Method Statement For Steel Pipe Pile Fabrication Corrected

LEKKI DEEP SEA LDSPP-CHELE-
MS FOR STEEL PIPE PILE Document No. MW-MS-009(C03)

PORT PROJECT FABRICATION
NIGERIA
Rev. C03
Issued By CHELE Issued Date 25 May.2020 Page 1 / 40
Method Statement for Steel Pipe Pile Fabrication
Document No : LDSPP-CHELE-MW-MS-009(C03)
Revision: 3
Date of Issue : 25 May. 2020
CHINA HARBOUR ENGINEERING

CONTRACTOR:
COMPANY LTD.
Name Title Date Signature
Prepared By Nikhil Agarwal Deputy Technical Manager 25/05/2020
Lan Jinping Technical Manager 25/05/2020
Hong Xiaoliang Deputy Manager 25/05/2020

Reviewed By
Liu Jianwei HSE Manager 25/05/2020
Approved By Tang Minggang Project Manager 25/05/2020

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Rev. C03
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Issued By CHELE Issued Date 25 May.2020 Page 3/53
Method Statement for Steel Pipe Pile Fabrication Ref.No: LDSPP-CHELE-LB-LS-0683(C03)

Doc.No: LDSPP-CHELE-MW-MS-009(C03)
No. section page Comment(LDSPP-CHELE-LB-LS-0683) Response(CHELE)
This is submittal number, not document

Contractor’s Method
13 number. Please correct to LDSPP-CHELE-MW- It have been corrected
Statement Submission
MS-009
Why is this org chart shown? It is not

5.1 Organization 10 relevant to the fabrication works. Please It have been corrected
add relevant org chart
1. whilst being protected from adverse

weather conditions.
1. It have been corrected
2. All dimensions shall be recorded prior
2. It have been corrected
to and after completion of a Butt Weld to
Butt joint welding ensure tolerances are within 3. Encircling of the pipe pile
9.4 process of steel pipe 22 specification pre-welding and post-
pile 4. Encircling of the pipe pile
welding.
3. I don't understand the reference to "
One Week "
4. I don't understand " for a week " ?
10.1 Coating Elevations 36 How often will this be done? Such as the measuring instrument is checked
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Internal calibration and checks should once a year. Different types of pipe pile
also be done, please describe the prior to production of equipment for testing
frequency.
To say that the HSSE plan will be

followed is inadequate. There was
agreement with CHELE's HSSE Department
It has been corrected.
that HSE Section of all Method Statements
11.1 HSE 40 will follow "LDSPP-CHELELBG- MS-016 Rev
03 Submission of the Revised Breakwater
Method Statement" This section must be
revised to reflect the acceptable and
agreed method.
The Risk Assessment must be done on the

project approve format. It must be signed
off by CHELE's HSSE Director and HSE It has been corrected.
Appendix A - Risk
12 41 Manager ."Be guided by Risk Assessment
Assessment
#00 attached to LDSPP-CHELELBG- MS-016
Rev 03 Submission of the Revised
Breakwater Method Statement.
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Table of Contents
1. General............................................................................................................................... 7
2. Terms................................................................................................................................. 8
2.1 Definition.................................................................................................................... 8
3. Scope of Works................................................................................................................. 8
4. References......................................................................................................................... 9
5. Organization & Responsibility.......................................................................................10
5.1 Organization............................................................................................................. 10
5.2 Responsibility........................................................................................................... 11
5.2.1 Project Manager.....................................................................................11
5.2.2 Deputy Project Manager.........................................................................11
5.2.3 Construction Manager............................................................................12
5.2.4 QA/QC Manager.....................................................................................12
5.2.5 HSE Manager.........................................................................................12
5.2.6 Site Engineer..........................................................................................13
5.2.7 Quality Control Engineer........................................................................13
5.2.8 HSE Officer............................................................................................13
5.2.9 Site Supervisor.......................................................................................14
6. Materials & Equipment....................................................................................................14
7. Manpower........................................................................................................................ 15
8. Construction Flow Chart.................................................................................................16
9. Fabrication Methodology for Steel Pipe Pile.................................................................17
9.1 Production process spiral steel tube.........................................................................17
9.2 Pipe Section Joints...................................................................................................21
9.3 Shear Ring Production.............................................................................................23
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9.4 Butt joint welding process of steel pipe pile..............................................................24

9.5 Welding/Installation C9 Interlocks............................................................................26
9.6 Weld Quality Inspection............................................................................................29
9.7 Blasting and Automatic spraying..............................................................................31
9.8 Final Inspection and Product Identification...............................................................35
9.9 Hoisting and Delivery...............................................................................................36
10. Quality Control.............................................................................................................. 37
10.1 Overall Quality Control Measures...........................................................................37
11. HSE................................................................................................................................. 40
11.1 General.................................................................................................................. 40
11.2 Reference............................................................................................................... 40
12. Appendix........................................................................................................................ 41
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1. General
The purpose of this method statement is to provide fabrication method and resource
deployment for steel pipe pile fabrication for Lekki deep sea port project. The port project is
680m, which includes 2 container berths, the coastline terminal for the tug boat berthing
which is 104m long and also the approach bridge structure as shown in the below figure.
The steel pipe pile will be manufactured using materials as shown in the below table.
Table 1: Steel Pipe Piles Details
Item Pile Diameter Pile thickness Steel Pile No. of Piles Length of Piles (m)
No. (mm) (mm) Material
1 1000 14 X52 40 See table in Section 3.
2 2300 23/20 X70 89 29+12=41
3 2000 23/19 X70 136 27.5+12=39.5
4 1400 18 X60 220 16.50
5 1200 16 X52 187 39.50
Figure 1a: Elevation View of Tug berth (Pile diameter 1000mm)

