed
3 to remove blasting dust from the substrate profile
The pipe is blasted in a rotary wheel abrader (Post blast dust residue acts as a barrier between the coating
to achieve SA2.5 blast with 100-micron surface profile and the surface reducing adhesion)
Mill-Pro Steel Pipe Piles – Australia AS 1579 | 27
› C O AT I NG S

6 7 8 9
The pipe then enters a The two coating components The spray fan is approximately The coated pipe enters the
pre-heat oven to standardise are held in 1000L heated 400mm wide, in this case with curing over where the surface
the temperature to 500 C, tanks at 600 C and constantly 350mm overlap, it provides temperature reaches 1000 C.
this eliminates both humidity agitated. The components are eight wet-on-wet coats This combination of pre-heated
and the climatic effects pumped to the nozzle in the ensuring a completely uniform pipe and hot applied coating
of winter correct ratios and applied and holiday free coating cures the coating to touch-dry
via airless spray 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 11 12 13
build epoxy can take 3 to 5 days to cure sufficiently to be Inspections for dry film thickness, holiday testing and Finished pipes are lifted off the rotators The increased toughness and impact resistance of HAHC coatings
handleable depending on ambient climatic conditions) adhesion are conducted and any necessary repairs applied and can be slung, marked and loaded out results in minimal (if any) coating damage during transit

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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

Rolled & fabricated piles shoes of any configuration with tapered interfaces,

ACCE S S O R IE S
fitted to piles with complete penetration welds, 100% NDT inspected to AS
1554.1 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

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› ACCE S S O RI E S

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.

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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.

Our polyethylene pressure pipe has been third party reviewed under a product

CE R T IFICAT IO N
certification scheme as compliant to AS/NZS 4130.
Our polyethylene fittings are manufactured to AS/NZS 4129.
› 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 12201-2
BS EN 12201-3
ISO 4427-2
ISO 4427-3

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.

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Mill-Pro › HONG KONG

info@mill-pro.com.hk
phone +852 3975 1328
office Level 43, AIA Tower, 183 Electric Road, North Point, HK SAR

AUSTRALIA
info@mill-pro.com.au
phone +61 2 9492 4503 fax +61 2 9954 0919
office Suite 3801, Northpoint Bldg, 100 Miller St. Sydney, NSW 2060
phone +61 2 9492 4503 fax +61 2 9954 0919
office Lot 16, 146 St Andrews Drive, Yanchep, Perth, WA 6035

NEW ZEALAND
info@mill-pro.co.nz
phone +64 6 836 7919
post PO Box 7014 Taradale, Napier 4141

› 2014 Steel Pipe Piles – Australia AS 1579