Roy Hill Project

Port Marine – Specification for Supply

and Fabrication of Marine Piles

100RH-5210-MA-SPC-2002

2-February-12

HPPL House
28 – 42 Ventnor Avenue
West Perth 6005
Western Australia
Tel: +61 8 6143 1500
Fax: +61 8 6143 1600
Roy Hill Holdings Pty Ltd
ABN 71 123 721 077
© Copyright 2012 Roy Hill Holdings Pty Ltd
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PORT MARINE – SPECIFICATION FOR SUPPLY AND FABRICATION OF MARINE PILES

DOCUMENT 100RH-5210-MA-SPC-2002 – ROY HILL PROJECT

REV DESCRIPTION ORIG REVIEW PMC DATE CLIENT DATE
APPROVAL

0 Issued for Contract 3-Feb-12

T F T Koch
Karagiozis Drummond

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CONTENTS

1. INTRODUCTION ............................................................................................................1

1.1 Overview ........................................................................................................................1

1.2 Purpose .........................................................................................................................1

2. DEFINITIONS AND ABBREVIATIONS ...........................................................................2

2.1 Definitions ......................................................................................................................2

2.2 Abbreviations .................................................................................................................2

3. REFERENCED DOCUMENTS .......................................................................................3

3.1 Standards.......................................................................................................................3

3.2 Documents .....................................................................................................................4

4. GENERAL ......................................................................................................................5

4.1 Scope.............................................................................................................................5

4.2 Description of Site ..........................................................................................................5

4.3 Notice of Commencement and progress .........................................................................5

4.4 Inspection and access to site ..........................................................................................6

5. SUPPLY.........................................................................................................................7

5.1 General ..........................................................................................................................7

5.2 Pile Materials..................................................................................................................7

5.3 Material Testing..............................................................................................................7

6. PILE PREPARATION .....................................................................................................9

6.1 General ..........................................................................................................................9

7. PILE FABRICATION.....................................................................................................10

7.1 Welding Standards .......................................................................................................10

7.2 Welders and Testing Personnel .................................................................................... 10

7.3 Welding Materials .........................................................................................................11

7.4 Seam Welds.................................................................................................................11

7.5 Weld Inspection and Testing.........................................................................................11

7.6 Fabrication Tolerances .................................................................................................12

7.7 Dimensional Accuracy and Corrections to Dimensions.................................................. 13

8. PILE CORROSION PROTECTION ............................................................................... 14

8.1 General ........................................................................................................................14

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8.2 Inspection and testing...................................................................................................15

8.3 Repair ..........................................................................................................................15

9. INDEPENDENT THIRD PARTY INSPECTION ............................................................. 17

10. PACKAGING, STORAGE, HANDLING AND DELIVERY TO SITE ................................ 18

10.1 General ....................................................................................................................18

10.2 Driving Marks ...........................................................................................................18

Appendices
APPENDIX 1 – REPAIR PROCEDURE FOR MDPE COATING

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1. INT ROD UCT IO N

1.1 Overview
The Roy Hill Iron Ore Project includes a new iron ore mine at the Roy Hill 1 deposit, a mine process
plant, a heavy haul railway system from mine to port and new port facilities at Boodarie Industrial
Estate, south west of Port Hedland, Western Australia.

The Roy Hill 1 deposit is located approximately 277 kilometres due south of Port Hedland and is at
the eastern end of the Chichester Range in the Pilbara region of Western Australia.

The mine, rail and port facilities will be designed to produce 55 million tonnes per annum (Mtpa) of
Hematite direct ship ore (DSO) as Lump and Fines.

1.2 Purpose

The Contractor shall develop and complete this specification as part of the design development
obligations of the Contract for the purpose of specifying the works to be constructed. The minimum
requirements of this specification shall not be relaxed without written consent from the Principal.

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2. DEFINIT IO NS AND ABB REVIAT IO NS

2.1 Definitions
The Contract Formal agreement between The Principal and The Contractor.

The Principal Roy Hill.