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Figure 1b: Section View of Quay Wall (Pile diameter 2.3m, 2.0m, 1.4m and 1.2m)
2. Terms
2.1 Definition
Project LEKKI DEEP SEA PORT PROJECT NIGERIA
Works Method Statement for Steel Pipe Pile Fabrication
Employer LEKKI PORT LFTZ ENTERPRISE LTD.
Contractor CHELE
3. Scope of Works
This method statement is applicable for the production of steel pipe tubular piles. The
method statement covers the fabrication process of steel pipe piles and equipment used for
the fabrication of piles. The number of piles for each section is shown in the table above.
The material for steel pipe pile is shown in the below table in accordance to the specification.
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The length of 1000mm diameter pile is variable and is shown in the below figure.
The scope of work consists of the following:

1. Processing and production of steel pipe;
2. Butt joint of circular seam, tube forming and welding to form steel pipe piles;
3. Installation and welding of shear rings/clutches etc. items in the steel pipe pile;
4. Anti-corrosion protection of steel pipe pile.
4. References
（1）API 5L (2007) Specification for Line Pipe
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（2）API RP 2A WSD Recommended Practice for Planning, Designing and Constructing

（3）A6/A6M Specification for General Requirements for Rolled Structural Steel Bars
（4）E165 Standard Method for Liquid Penetrant Examination
（5）A252 Specifications for Welded and Seamless Steel Pipe Piles
（6）A572 Standard Specification for High-Strength Low-Alloy Columbium -Vanadium
（7）BS EN 287 Approval testing of welders for fusion welding
（8）BS EN 288 Specification and approval of welding procedures for metallic materials
（9）BS EN 571 Non-destructive testing-Penetrate testing
（10）BS EN 875 Destructive tests on welds in metallic materials –Impact tests-Test
（11）15S156-DD-MR-SPC-6002-C01 SPECIFICATION FOR CORROSION PROTECTION
COATING OF PILES
（12）15S156-DD-MR-SPC-6001-C03 SPECIFICATION FOR FABRICATION OF STEEL
PILES.
（13）15S156-DD-MR-SPC-6002-C01 SPECIFICATION FOR CORROSION
PROTECTION COATING OF PILES.
（14）15S156-D9-MR-DRW-5011-C01 TYPICAL SECTION OF TUG BERTH.
（15）15S156-D9-MR-DRW-6011-C02 TYPICAL SECTION 1-1 OF QUAY WALL
（16）15S156-D9-MR-DRW-6012-C02 TYPICAL SECTION 2-2 OF QUAY WALL
(17) The Lekki deep sea project Master contract
(18) BS5493Code of practice for protective coating of iron and steel structures against
corrosion
（19）Other Approved Drawings for quay wall, tug berth and access trestle.
5. Organization & Responsibility

5.1 Organization
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Figure 3: Organization Chart of Project
5.2 Responsibility
The responsibilities of the key personnel are outlined as follows:
5.2.1 Project Manager
a) To manage overall execution of the work.
b) To ensure project can fulfill the Employer’s Requirement.
c) To coordinate contractor between Employer and Engineer.
d) To conduct a project evaluation review to assess how well the project was managed.
e) To manage project administration.
f) To monitoring and report the work progress to the Employer.
5.2.2 Deputy Project Manager
a) To assist Project Manager to manage HSE and Quality issues
b) To ensure that all personnel involved in construction are fully aware of safety,
environmental and emergency procedures.
c) To ensure that all personnel involved in construction are fully aware of their HSE
responsibilities and HSE plan for the Project.
d) To Schedule all the construction works.
e) To ensure that all construction works are carried out in compliance with specification and
schedule
f) To ensure deadlines are met.
g) To monitor and report the work progress to the Project Manager.
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5.2.3 Construction Manager

a) To manage overall execution of works.
b) To ensure that all works are planned, performed and completed in accordance with the
approved method statement and employer’s requirements.
c) To ensure that sufficient qualified and trained personnel are deployed at site.
d) To ensure that construction team will conduct the works in the safest manner complying
with HSE requirements.
e) To arrange and maintain construction equipment and manpower to meet with the
construction schedule.
f) To review the work progress on daily basis.
g) To coordinate personnel and equipment for work.
5.2.4 QA/QC Manager
a) To establish the quality management system in accordance with Project Construction
Quality Plan (PCQP)
b) To ensure that all project activities are performed in compliance with the PCQP, Quality
Procedures and relevant Technical Specifications.
c) To carry out quality inspection and check of all site works.
d) To ensure activity at site are based on approved method statement and inspection test
plan.
e) To prepare related QA/QC documents and also responsible for closure of Non-
conformance reports.
f) To coordinate with the consultant’s representative and Site in-charge for inspection and
meeting about quality problems including closure of Non-Compliance Report.
g) To carry out Internal Audit as scheduled in the Project Quality Plan, PQP.
5.2.5 HSE Manager

a) To arrange HSE officer to provide appropriate safety and health training and accident
prevention training to all staff members and supervisors.
b) To prepare appropriate notices for management for any identified risks and hazards.
c) To ensure that suitable Personnel Protective Equipment (PPE) are being organized.
d) To provide promotional materials and to develop and manage effective systems to
promote safe and healthful work performance.
e) To assure that claims for injuries and illnesses posted in SMIS are posted in the
Occupational Safety and Health Administration log.
f) To conduct periodic reviews of the procedures and updates as required, to ensure that the
HSE Plan is kept updating.
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5.2.6 Site Engineer

