No.

Dokumen : JKR 20800-0226-20

SECTION C: FOUNDATION No. Keluaran : 01
WORKS AND WORKS BELOW No. Pindaan : 00
LOWEST FLOOR LEVEL Tarikh : 02 Januari 2020
JKR MALAYSIA Muka Surat : C/20

5.6.2.2. Matching of Pile Lengths

Longitudinal seam welds and spiral seam welds of lengths of pipe

piles forming a completed pile shall, whenever possible, be
evenly staggered. However, if in order to obtain a satisfactory
match of the ends of piles or the specified straightness, where the
longitudinal seams or spiral seams are brought closely to one (1)
alignment at the joint, then they shall be staggered by at least
100mm.

5.6.2.3. Straightness of Piles

The deviation of pile from straightness shall be within the

compliance provisions of BS EN 10034 and in accordance with
sub-section 5.5.2.3..

5.6.2.4. Fabrication of Piles on Site

When pile lengths are to be made up on Site, all test procedures

and dimensional tolerances shall conform to the Specification for
the supply of pipe materials. Adequate facilities shall be provided
for supporting and aligning the lengths of pile.

5.6.2.5. Handling and Storage

All piles within a stack shall be in groups of the same length and
on approved supports. All operations such as handling,
transporting and pitching of piles shall be carried out in a manner
such that no damage occurs to piles and their coatings. Piles that
are damaged during handling and transporting shall be replaced
by the Contractor at his own expense. All damaged and rejected
piles shall be removed from the Site forthwith.

5.6.2.6. Marking of Piles

Each pile shall be clearly marked with white undeletable marking

near the pile head showing its reference number and overall
length. In addition, for pile installation monitoring purposes, each
pile shall be marked at intervals of 300mm along its length before
being driven.

5.6.3. Workmanship

5.6.3.1. Welding Procedures

(i) The Contractor shall submit for approval, full details of the
welding procedures and electrodes with Drawings and
schedules as may be necessary. Tests shall be undertaken
as may be required by the S.O. and shall be in accordance
with the requirements of BS EN 288

(ii) All welding procedures shall have been qualified to BS EN

ISO 15607, BS EN ISO 15609-1, BS EN ISO 15613 and BS
EN ISO 15614-1 and the Contractor shall make available full
details of the welding procedures and electrodes, with
Drawings and schedules as may be necessary. Tests shall
be undertaken as may be required by the S.O..

© COPYRIGHT JKR MALAYSIA

 No. Dokumen : JKR 20800-0226-20
SECTION C: FOUNDATION No. Keluaran : 01
WORKS AND WORKS BELOW No. Pindaan : 00
LOWEST FLOOR LEVEL Tarikh : 02 Januari 2020
JKR MALAYSIA Muka Surat : C/21

5.6.3.2. Weld Tests

(i) During production of welded tube piles, at least one (1)

radiograph or ultrasonic test approximately 300mm long
shall be required on each end of a length as a spot check on
weld quality. This shall be taken on a circumferential or
longitudinal weld and its position shall be as directed by the
S.O..

(ii) For spirally welded piles, one (1) of the following tests shall
be carried out:

a) For tubes of wall thickness 12mm or less, three (3) spot

check radiographs, one (1) at each end of each length of
the tube as manufactured and one (1) at a position to be
chosen at the time of testing by the S.O. and spot check
radiographs as required by the S.O. on the weld joints
between strip lengths;

b) For tubes of any wall thickness, continuous ultra-sonic

examination over the whole weld, supplemented where
necessary by radiographs to investigate defects
revealed by the ultrasonic examination.

Weld tests shall be performed by radiographic or

ultrasonic methods as specified. Provided that
satisfactory results are being obtained, one (1) test of a
length of 300mm shall be made for 10% or more of the
number of welded splices in the case where the load will
be carried by the wall or section of the pile will not
normally exceed 10%. Results shall be made available
to the S.O. within ten (10) days of completion of the
tests.

5.6.3.3. Standards for Welds

(i) Longitudinal Welds in Tubular Piles

For piles of longitudinal or spiral weld manufactured where

the load will be carried by the wall of the pile, and if the pile
will be subject to loads which induce reversal of stress
during or after construction other than driving stresses, the
standard for interpretation of non-destructive testing shall be
the American Petroleum Institute Specification 5L. The
maximum permissible height of weld reinforcement shall not
exceed 3.2mm for wall thicknesses not exceeding 12.7mm
and 4.8mm for wall thicknesses greater than 12.7mm.

(ii) Circumferential Welds

a) For circumferential welds in tubular piles the same

maximum height of weld reinforcement as specified
above for longitudinal welds in tubular piles shall apply,
the standard for interpretation of non-destructive testing
shall be the American Petroleum Institute Specification
5L.

b) If the results of any weld test do not conform to the

specified requirements, two (2) additional specimens

© COPYRIGHT JKR MALAYSIA

 No. Dokumen : JKR 20800-0226-20
SECTION C: FOUNDATION No. Keluaran : 01
WORKS AND WORKS BELOW No. Pindaan : 00
LOWEST FLOOR LEVEL Tarikh : 02 Januari 2020
JKR MALAYSIA Muka Surat : C/22

from the same length of pile shall be tested. In the case

of failure of one (1) or both of these additional tests, the
length of pile covered by the test shall be rejected.

5.6.4. Protective Coatings

protective coatings are specified, the preparation of surfaces and the

application of the coatings shall be carried out by skilled labour having
experience in the preparation of the coatings specified.

Corrosion protection of permanent steel structure in accordance with

environment classified as C4 according to BS EN ISO 12944-2 shall require
durability resistance of 25 years.

The protective coating system shall comply with BS EN ISO 12944-5 and
shall comprise of at least:

5.6.4.1. First Coating or Prime Coat Zinc Epoxy 0.08mm thick

5.6.4.2. Two (2) layers of Intermediate coating 0.08mm thick epoxy for
each layer

5.6.4.3. Top coating of Polyurethane 0.08mm thick

5.6.4.4. Surface Preparation

(i) All surfaces to be coated shall be clean and dry

(ii) Surface preparation to cleanliness SA 2 ½ in accordance

with BS EN ISO 12944-4 and BS EN ISO 8501-1.

(iii) Blast-cleaning shall be done after fabrication. Unless an

instantaneous-recovery blasting machine is used, the
cleaned steel surface shall be air-blasted with clean dry air
and vacuum-cleaned or otherwise freed from abrasive
residues and dust immediately after cleaning.

5.6.4.5. Application and Type of Primer

(i) Immediately after surface preparation, the surface shall be

coated with an approved primer or the specified coating to
avoid recontamination. No primer coat shall be applied to a
metal surface which is not thoroughly dry. Within 4 hours
after surface preparation, before visible deterioration takes
place, the surface shall be coated with an appropriate primer
or the specified coating.

(ii) The primer shall be compatible with the specified coating

and shall be such that if subsequent welding or cutting is to
be carried out it shall not emit noxious fumes or be
detrimental to the welding.

5.6.4.6. Control of Humidity during Coating

(i) No coating shall be applied when the surface metal

temperature is less than 3°C above the dew point
temperature or when the humidity could have an adverse
effect on the coat.
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