Contractor The company responsible for the design and installation of all steel piles.

Shall A mandatory requirement that the Contractor must satisfy.

Must A mandatory requirement that the Contractor shall satisfy.

Approval of Approved Unless otherwise qualified means written agreement by the Principal

2.2 Abbre viations

Not used.

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3. REFERENCED DOC UME NT S

3.1 Standards
Table 3-1 Referenced Standards
Document Number Document Title

AS 1365 Tolerances for flat rolled steel products

AS 1391 Metallic materials - Tensile testing at ambient temperature

AS 1580 Paints and related materials – Methods of test

AS 1544 Methods for impact tests on metals

AS/NZS 1554 Structural steel welding

AS 1579 Arc-welded steel pipes and fittings for water and waste-water

AS 1627 Metal finishing - Preparation and pre-treatment of surfaces

AS 1710 Non-destructive testing – Ultrasonic testing of low alloy steel
plates and universal sections – Test methods and quality
classification

AS 1796 Certification of welders and welding supervisors

AS 1815 Metallic materials - Rockwell hardness test

AS 1816 Metallic materials - Brinell hardness test

AS 2159 Piling design and installation

AS 2177 Non-destructive testing – Radiography of welded butt joints in

metal
AS 2207 Non-destructive testing – Ultrasonic testing of fusion welded
joints in carbon and low alloy steel

AS 2214 Certification of welding supervisors - Structural steel welding

AS/NZS 2312 Guide to the protection of iron and steel against exterior
atmospheric corrosion by the use of productive coating

AS2400 Packaging

AS2852 Packaging – Pictorial marking for the handling of packages

AS/NZS 2980 Qualification of welders for fusion welding of steels

AS/NZS 3678 Structural steel – Hot rolled plates, floorplates and slabs
AS/NZS 3679 Structural steel – Hot rolled bars and sections – welded I-
sections

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AS3894 Site testing of protective coatings

AS 4100 Steel structures

AS/NZS 4856 Welding consumables - Covered electrodes for manual metal arc
welding of creep-resisting steels - Classification

AS/NZS 4857 Welding consumables - Covered electrodes for manual metal arc
welding of high-strength steels - Classification

DIN 30 670 Polyethylene coatings for steel pipes and fittings

JIS G 3469 Polyethylene coated steel pipes

3.2 Documents
Table 3-2 Referenced Documents
Document Number Document Title

100RH-5200-MA-DRG-3101 Drawing - Site Set-Out Plan

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4. GENER AL

4.1 Scope
This Specification provides the minimum technical requirements for the fabrication, supply and
delivery of steel piles for the Roy Hill Iron Ore Project (RHIOP) marine structures.

Each completed steel pile includes a spirally welded tube fitted with a pile collar, shear rings,
protective coating, and pile shoe if required.

The Contractor shall carry out work under the Contract strictly in accordance with this Specification.

The Contractor’s scope of work shall include but not necessarily be limited to the following:

• supply of raw material, labour, equipment and supervision necessary to fabricate steel pile
sections to the required quantity, dimensions and quality;

• supply of labour, equipment and supervision necessary to test materials, welds and coatings
and provision of all documentation (including mill certificates) to the Principal as required and
prior to shipping of piles;

• supply, fabrication and fitting to the steel piles all accessories such as pile shoes, pile collars
and shear rings;

• preparation of pile surfaces and application of surface corrosion protection;

• arranging and furnishing independent third party inspections of the piles and provision of all
documentation to the Principal as required and prior to shipping of piles;

• transportation of the piles to Port Hedland;

• offloading of piles as agreed with the Principal;

• following delivery to Port Hedland, testing and joint inspection of piles and provision of all
documentation to the Principal prior to pile handover: and

• provision of all assistance (including ensuring open workshop access) to the Principal, or to a
third party appointed by the Principal, for the inspection and testing of the piles.

4.2 Desc ription of Site

The site is located in the Port Hedland inner harbour.