a) To ensure construction progress comply with schedule.
b) To coordinate and direct construction workers and subcontractors.
c) To check construction materials regularly and work to ensure they comply with the
Employer’s Requirement.
d) To follow safety requirements.
e) To resolve technical issues with employer’s representatives, suppliers, subcontractors and
statutory authorities.
f) To perform quality control in accordance with GSB/procedures, method statements, quality
plans and ITP.
g) To liaise with company or project purchasing department to ensure that purchase orders
adequately comply with the requirements.
h) To supervise and counsel subordinate staff.
i) To be in charge of quantity measurement and valuation, in accordance with project
quantity.
j) To provide data with respect to variation orders and site instructions
k) To prepare drawings, technical reports and site construction records.
5.2.7 Quality Control Engineer

a) To inspect the quality of material according to the specifications.
b) To monitor construction quality and NCR measures.
c) To take care of QA/QC documents of the entire project including certificates, calibration,
test results, inspection requests, non-compliance reports, site instruction/observations
etc.
d) To perform daily inspection to achieve the quality of construction required as per the
drawings and specifications for all works mentioned under the employers requirements.
e) To report to the Quality Manager daily.
5.2.8 HSE Officer

a) To perform daily check on site.
b) To organize safety educations and trainings for all staffs working on site.
c) To carry out emergency measures as necessary.
d) To ensure that all measures to be taken for construction works are accordance with the
HSE requirements.
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e) To ensuring that suitable Personnel Protective Equipment (PPE) are provided to all
personnel working on site.
f) To assist management in the annual inspection of workplaces and to assure safe and
healthful conditions for workers.
g) To ensure that all new personnel are trained.
h) To ensure that tool box talks are performed daily prior to work commencement.
5.2.9 Site Supervisor

a) To ensure construction progress comply with schedule.
b) To coordinate and direct construction workers and subcontractors.
c) To check construction materials regularly and work to ensure they comply with the
Employer’s Requirement.
d) To follow safety requirements.
e) To perform quality control in accordance with GSB/procedures, method statements,
quality plans and ITP.
f) To supervise and counsel subordinate staff.
g) To be in charge of quantity measurement and valuation, in accordance with project
quantity.
h) To report to site engineer.
i) To conduct daily Tool Box for workers.
6. Materials & Equipment
Table 1: List of Main Equipment
No. Description Specification Quantity
Uncoiling and Feeding

1 1
Machine
2 Milling Machine 1
3 Tube Forming Machine 1
4 Steel scroll 1
5 Plasma Cutting Machine PC50 2
6 Submerged Arc Welding 5
7 Ultrasonic Testing 1
8 Gas shielded welding 4

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machine
9 Gantry Crane for Hoisting 3
10 Trailer Truck 2
11 Sandblasting machine 1
12 Vernier calipers 2
13 Tpe measure 5
14 Polisher 5
14 Dry film thickness gauge 1
15 Adhesion puller 1
Table 2: List of Material

Unit
No. Material Quantity
Tons
1 Steel Coils (X70) 10476
Tons
Tons
Tons
4 Solvent-free epoxy coating 175
Tons
5 Epoxy diluent 15
7. Manpower
The manpower required for the execution of the works includes the following personnel: .
Table 3: List of Manpower
No. Description Quantity
1 Equipment Manager 1
2 Site Engineer 1
3 Equipment engineer 1
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4 HSE officer 1
5 Labor 15
6 Machine operators 10
7 Crane operator 2
8 Truck operator 4
9 QA/QC Engineer 2
10 Lab engineer 2
8. Construction Flow Chart

Construction sequence for Site Clearance and Dike Building is shown as follows:
Preparation
Steel Coil Feeding
Side Trimming/Milling
(If required)
Tube Forming
Internal and External Welding
Cutting & End Facing

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Weld Clutches/Internal Shear rings/Drill Holes etc
Anti-Corrosion Protection
Inspection & Delivery for Installation
Figure 8.1: Construction flow chart for Pile Fabrication
9. Fabrication Methodology for Steel Pipe Pile

Manpower, materials and construction equipment should be deployed, prepared before
commencement of works.
All personnel entering the site shall have received a site safety induction and have attended
a job toolbox talk.
Permits shall be obtained before starting the fabrication works.
The steel pipe pile fabrication process will be followed as per the steps mentioned below:
1. Production of spiral pipe in different diameter sections;
2. Butt joint of two spiral pipe with different wall thickness to form one pipe pile;
3. Fabrication of pile tip reinforcement section;
4. Weld quality inspection;
5. Anti-corrosion treatment and C9 interlock installation;
6. Final inspection and marking of pile in accordance to the drive location;
7. Steel pipe pile hoisting and transportation by trailer trucks/shipping.
9.1 Production process spiral steel tube

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This procedure is one component of a complete fabrication and inspection process of steel
pipe pile. This procedure will be used, as needed, to provide quality assurance and
fabrication activities are being conducted as required by the specification.
Below are the steps for production process of steel pipe pile:
 Uncoiling, plate feeding and leveling

