Weld Quality.

—The fabrication welding procedure was changed after

the first 70 piles were produced. Inasmuch as Pile B-5 and others listed
above were among this group, initial concern was that the fatigue fail-
ures might somehow be attributable to poor weld quality. A radiograph
of the entire girth weld of Pile C-1 was obtained for evaluation. Several
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indications of lack of fusion were observed approximately 2 mm (0.080

in.) from the toe of the backing weld, probably at the location of the
original root pass. Two major cracks, one approximately 64 cm (25 in.)
and the other 5.5 cm (2.2 in.) long, were detected 180° apart. The lo-
cation of each crack was clearly aligned with the toe of the backing weld
and not in line with the regions where lack of fusion was observed. This
and evidence from other piles supported the notion that weld quality
was not a critical factor; however, geometric irregularities in the weld
profiles were important in producing stress concentrations from which
cracks initiated.
In-Situ Radiography.—With fatigue established as the failure cause,
it became apparent that piles remaining in place would need to be checked
for cracks in the mudline welds. Thus, a radiographic inspection pro-
gram was begun with special emphasis on the piles in the northern half
of Loading Platform A that were the first to be installed. Mudline welds
were located and cleared by a diver and film was placed in position
around the outside. Each pile was then dewatered and cleared of mud
on the inside as needed, and an X-ray source was lowered inside to a
position opposite the weld. The film was exposed and recovered for
interpretation.
Early in the inspection program a 10-in. (254-mm) long defect was de-
tected in a battered pile in Mooring Dolphin 5. The program was then
extended to cover all accessible suspect piles. Several battered piles were
capped at various dates prior to the December 4-6 storm; therefore, it
was not possible to enter and inspect these piles without causing the
whole construction program to be delayed significantly. Nevertheless,
90 out of a population of 148 battered piles were inspected, with evi-
dence of the one unacceptable crack in Pile MD5 A-1NE being found in
the tested sample. In addition to the vertical piles, six battered piles were

TABLE 2.—Pile Damage Summary

Location Pile Driven Comment
(1) (2) (3) (4)
LPA . B-5 8/06/74 Failed 12/15/74
LPA B-3 8/14/74 Reported down 12/20/74
LPA C-1 8/20/74 Through thickness crack
1/25/75
LPA D-6 9/27/74 Through thickness crack
2/03/75
LFA C-9 10/03/74 5-in. defect in laboratory
test specimen
MD5 A-1NE 10/29/74 14-in. crack, 5/8-in. deep
MD5 A-3NW 10/29/74 15-in. flaw, 1/10-in. deep
Note: 1 in. = 25.4 mm.

211

J. Waterway, Port, Coastal, Ocean Eng. 1987.113:205-214.