The port site is well protected from open seas and has an approach channel and berth pocket, the
site set-out plan is shown on drawing 100RH-5200-MA-DRG-3101.

4.3 Notice of Commencement and progress

The Contractor shall provide the Principal notice in writing of the program for the manufacture of piles
and the application of corrosion protection coatings a minimum of 28 days before such
commencement. This is to enable the Principal to schedule and carry out inspections and any
additional testing in the pile fabrication workshops.

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4.4 Inspection and access to site

The Contractor shall permit the Principal free access to all pile fabrication and coating workshops at
all times for the purpose of carrying out inspection and additional testing. The Contractor shall
provide all necessary facilities for the carrying out of such inspections. The inspection by the
Principal shall not prevent the later rejection of any work materials in which defects have been found.

The Principal may choose to appoint a third party testing agency to witness and inspect any part of
the fabrication and coating process. The Contractor shall at all times provide this testing agency with
free access to the fabrication workshops including the use of all necessary facilities for the carrying
out of such inspections.

All testing equipment referred to in this Specification shall be supplied by the Contractor. This
equipment may be used by the Principal or an appointed testing agency to carry out various
inspections required to determine the quality of the work.

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5. SUPPLY

5.1 General
The Contractor shall supply all materials necessary for the fabrication of piles.

5.2 Pile Materials

Only new materials shall be used unless written approval from the Principal is obtained prior to
material being procured or fabricated. The materials shall be free of defects, loose scale, slag and
rust.

Steel composition shall conform to the requirements of AS/NZS 3678 or an acceptable equivalent
International Standard as approved in writing by the Principal.

Pile tubes shall be fabricated as spirally seam welded. Pile shoes and pile collars shall be
longitudinally welded.

The pile material (including pile shoes and pile collars) shall have the following minimum properties
determined using testing requirements in AS/NZS 3678:

• Minimum yield stress for all thicknesses 380 MPa

• Minimum tensile strength 450 MPa

• Minimum elongation on gauge length of 5.65 S0 20%

All pile materials shall be supplied with mill certificates or certified reports of tests made by a National
Association of Testing Authorities (NATA: Australia) certified testing laboratory or a facility which is
approved in writing by the Principal.

5.3 Material T esting

Prior to fabrication, the Contractor shall obtain and forward to the Principal, test certificates stating
that the materials to be used in fabrication have been tested and found to comply with the
requirements of the relevant Australian Standards referenced in this Specification.

Pile plate material with a nominal thickness greater than 20mm shall be tested for lamellar defects
prior to forming. This testing shall be carried out at the steel maker’s mill as part of the plate
manufacturing process and the supplied plate shall be certified to be free of lamellar defects.

In the event that the Contractor is unable to supply the steel maker’s certificates, the Contractor may
be required to submit samples to a National Association of Testing Authorities (NATA: Australia)
certified testing laboratory for testing. An alternative facility may be used if approved in writing by the

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Principal. The cost of this testing shall be borne by the Contractor. The manufacturer’s certificates
and mill inspection reports or certified material reports shall be submitted to the Principal for review
and acceptance, and authorisation is required before fabrication work commences.

The testing and preparation of specimens shall be carried out in accordance with;
• AS 1391 – “Metallic materials - Tensile testing at ambient temperature”,
• AS 1544 – “Methods for impact tests on metals”,

• AS 1815 – “Metallic materials - Rockwell hardness test” or

AS 1816 – “Metallic materials - Brinell hardness test “,
• AS 2207 – “Non-destructive testing - Ultrasonic testing of fusion welded joints in carbon and
low alloy steel”.

All pile plates shall have clear and distinct manufacturer’s marking identifying the respective grades of
steel.

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6. PILE PREP AR AT IO N

6.1 General
All piles shall be finished free of surface flaws, cracks, laminations and any other defects which may
adversely affect structural performance and durability. Repairs to minor defects are only permitted
with the prior written approval of the Principal. Proposed repair procedures shall be submitted to the
Principal for review and acceptance prior to any repairs being carried out.