The base material (steel coil X70/X60/X52) will be uncoiled small after putting the steel coil
on the roller as shown in the below picture.
Steel coil will be than levelled by the levelling roller which is controlled by the auxiliary drive
of the main engine.
The uneven degree of the base material (i.e. tolerance) is kept within 2mm through real-time
adjustment of the leveling roller. The plate making process ensures the correct arc surface of
the pile tube, which controls the circumference and radius of the tubular pile while ensuring
the straightness of the pile.
Picture 2-1 Uncoiling Picture 2-2 hanging steel coils
Picture 2-3 plate feeding Picture 2-4 leveling
Figure 9.1: Step 1 for fabrication of steel pipe pile
 Milling
The main machine is equipped with a special trimming process by using milling machine to
ensure consistent plate width and groove formation in accordance to specification
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requirements for maintaining the consistent circumference of the tubular pile. This will help is
ensuring good welding quality at the edges of the plate and straightness in the pipe.
Picture 2-5 edge milling
 Forming
The forming process is relatively complicated. In this process, the circumference and
straightness of the tubular pile is to ensured by adjusting the position of the forming wheel
and the position of the back wheel.
There are three main steps to ensure the bending degree of steel tube in the forming
process:
A, Side trimmer or milling the edge of the steel role to ensure that the width of the base
material is consistent;
B. Plate feeding by adjusting the side regulating wheel so that the base material is always
fed in the middle line of the main engine;
C. Adjust the position of conveying platform in real time within the allowed degree of
tolerance for pipe fabrication.
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Picture 2-6 tube forming
 Internal/External Welding
Tangshan kaiyuan DC and AC welding machine will be used for internal and external
welding, which adopts AC/DC tandem double wire submerged arc automatic welding.
Benefits of automatic submerged arc welding are that, it will help in one-time forming, full
depth penetration weld, few weld defects and perfect forming. During the implementation
process of welding, the process requirement will need to adjust and monitor the current and
arc voltage in real-time, which are the important factors to ensure the good quality of the
welding.
Picture 2-7 External welding Picture 2-8 internal welding
Notes: All welding requirements shall follow the approved specification requirement (clause
2.3.2 Welding requirement).
Below is table for welding parameter to be followed for Tubular pile welding process.
Table 9-1 Welding parameter table
Internal weld outer weld
Welding specification Forward backward Forward backward
welding welding wire welding wire welding
wire wire
Welding current(A) 1150 800 1100 800
Arc voltage(V) 32 42 32 42
Welding speed(mm/min) 550~800(plate thickness 23mm)
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welding Wire polarity DC+ AC DC+ AC

Dip Angle of welding Backward Forward of Backward of Forward of
wire/（°） of 5 10 10 5
Wire spacing(mm) 15 20
Wire offset center 75~85mm(rotation direction of reverse tube)
Wire elongation 30-50mm
The welding groove Double V-groove without gap, bevel angle 60 °, blunt
edge 9mm
Flux bulk height 25-40mm
Welding material in accordance with the specification
 End Cutting
Measure the length of the pipe before end cutting. Allowable tolerance shall be followed in
accordance to the specification. Use plasma arc cutting machine to cut the pipe end with
flatness deviation of less than +/- 2mm.
The deviation in length shall be within +0 to +20mm.
Picture 2-9 plasma cutting
Note: Toelrance from the specification shall be followed for the fabrication of steel pipe piles
as shown in the table below under Section 10 of this MS.
9.2 Pipe Section Joints

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The pipe sections for 2000mm and 2300mm diameter pipe pile has two different thickness,
while other pipe piles are of same thickness. The welding procedure for joining the pipe piles
are mentioned below.
Butt welding will be used for pipe piles different wall thickness or same wall thickness for
joining the pipe piles sections.
Since the steel pipe pile is formed by butt joint with the same outerdiameter and different
plate thickness, in order to ensure the straightness or concentricity after butt joint of the two
pipes, the following points should be noted:
A. Adjust the measuring line and bus of the roller frame so that the center line of the two
tubes is in the same line;
B. Make sure the flatness of the ends of the two connected pipe piles meets the
requirements through the flat mouth procedure, so as to reduce the bending degree of the
steel pipe;
C Due to the different thickness of the plate, the transition groove and the welding groove of
the thick pipe joint are made according to the specification to ensure the bending degree and
welding quality at the joint.

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The welding of butt ring seam adopts dc single (double) wire automatic submerged arc
welding, which is completed in five steps as mentioned below:
 Splicing: pre-welding of gas protection welding and outer welding back cover;
 Internal welding is divided into base and cover surface welding with two consecutive laps.
 Tube outside air gouging root;
 External welding is divided into base and cover surface welding in two consecutive laps.
 Cleaning/Grinding
9.3 Shear Ring Production
Shear rings are first made into corresponding rings of diameter equivalent to internal
diameter of 2300mm, 2000mm etc. pipe piles. Shear rings are made according to the
specifications of the same material as that of pipe pile by utilizing the tube-making process.
After shear rings are fabricated and inspected it will be welded on the marked position in the
internal diameter of the pipe pile (inside of the steel pipe) according to the approved
drawings.
First the shear rings are manually installed to the designated position, and then it will be
welded by certified welders into the pipe body by gas shielded arc welding. After the shear
rings are welded, the diagonal welds are inspected by magnetic powder detection method,
the height of welds and welding feet are measured with the welding inspection ruler, and the
distance between shear rings is also measured to align with the drawings.
In the process of shear ring welding, in order to disperse the welding stress, the operation
method of point separation assembly and multi-stage welding will be adopted to ensure that
the physical size of the pipe body, such as bending degree and ellipticity, can still meet the
requirements after a large number of welding procedures.
Picture 2-17 Shear ring fabrication Picture 2-18 Welding of shear ring
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Picture 2-19 Shear ring detection Picture 2-20 Shear ring finished
9.4 Butt joint welding process of steel pipe pile