The ends of piles shall be cut accurately and square to the longitudinal axis of the pile and shall be
prepared for welding at splice locations.

Piles must not be fabricated from off-cuts less than three (3) metres in length.

Before assembly begins, all rolled sections shall be free from kinks, defects, or creases. Any sharply
bent or kinked material shall be rejected. Materials rejected shall be replaced by the Contractor at no
cost to the Principal.

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7. PILE F ABR IC AT IO N

7.1 Welding Standards

All pile fabrication splices shall be undertaken with prequalified full penetration continuous butt welds
complying with the requirements of AS/NZS 1554.1 – “Structural steel welding”.

All pile splice welds shall be “SP” category. All welds shall be continuous.

The pile shoes and pile collars shall be longitudinally welded and circumferentially spliced to the piles.
This shall be done using a full penetration butt weld.

The finished surface profile of all welding shall be smooth and free from sharp edges or crevices that
would be detrimental to the performance of the structure or to the protective treatment. All slag and
weld splatter shall be thoroughly removed, and the affected pile surface shall be replaced, or repaired
and ground smooth.

Arc strikes outside the area of permanent weld shall be avoided. Cracks or blemishes resulting from
arc strikes shall be ground to a smooth contour and checked using ultrasonic testing to ensure
soundness.

Spiral welds shall have a flat well-formed weld bead with an offset dimension no greater than 3 mm,
free from discontinuities, sharp edges and undercuts that can reduce performance of the pile
protective coating at the edges of the spiral weld.

Welding of shear rings shall be carried out during the fabrication process prior to any coating activity.

7.2 Welders and T esting Personnel

All welding shall be carried out by welders who are fully qualified, experienced, and meet the
requirements of AS2980 – “Qualification of welders for fusion welding of steels”. Welder qualifications
and weld procedures shall be submitted to the Principal for acceptance prior to the commencement of
production.

All mechanical and non-destructive test results submitted with the qualification documents must be
performed by NATA (National Association of Testing Authorities - Australia) qualified personnel. A
qualification from an equivalent authority may be used if approved in writing by the Principal. The
Principal may choose to witness weld testing and every effort shall be made to accommodate this.

All testing shall be performed by certified welding inspectors. Weld inspectors certificates shall be
submitted to the company for review prior to inspection of welds.

Additional testing may be required if in the opinion of the Principal the welding quality is not
acceptable. All requirements specified for welder and weld procedures shall also be applicable to
these tests.

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Welders who fail any test shall be given another test as soon as practicable and shall be deployed on
welding only after passing such a retest. Welders who have failed a repeat acceptance test shall not
be permitted to weld.

7.3 Welding Materials

Electrodes, electrode wires and fluxes shall conform to AS4855 – “Welding consumables—Covered
electrodes for manual metal arc welding of non-alloy and fine grain steels” or AS1858.1-“Electrodes
and fluxes for submerged Arc Welding Part 1: Carbon Steel and carbon-manganese steels, or to an
equivalent international standard approved in writing by the Principal.

Welding materials shall be of such quality as to ensure thorough penetration and to ensure sound
welds. Electrodes shall be used to give a minimum tensile strength of 480 MPa.

Electrodes and fluxes shall be stored in their original packets or cartons in a dry place, protected from
the effects of weather. Where special protection during storage and use is recommended by the
manufacturer, such recommendations shall be strictly complied with. Electrodes and fluxes which
become affected by dampness, but not otherwise damaged, may be used after being dried out in a
manner specified by the electrodes manufacturer. Electrodes which have areas of the flux broken
away or damaged shall be discarded.

Reclaimed flux must not be used for welding purposes.

7.4 Seam Welds

Weld seams in pile sections shall be evenly staggered during assembly to form the complete pile
pitching length. Where it is not practical to evenly stagger the seams to meet out of straightness
tolerances at fit up, the seams shall be staggered by at least 100 mm around the pile circumference.

7.5 Weld Inspection and T esting

Inspection of welds shall be carried out in accordance with AS/NZS 1554 – “Structural steel welding”,
or to an equivalent international standard approved in writing by the Principal. Copies of all inspection
and test reports shall be forwarded to the Principal.

The Contractor shall be responsible for carrying out visual inspections, ultrasonic testing, and
magnetic particle inspection of weld preparations and the weld quality. The testing procedures to be
used are:
1) Visual Scanning
2) Visual Inspection
3) Ultrasonic Testing
4) Magnetic Particle Inspection

The extent of testing and inspection of welds shall be as follows:

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a) visual inspection of all weld preparations prior to welding

b) inspection of all weld quality using both visual scanning and visual inspection
c) testing of full strength butt weld splices using ultrasonic testing with an acceptance to AS/NZS
1554 Part 1:

• pile spiral welds shall be 100% ultrasonically tested and subject to a magnetic particle
inspection on the first five piles fabricated

• pile spiral welds shall be ultrasonically tested and subject to a magnetic particle
inspection on 40% of the total spiral weld length on every fourth pile manufactured, as
directed by the Principal

• pile welds shall be 100% ultrasonically tested and subject to a magnetic particle
inspection where a change to material thickness or grade occurs at a joint

• pile welds shall be 100% ultrasonically tested and subject to a magnetic particle
inspection at pile section joints

• welds on shear rings, pile shoes and pile collars shall be 100% ultrasonically tested and
subject to a magnetic particle inspection

• testing shall comply with AS 2207 – “Non-destructive testing – ultrasonic testing of fusion
welded joints in carbon and low alloy steel” or with an equivalent international standard
approved in writing by the Principal

The Contractor shall be responsible for all testing procedures. Prior to testing the Contractor shall
provide an inspection and test plan to the Principal for review and written approval.

A copy of all inspection and test reports shall be approved in writing by the Principal prior to the
application of the coating.

Qualified weld procedures shall be prepared by the Contractor for all weld types, before
commencement of fabrication work. Equipment employed shall be qualified for these procedures. A
copy of the procedures shall be forwarded to the Principal for review and acceptance prior to welding
commencing.

No welding shall be carried out on steel which is in a state of stress.

All costs associated with repairing and retesting defective welds shall be borne by the Contractor. All
repaired welds shall be retested.

7.6 Fabrication Tolerances

Pile sections shall be supplied in the numbers and lengths shown by the Drawings and fabricated with
pile shoes, pile collars and shear rings.

Piles shall be rolled/formed (i.e. prior to the application of the coating) to the following tolerance limits.
Fabrication tolerances must be attained on both the final product (i.e. the full length pile) and on
individual splice lengths.

Allowance for sag shall be made when measuring pile dimensions.

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Table 2.1 Pile Fabrication Tolerances

Minimum thickness 20.0 mm. This is an absolute minimum and
must not be averaged.

Circumference +/- 10 mm

Difference between maximum and minimum +/- 5 mm

external diameters at any particular cross
section

Deviation from circular arc within a chord of +/- 3 mm

300 mm

Alignment of splices < 10% of the thickness of the thinner part

joined

Perpendicularity of the end face 3 mm

Flatness of end face 3 mm max over circumference

Outside diameter of pile measured across any +5 mm/- 8 mm

particular cross section of the pile

Straightness Length/1000

Overall pile lengths -0 mm/+150 mm

7.7 Dimensional Accura cy and Correc tions to Dimensions

The Contractor shall verify all dimensions are within tolerances given in this Specification, as well as
compliance with Australian Standards listed in this Specification. The Contractor shall be responsible
for the accuracy of all dimensions.

Remedial or repair work necessary to correct dimensional errors must not be carried out until the
methods proposed by the Contractor are approved in writing by the Principal.

The remedial work must not reduce the properties of materials used in the work below the values
assumed in the design. Any remedial work must not delay the pile delivery program.