Preparations:
The following guidelines are of importance when making a proper butt-weld:
 Establish a work space where the joining can be done whilst being protected from
adverse weather conditions.
 Check the equipment functions properly. Welding equipment used on site deserves
special attention and shall be checked by certified welder.
 The fittings and or pipe piles need to be aligned with the welding machine. Any mis-
alignment shall be within the tolerance limits.
 Clean the heating element before each jointing operation with a lint-free cloth and
suitable cleaner.
 Cut the pipe pile edges to make its surface plain and make the end square. Make sure
that once the pipe pile ends have been machined, they do not get dirty. The surface
needs to be clear of oil, grease and dirt.
 A firm hold of pipe pile shall be ensured during the jointing process.
 All dimensions shall be recorded prior to and after completion of a Butt Weld to ensure
tolerances are within specification pre-welding and post-welding.
1、Adjust the roller frame required for holding the steel pipe pile, the deviation of the side
line and the bus bar shall be ≤10mm, and the two tubes for the docking of the active roller
frame must be checked properly for alignment.
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2. Pile end bevel: shall be square and flat with a maximum deviation of less than or equal to
1.5mm. Pipe piles of the same diameter but differing wall thicknesses that are required to be
butt welded shall be transitioned with a 1:5 ratio until wall thicknesses are matched and
within specification.
3. Select the two pipe piles with the same specifications (diameter) and having a
circumferential deviation of ≤5mm to be adjusted within tolerance limits inside the roller
frame. After adjusting the pipe piles use the active roller frame to rotate the counter seam.
The spiral welding seam of the two pipe piles ends must be staggered around the
circumference by at least 1/3.
4. Pre-connect with CO2 welding torch before starting the welding., Start spot welding from
the position where there is no misalignment and smallest gap. While welding turn the pipe
pile in the direction of welding. If required, instruct the person to adjust the tube
misalignment with a jack (if needed); the person holding the CO2 torch outside welds to
adjust the section in place, and so on in order to encircle the pre-welding (using spot welding
only) (no full welding is required to ensure that the pipe can rotate normally).
5. Inner welding (i.e. DC monofilament submerged arc welding, two-pass forming, bottoming
and cover surface). For inner welding the installed welding trolley, flux, etc. will be
transported inside the tube; install the monofilament for welding the inner edges of the pipe,
adjust the level of welding wire to measure the trolley speed in synchronization with the
circumferential speed of the pipe pile to ensure that the welding wire is welded at the same
position (the welding wire moves in parallel with the pipe pile and remains at a fixed position
with respect to welding location). The conductive rod, the conductive tip, and the welding
wire are perpendicular to the pipe pile diameter in upwards direction 0.07R-0.08R (R is Tube
radius), welding wire extension 30-50mm.
6. Install the outer liner of the pipe. Welding liners generally used for butt welding of pipes.
When useing Sub Arc the round iron pan filled with flux is offset from the center and aligned
with the inner weld to prepare for the welding, and the flux pan is pressed against the outer
wall of the weld with external force; the pipe pile to be butt welded than rotates and the liner
pan rotates with it. In this process manual labor is used continuously to supplement the
backing flux and to ensure the quality of the bottom welding.
7. After the internal and external preparations for internal welding are completed, adjust the
parameters required for the bottom welding on the control box. The parameters will be set as
current 750A, voltage 42V, welding speed 19m / h, adjust the parameters to open the flux
delivery port, flux accumulation will be 30-40mm High, arc starting welding, trolley walking,
tube rotation, welding wire and infrared tracking light should be in a line. All adjustments for
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welding parameters shall be made prior to the welding to avoid welding defect. Do not stop
after the bottom welding butt joint (i.e. 1st pass) is completed, just adjust the welding
parameters, and continue with the second pass of welding (2nd pass parameters: current
700A, voltage 48V, welding speed 21m / h). After the two passes of welding are completed,
use the chipping hammer/grinder to remove undesirable parts such as slag deposition. Note:
The selection of welding parameters is adjusted according to the implementation.
8. Gouging around the outer welding , the depth of the welding plane is randomly determined
according to the quality of the inner welding, the welding root shall be clean and the welding
plane is straight. After gouging is completed, polish the root and if required,the deep part of
the gouging should be repaired manually, so that the depth of the weld is consistent.
9. Outer welding (DC single wire submerged arc welding, downhill welding, two forming,
bottoming and cover) will install the trolley, the welding wire is adjusted to 0.07R-0.08R
perpendicular to the downhill direction of the pipe diameter ( (R is the radius of the tube), the
tip is tilted forward 15 °, the welding wire is extended by 30-50mm, the welding wire and the
infrared tracking lamp are on the same line, the current is adjusted to 750A, the voltage is set
to 35V, and the welding speed is set to 17m / h. Open the flux delivery port, the flux
accumulation shall be around 30-40mm high, the first arc (bottom) welding is started. During
the welding the tube will rotate however, the trolley will not move, and the welding wire can
be adjusted at any time during the welding process, but the weld cannot be offset; otherwise,
there will be appearance of welding defects. Do not stop after the bottom welding butt joint is
completed. Just adjust the parameters and continue the second pass of welding (2nd pass
parameter: current 700A, voltage 45V welding speed 19m / h). After the two passes, use the
chipping hammer/grinder to trim the butt and remove slag deposition. Note: The parameter
selection is adjusted according to the implementation.
9.5 Welding/Installation C9 Interlocks

1) Method for welding C9 interlocks in Pipe piles
A. Determine the location of the lock. The center line of the lock must pass through the
center of the steel tube, as shown in the below figure. Before welding the lock, mark the
centerline of the lock on the surface of the steel sheet pile and the non-open side boundary
of the lock 24mm away from the centerline. The position of the green line is shown in figure 1
below.
NIGERIA
Rev. C03
Figure 9.8: An example showing the detail position of C9 Interlock on steel pipe pile
B. Recommended method for determining the location of the lock plane

The steel pipe pile must be placed horizontally and shall be checked for the alignment and
straightness and be leveled with the help of the levelling instrument every 2m~3m.
The plane position of the C9 interlock shall be determined according to the following:
(1) Determine the highest point of pipe pile point E and point F with perpendicular line and
leveler, and ensure that the circumference of EKF is equal to the circumference of EJF as
shown in the below figure.
(2) Determine the position of K and J points and ensure that K and J points bisect the
circumference of EF
(3) Adopt the same method to determine the G, H, L, M points on the other end of the pipe
pile
(4) Draw and inspect with the help of the leveler the straight line KM, JL
(5) Check and inspect whether the circumference distance QP from Q to KM, the highest
point of any pipe pile, is equal to the circumference distance QO from JL
NIGERIA
Rev. C03
Figure 9.9: Determining central position of C9 Interlock on steel pipe pile
6. As shown in above figure take K and J positions as the center points of the lock, 24mm
apart, and make the non-open side boundary of the lock.
7. Quality engineer during inspection must ensure that the non-open side of the lock must be
aligned with the boundary/marked line.
The below pictures show the welding of C9 interlocks on steel pipe pile.
Picture Installation of interlock Picture Spot welding of interlock

NIGERIA
Rev. C03
Picture Welding of C9 interlock Picture Cleaning/Grinding after welding
Figure 9.10: Installation and Welding of C9 Interlock
Figure 9.10: Inspection of C9 Interlock
9.6 Weld Quality Inspection

Qualified and experienced independent weld inspectors shall be allocated for weld quality
inspection in all aspects of inspection and Non-Destructive Testing (NDT) of welds. Weld
inspection shall be done as per the specification requirements. NDT tests shall be performed
for the entire length of welds.
i) Visual inspection
Visual examination of welds shall be in accordance with AWS D1.1. table 6.1
NIGERIA
Rev. C03
ii) Dye penetrant test (DPT)

Dye penetrant (PT) shall be performed in accordance with ASTM E165. Acceptance criteria
shall be AWS D1.1, Section 6, Part C.
iii) Magnetic particle Inspection (MPI)

Magnetic particle test (MT) shall be performed in accordance with ASTM E709. Acceptance
criteria shall be AWS D1.1, Section 6, Part C.
iv) Ultrasonic test(UT)

Ultrasonic test (UT) shall be performed in accordance with AWS D1.1 Section 6, Part F.
Repair or rework shall be subject to the same level and type of NDT as required for the
original weld.
Frequency of visual inspection is shown in the below table.
100% of all pile shoe/end plate welds (if have), pile splices (i.e. circumferential welds), skelp
joints and weld repairs shall be 100% UT tested.
Figure 9.11: Ultrasonic Inspection and Defect Repair
Note: For all the welding quality inspection ITP shall be followed for all items and all types of
welding.
NIGERIA
Rev. C03
9.7 Blasting and Automatic spraying
1） Sandblasting construction procedure
Pre- Transport qualified Surface Blasting

Construction pipes to sandblasting checking
De-rusting
shop
2) Anti-corrosion construction procedure
Surface Confirming painting

施工准备
Pre- Paint checking
treatment area
Construction
Checking
Painting paint Delivery acceptance Removal
thickness & tools
repairing
cleaning
3) Surface treatment
 All metal surfaces that need to be painted shall be treated with sand blasting. The de-
rusting grade of the metal surface shall reach Sa 2.5 level, and the surface roughness
shall reach in limits of 40 ~ 75 μm. Visual inspection test to be made after blast
cleaning shall be tested or interpreted in accordance to the representative
photographic examples as given in Note 10 of the ISO 8501-2.
NIGERIA
Rev. C03
Figure 9-12: Representative photographic examples of surface preparation grades

NIGERIA
Rev. C03
 Before de-rusting treatment, the surface shall be pretreated in accordance to the

following steps: finishing of structural surface defects → removing grease →
sand/shot blasting to remove oxide skin and rust → surface cleaning.
 Fabrication environment control shall be ensured to avoid any rust formation.
A. Ambient temperature: generally, fabrication should be carried out under the condition of 5
~ 40℃. Fabrication shall be forbidden if the temperature is too low or too high.
B. Environmental humidity: the environmental humidity during construction should be less
than 85%;
C. Dew point: In order to avoid condensation, the surface temperature of the substrate
material should be 3℃ higher than the air dew point temperature in the construction
environment to prevent condensation from affecting the quality of the coating.
Note: As environmental conditions in Nigeria is favourable for fabrication of steel pipe pile’s
blast surface cleaning, the above conditions will not cause any damage to the steel surface
of the pipe pile for coating.
Figure 9-13: Picture of steel tubular pile after outer sand/shot blasting
NIGERIA
Rev. C03
Figure 9-13: Picture of steel tubular pile after automatic paint spraying
4)Coating Elevations
 The mixture proportion of paint base material, curing agent and diluent should meet
the requirements of the product specification or paint manufacturer data sheet. After
mixing, the paint should be fully stirred and evenly mixed with a mixer. The paint
configuration should be used as needed. Epoxy paint should be constantly stirred
during its use to prevent uneven paint film quality caused by paint precipitation.
 While painting, pour most paint materials in the bucket into another bucket first, stir
the remaining pigment precipitation in the bucket fully with the mechanical stirring
device, and then mix the two parts together fully, so as to make the color consistent.
 Paint shall be mixed or prepared depending upon the requirement. At one time only
one paint box shall be used. Also calculate the amount of surface area to be coated
with paint and then mix only the required amount of paint. Paint mixing time shall
follow the data sheet of the manufacturer or mixing time shall be less than 2 hours
before use.
 The coated steel pipe pile can only be put into use after curing and maintenance for a
period of time (7 ~ 14 days for natural drying). Normally 7 days is recommended in
the data sheet. Data sheet shall be followed for exact number of curing days.
 Coating system for steel piles shall follow the below table in accordance to the
specification. Coating system for C5 environment for sea application shall be used.
Hempel and Carboline are well known coating system used for C5 category.
NIGERIA
Rev. C03
9.8 Final Inspection and Product Identification