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8. PILE CORROSIO N PROT ECT IO N

8.1 General
A 3-layer medium density polyethylene (MDPE) coating shall be applied to the piles to the extent
indicated on the Drawings (but not less than from 5m below Chart Datum to the top of the pile). The
coating system shall consist of the following layers:
• approximately 75 microns of electrostatic epoxy powder
• approximately 200 microns of co-polymer adhesive
• minimum 2500 microns of medium density polyethylene film

The coating and application shall meet the standards set out in JIS G 3469 – “Polyethylene coated
steel pipes” and DIN 30670 – “Polyethylene coatings for steel pipes and fittings”. In addition, the
corrosion protection system shall meet or better the standards and requirements for the preparation,
application, and properties of the NS-PAC 3-layer coating by Nippon Steel Corporation.

The particular coating system to be used and the associated coating specifications are to be as
agreed in writing with the Principal. Alternative standards and specifications can be submitted to the
Principal for acceptance or rejection. These alternatives need to have been approved in writing by
the Principal before any coating is procured or works take place.

Pile surfaces shall be prepared for corrosion protection by abrasive ‘white metal’ blast cleaning
equivalent to Class (Sa) 3 to AS 1627.4 – “Metal finishing – Preparation and pretreatment of
surfaces”. In addition, the surface shall be prepared to meet the coating manufacturer’s
recommendations.

Preheating, primer and adhesive application, the extraction of resin onto the pile, and water cooling
shall all be carried out in accordance with the manufacturer’s recommendations.

The finished surface shall be free from sagging, streaking, running, cracks, embedded dust,
imperfections or damage, and have a uniform thickness under normal vision.

Only applicators approved by the Principal shall be employed on the Works. In addition, tradesmen
applying coatings shall be individually certified by the manufacturer as being competent to apply the
coating.

The area where blast cleaning and application is undertaken shall be covered, ventilated and
maintained to a high degree of cleanliness.

Steelwork shall be coated only in the workshop of the applicator as agreed with the Principal. Once
the coating has cured the piles shall be lifted, stacked and transported in a finished condition in
accordance with the corrosion protection system specifications and practice manuals. All lifting shall
be done with the use of soft material slings and other apparatus so as not to damage the coating.

Suitable repair material (polyethylene sticks or patching sheets and aluminum) shall be provided with
the coated piles to enable onsite repair to any damage that may occur during the installation process.
Details of suppliers in Australia capable of undertaking repairs shall be provided to the Principal.

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At the beginning of each day's operation or following a prolonged shut-down, the Contractor shall
carry out a test to confirm that the coating will cure satisfactorily and the equipment is correctly
adjusted.

The specified 2500 micron coating thickness is an absolute minimum. Measurements must not be
averaged. Piles found to have inadequate coating thicknesses shall have the coating stripped, be
blast-cleaned to Sa 3, and be recoated at the cost of the Contractor.

8.2 Inspection and testing

The Contractor shall inspect, test, and document the quality of the surface preparation, coating
application and cured coating film. As a minimum this will include:
1) Inspection of blast cleaning with reference to AS 1627.4 – “Abrasive Blast Cleaning”.
2) Inspection of cover extent for both the primer and the final 3-layer polyethylene coating.
2) Inspection and documentation of application methods and techniques.
3) Measurements of coating thickness for both the primer and final 3-layer polyethylene
coating.
4) Measurements of coating and drying conditions, steel temperature, ambient temperature
and humidity.
5) Hardness checks to determine the degree of cure of the polyethylene resin.
5) Identification of cure and film defects.
6) Adhesion check of full coating system (disbondment tests).
7) Holiday and pinhole checks of the full coating system by suitable methods (including
visual).

All inspections and measurement of coatings shall be completed and defects made good prior to the
piles leaving the workshop. A copy of all inspection and test reports shall be forwarded to the
Principal.

8.3 Repair
All MDPE coated areas which are defective or damaged (including during transport) shall be repaired.
The Contractor shall ensure that repairs provide a comparable level of corrosion protection to the
undamaged coating. The repair methods shall as a minimum comply with the methods described in
the attached technical guidelines (Appendix A).

Coatings that are loose, weakly bonded, blistered or otherwise defective shall be removed and the
surface recleaned in accordance with the method prescribed for the specified coating. The surface
shall then be recoated.

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The Principal shall be provided written notification of damaged coatings prior to repair. The cost of all
repairs are to be met by the Contractor.

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9. INDEPE NDE NT T HIRD P ART Y INSPECT ION

In addition to the testing performed by the Contractor during fabrication, the Contractor shall also
arrange for third party inspections and testing of the piles. This shall be by a reputable independent
company certified in writing by the Principal, and occur at the pile fabrication workshops prior to
loading the piles into the hold of the shipping vessel. These reports shall be provided to the Principal.

Details of the proposed inspection company and proposed inspection scope shall be provided with
the Contractor’s tender.

As a minimum the third party inspections shall include:

• Dimensional check measurements of 10% of the piles to ensure fabrication is within

tolerance. This shall include wall thickness, length, and all other dimensional tolerances
listed in this Specification.
• Ultrasonic testing and magnetic particle inspection on the complete pile spiral welds on 10%
of the piles.

• Ultrasonic testing and magnetic particle inspection on all pile shoe and pile collar splice welds
on 20% of the piles.

• Review of all manufacturing data including steel certificates for compliance and sighting of
steel markings prior to coating.

• Coating thickness, extent, adhesion and pinhole conformance checks at the coating
workshop.

• Photographic records of the shipment prior to loading on vessels.

The inspection by the third party inspection company shall not prevent later rejection of any work or
materials in which defects have been found.

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10. P ACK AGING, ST OR AGE, HANDL ING AN D DELIVER Y T O SIT E

10.1 General
Before and after fabrication, during transit and on the site, all piles shall be handled and stacked in
such a way that they are not damaged or overstressed. Details of the transportation and stacking
system shall be provided to the Principal for written approval prior to fabrication beginning. This shall
include details on all protective measures to be used (ie scalloped cradles, placement of rubber lifting
slings).

The Contractor shall advise the Principal of lifting points and procedures to avoid damage or overload
to the pile including pile coatings.

Piles bent or buckled from handling or storing shall be liable to rejection. All steelwork shall be stored
clear of the ground in such a way that water will run off freely. Piles shall be packed and marked in
accordance with AS2400 – “Packaging”

Piles must not be handled until the protective coating has completely cured and dried hard.

Slings used for the handling of finished coated piles shall be made of a suitable soft material.

Supports in contact with piles during transport and storage shall be covered with a similar soft
material to minimize damage to the coating.

Similarly, soft material or yokes shall be used between coated piles and holding down chains and
fixings to prevent damage to the coating during transportation.

All piles shall be marked to allow easy identification during transit and upon delivery to the site in
accordance with AS2852 – “Packaging – Pictorial marking for the handling of packages”. A packing
list shall be provided to the Principal.

10.2 Driving Marks

Piles shall be clearly marked with an identifying pile number, lifting locations, overall length and in
quarter meter increments to enable the Principal to readily verify the pile installation depth during
installation of the piles. The identification marking must not adversely affect the surface finish of the
member.

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ROY HILL PROJECT
PORT MARINE – SPECIFICATION FOR SUPPLY AND FABRICATION OF MARINE PILES

Appendix A – Repair Procedure for MDPE Coating

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1. Scope

This procedure is applied to repair methods of defect which may occur during storage,
transportation, handling and splicing joint area for anti-corrosion.

2. Purpose
The purpose of this manual is to get complete anti-corrosion effect by fast repair within a
short time when the coated pipe is damaged.