For final inspection, all dimensional tolerance shall be checked in accordance to
specification. The tolerance table is given below.
 External dimension recheck

Steel tube: use tape and leveller to measure and recheck all dimensions of steel tube;
NIGERIA
Rev. C03
Figure 9-14: Picture of steel pipe pile for inspection
 Anticorrosion: Use paint thickness measurement gauge to check and test the outside
anticorrosion coating of steel pipe pile with multi-point thickness and binding force.
Also check by visual inspection
 Product identification mark and storage:

The steel pipe pile that passes the final inspection shall be sprayed according to the
standard, including manufacturer name, production date, factory number, steel pipe
specification etc.
The storage site shall be leveled and made ready for the storage of steel pipe piles.
Pipe piles should be stored no more than 3 layers, and stone powder bag or sand bag
shall be used as fulcrum and evenly laid to achieve soft landing between the steel
pipe pile and the landing site, so as to reduce the damage of anti-corrosion coating
and prevent the deformation of steel pipe pile due to uneven stress in stacking. Steel
pipe piles must be separated with sleepers or coarse hemp rope to prevent the
corrosion coating damage in storage.
Figure 9-15: Picture of steel pipe pile with marking and storage
9.9 Hoisting and Delivery

 2-point hoisting shall be used throughout the hoisting process. When hoisting, cloth
should be wound on the wire rope to prevent damage to the coating. If there is any
damage to the coating, use epoxy liquid paint to repair the damage manually.
NIGERIA
Rev. C03
 2 set of 40T gantry cranes are used for transportation in the factory, which will be
used to lift and place the pipe pile on the trailer trucks/transporting girder gently. Steel
pipe pile shall be tied using nylon slings to the ends of trailer trucks/transporting
girder vehicle and shall be handled firmly to avoid any damage. After loading the pipe
piles will be transported to the storage yard or piling area.
Figure 9-16: Picture of steel pipe pile loading and transportation
10. Quality Control

10.1 Overall Quality Control Measures
Instruments or equipment should be calibrated by a third party before application. Such as the
measuring instrument is checked once a year Different types of pipe pile prior to production of
equipment for testing.
1) QC personnel track checking records to ensure that the instruments are under normal
condition.
2) Technical supervisor should hold a technical clarification meeting before construction
works entrance to site and supply them skill guidance.
3) Construction works should comply with the approved drawings/specification. steel tubular
piles shall be rolled/formed to the following tolerance requirements in accordance to the
specification
NIGERIA
Rev. C03
NIGERIA
Rev. C03
NIGERIA
Rev. C03
11. Health, Safety, Security and Environment

11.1 General
CHELE is committed to a safe and healthy work environment in line with our HSE policy,
plan & manual. We will endeavourer to ensure approved HSE procedures for the projects are
complied with throughout the construction process. In this regard Risk Assessments/Job
Hazard Analysis (RA/ JHA’s) will be conducted at all new or complex activity. The HSSE
Department in conjunction with the work supervisors, foremen and workers who carry out the
work shall conduct a thorough risk assessment / job hazard analysis to identify the
hazards/risk associated with the job, identify which workers or group of workers are
particularly at risk, evaluate the risk and develop controls.
The Risk and Control measure identified in the attach RA will be strictly implemented in
conjunction with relevant requirements of the Project HSE plan and other associated project
HSE requirements.
11. 2 Reference
Regarding to following content which included but not limited please refer to approved HSE
plan:
1) HSE Meeting and Communication
2) Training Requirements
3) Personal Protective Equipment
4) Tools and Equipment Inspection and Maintenance Reports.
5) Safe Use of Electricity
6) Traffic Safety
7) Security Management record on RA
8) Fire Protection
9) Emergency Preparedness and Response
10) Incident/Accident Reporting
11) Incident/Accident Investigation
12) Community Communication
NIGERIA
Rev. C03
12. Appendix
Appendix A - Risk Assessment
Review and approval record of the present document
Project Name LEEKI DEEP SEA PORT PROJECT
THE LAGOS FREE TRADE ZONE AT IBEJU LEKKI, LAGOS STATE,

Project Location
FEDERAL REPUBLIC OF NIGERIA
CHELE
Contractor
(CHINA HARBOUR ENGINEERING LFTZ ENTERPRISE)
Client LEKKI PORT LFTZ ENTERPRISE LIMITED
Consultants LOUIS BERGER GROUP, INC.
Ref. No Risk Asst. 00
Action Name Function Signature Date
Approved by Li Wei HSSE Director 14. June. 2020
Reviewed by Kevin Shuai HSE Manager 14. June. 2020
HSSE Manager (Quay

Reviewed by Liu Jianwei 14. June. 2020
Team)
Prepared by Chen Jaiyu HSSE Supervisor 14. June. 2020
Revision status
Rev. Date
Description
Draft issued for review
STEEL PIPE PILE FABRICATION 14/06/2020

EP SEA PORT PROJECT, NIGERIA
NIGERIA
Rev. C03
AFETY AND ENVIRONMENT RISK ASSESSMENT
ssification [severity s] Likelihood of occurrence [probability p] Risk Rating Level [RRL]

1 - Extremely unlikely. L-Low 1-8
njury 2 - Very unlikely. M- Medium 9-15
njury. 3 - Unlikely. H-High 18-25
njury/death. 4 - Likely.
e deaths. 5 -Very likely.
ns
R:Risk
y RRL: Risk Rating Level
Person Accountable
al Conversation Meeting
ng Authority
Leakage Circuit Breaker
ion Board
d Effect
COMMENTS:
e conducted prior to job start.
E’s are mandatory for all workers.
ping of the area will be carried out on basis.
r full time will be available.
vehicle/Ambulance will be available at site to rescue the victim.
Risk Precaution/ Action to be taken R
Evaluation R
Task Hazard Hazard Controls
Effect
S P R/L Additional Control Man-power
Measure (Describe
action)

PORT PROJECT
Steel Pile Pipe Fabrication Activities FABRICATION
NIGERIA
Toolbox talk meetingRev. C03
1.
Manual Personnel 8 3 24/H Continuous monitoring SPA: 1. Welding
Preparation and
selection of Issued By Injury. CHELE
handling. Issued Date 25 May.2020
conducted by supervisor. Page
of activities. 43 / 53
Supervisor.
materials, tools Untrained Skilled Personnel. 2. Safety
and workers for personnel. Use of standard manual Supervisor
the fabrication Adhere to Equipment
Burns. handling technique.
and welding of Pinch-point. Handling procedure.
steel tubular Work area must be
Improper
pipe pile demarcated to prevent
supervision.
Fatality. unauthorized entry.
Ensure to barricade
Physical injury. Operative must be suitably
the area with signage
Fire. trained for the task.
and barricade tape.
Dehydration Permit to work duly Signed
and present at job site.
Portable Fire Extinguisher

available at work location
Trained First Aider Available

with First Aid kit.
Ensure sufficient drinkable

water is available. Drink at
least one glass of water every
one hour.
Emergency team including

Ambulance & On-site clinic
must be readily available for
any emergency.
Safety Officer must also be on

ground to monitor the
operations.
Provide all necessary PPE for

the workers (safety shoes,
coverall, helmet, reflective
vest, fire blanket, Hand gloves,
safety glasses, earmuff, and
Nose Mask.
2. Steel Coil Poor visibility Injuries to 7 3 21/H The object of area lighting by Conduct GCM with all SPA: 1.
Feeding, Milling arising from Workers using tower lights will be employees. Supervisor.
and Forming low light produced for an overall level 2. HSE
Unconsciousne
process conditions. of illumination sufficient for Supervisor
ss
workers and equipment to Adequate
Slips and trips
Electric Shock move around in safely and to preventative
Risk of Fatigue.
inspection and
Poor Falls carry out work activities
maintenance to be
concentration without any risk.
Caught–in by carried out on all
Machine Only Trained workers shall be Electrical Equipment
malfunctioning moving
engaged. such as ELCB, DB.
Pinch Points Equipment
Exposed parts Inspection of work locations.
Electrical
Inspection of all electrical Ensure checklist of
components
due to defects components prior to start of specified Electrical
work. DB, Generator.
Complacency.

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LEKKI DEEP SEA LDSPP-CHELE-

MS FOR STEEL PIPE PILE Document No. MW-MS-009(C03)

Method Statement for Steel Pipe Pile Fabrication

CHINA HARBOUR ENGINEERING

Name Title Date Signature

Prepared By Nikhil Agarwal Deputy Technical Manager 25/05/2020

Lan Jinping Technical Manager 25/05/2020

Hong Xiaoliang Deputy Manager 25/05/2020

Approved By Tang Minggang Project Manager 25/05/2020

Method Statement for Steel Pipe Pile Fabrication Ref.No: LDSPP-CHELE-LB-LS-0683(C03)

No. section page Comment(LDSPP-CHELE-LB-LS-0683) Response(CHELE)

This is submittal number, not document

Why is this org chart shown? It is not

1. whilst being protected from adverse

To say that the HSSE plan will be

The Risk Assessment must be done on the

9.4 Butt joint welding process of steel pipe pile..............................................................24

1 1000 14 X52 40 See table in Section 3.

2 2300 23/20 X70 89 29+12=41

3 2000 23/19 X70 136 27.5+12=39.5

4 1400 18 X60 220 16.50

5 1200 16 X52 187 39.50

Figure 1a: Elevation View of Tug berth (Pile diameter 1000mm)

The scope of work consists of the following:

（2）API RP 2A WSD Recommended Practice for Planning, Designing and Constructing

5. Organization & Responsibility

Figure 3: Organization Chart of Project

5.2.3 Construction Manager

5.2.5 HSE Manager

5.2.6 Site Engineer

5.2.7 Quality Control Engineer

5.2.8 HSE Officer

5.2.9 Site Supervisor

No. Description Specification Quantity

Uncoiling and Feeding

3 Tube Forming Machine 1

5 Plasma Cutting Machine PC50 2

6 Submerged Arc Welding 5

8 Gas shielded welding 4

9 Gantry Crane for Hoisting 3

14 Dry film thickness gauge 1

Table 2: List of Material

No. Description Quantity

8. Construction Flow Chart

Steel Coil Feeding

Cutting & End Facing

Weld Clutches/Internal Shear rings/Drill Holes etc

Inspection & Delivery for Installation

Figure 8.1: Construction flow chart for Pile Fabrication

9. Fabrication Methodology for Steel Pipe Pile

9.1 Production process spiral steel tube

 Uncoiling, plate feeding and leveling

Picture 2-1 Uncoiling Picture 2-2 hanging steel coils

Picture 2-3 plate feeding Picture 2-4 leveling

Figure 9.1: Step 1 for fabrication of steel pipe pile

Picture 2-5 edge milling

Figure 9.2: Step 2 for fabrication of steel pipe pile