3. Repair procedure of coated steel pipe (Multi-layer)

3.1 Applied patch sheet for small damaged area
1) Before repairing the damaged area, check the form of the damaged area and make the
damaged area to be regular or rectangular. (Refer to fig.1)
2) At this time, make the angle of cutting P.E surface 15°- 30°with a grinder or a knife.(Refer to
fig. 1)

(FIG. 1)
3) Remove dirt, scale, grease and other contaminants which impair the adhesion of the repair
material on the stripped area of steel pipe surface with a wire brush or sand paper.

4) Heat the melt stick and the repair zone simultaneously with the torch until it becomes fluid
and spread the melt stick over the damaged area. (Refer to fig. 2)

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(FIG. 2)
5) Cut a patch sheet about 30mm ~ 50mm larger on all sides than the damaged area and
Place the patch with the adhesive side on a gloved hand or on top of the pipe or suitable
space and heat gently.
Heat until adhesive becomes soft and the surface becomes glossy.

(FIG. 3)
6) Apply softened adhesive side of the patch to damaged area firmly.
7) Heat the patch with a low intensity flame until uniform, and using a roller or a gloved hand,
Pat down until the wrinkles are removed.

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(FIG. 4)

8) In case of direct heating (petroleum, propane torch), heat the area after covering with
aluminium foil over the patch sheet.
9) In case of indirect heating (hot jet gun), there is no need to use aluminium foil.

10) After finishing the repair, test using holiday detection.

3.2 Applied Heat Shrinkable Sheet for large damaged area

1) Before repairing the damaged area, check the form of the damaged area and make the
damaged area to be regular or rectangular. (Refer to Fig. 1)

2) At this time, make the angle of cutting on the PE surface about 15 ~ 30○ with a grinder or a
knife. (Refer to Fig. 1)
3) Remove dirt, scale, grease and other contaminants which impair the adhesion of the repair
material on the stripped area of steel pipe surface with a wire brush or sand paper. (Refer
to Fig. 1)

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(FIG. 5)
5) Heating slowly the centre of heat shrinkable tube from the underside with a butane torch,
an hour-glass-shaped drum and pull out wooden wedges.
6) Heat slowly from side to side and stick the sheet fast to the pipe.

7) Also from opposite side, heat slowly and stick the sheet fast to the pipe completely.

(FIG. 6)
8) After finishing the repair, test by holiday detection. (Refer to Fig. 7)

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(FIG. 7)

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4. Procedure of coated steel pipe (F.B.E.)

4.1 Applied painting material for minor defect

1) minor defect area: pinholes, scratches, inadequate film thickness and small defects. But,
damaged area shall be less than 100cm 2 and the greatest length shall not exceed 30cm.
2) Pipe requiring limited repair due to scars, slivers, coating imperfections and other minor
defects shall be repaired with the powder supplier’s recommended two-part liquid epoxy or
purchaser-approved equivalent.
3) Damaged area shall be cleaned by removing all rust, scale, dirt, other foreign material, and
loose coating (refer to Fig. 10)
4) The adjacent area from damage shall be suitable roughened by sanding or grinding (refer
to Fig. 10)

(FIG. 10)

5) Dust shall be removed with a clean, dry cloth or brush (refer to Fig. 11)

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(FIG. 11)
6) The paint mixing shall be made to comply with the raw material manufacturer
recommendation.
7) Damaged area shall be patched with the powder supplier’s recommended two-part liquid
epoxy or purchaser-approved equivalent. (refer to Fig. 12, 13)

(FIG. 12) (FIG. 13)

8) After the defective coating has been removed, a strip with a minimum additional width of 5mm
over the area removed shall be reamed to allow overlapping of the repairing material (Refer to
Fig. 13, 14)

9) During and after the application of touch up painting it shall be confirmed the condition by visual
and holiday detection (Refer to Fig. 14, 15)

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(FIG. 14)

(FIG. 15)

4.2 In case of major defect

Pipe sections with major coating defects such as partially uncoated, excessive holidays, or
inadequate film thickness shall be reworked.
4.3 Repair Area Inspection

1) External visual inspection

2) Thickness of repair area

3) Holiday inspection

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