SSAB’s European pile projects

SSAB’s European pile projectsPiet van Breukelen, SSAB

Content

• SSAB globally and locally

• Fundamental differences of pile projects and deliveries outside Nordics

• SSAB’s pipe production, value adding and services possibilities for demanding global customer needs

• Case examples of SSAB’s global pile projects

• Summary

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SSAB production sitesSales coverage

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Strong globally and locallyMore than 50 countries of sales coverage

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Fundamental differences of projects and deliveries outside NordicsExtremely fast installation required at the job site with improved quality and safety

Predefined exact pile lengths established by soil investigationInstallation in full lengths mainly by using vibros and sometimes impact driving in the final stagePiles and deliveries including value adding are requested to be delivered as “ready-to-be-installed”

Splice welding at the job site is generally always avoidedUp to 50 m long piles are delivered/installed in one pieceAll necessary value-adding (interlocks, consoles, shear rings, etc.) are made at the workshop

Rock shoe or bottom plate as a structure is unknownPiles are installed as open-ended to predefined depthSometimes reinforcement rings are used to protect the pile toe if the soils are very dense and/or the wall thickness of the pile is thin

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Fundamental differences of projects and deliveries outside NordicsOther differences

Requested pile diameters are largerD 1220 mm are more and more used due to increased draught requirement at the sites

Higher steel grades instead of standard S355J2HX70 steel grade has been widely used and nowadays even more savings can be received with the more and more popular S550J2H grade

No end bearing pilesCoating as a corrosion protection method is used frequentlyQuality expectations may be stricter than in the Nordics

Wall thicknesses specified up to 2 decimalsStricter tolerances as required in EN standards are sometime neededMill inspections made by the owner and/or contractor3.2 mill inspection certificate

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SSAB’s manufacturing from steel to pilesFull control and responsibility from steel production and rolling, to roll forming and welding to pile pipes

All tubes are manufactured using own steelSteel properties and composition are designed specially for tube manufacturing and end user needsFull quality control and traceability through own production chain

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SSAB’s tube production for piling

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Oulainen

Pulkkila

Lappohja

Spirally welded (SAW) steel pipes: 2 lines + 1 PE coating line• 406.4 D 1220.0 mm and t 23.0 mm • Lmax= 40 m without a splice weld• Lmax= 55 m with a splice weld• (>30 kton/a)

Longitudinally welded (HFW) steel pipes: 6 lines• 76.1 mm D 168.3 mm and 3 t 6.3 mm• Lmax=12 m • (100 kton/a)

Longitudinally welded (HFW) steel pipes: 1 line• 114.3 mm D 323.9 mm and 3 t 12.5 mm • Lmax=16 m • (130 kton/a)

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Longitudinally welded (MAG/SAW) steel pipes: 2 machines• 273 D 2000.0 mm and 6 t 100.0 mm • Lmax= 14 m without a splice weld• Lmax= 50 m with a splice weld• (>30 kton/a)

Presteel

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Value adding and servicesManufacturing of RR piles and RD piles at Hämeenlinna pile factory:

Manufacturing lines for RR piles (RR75-RR220/12.5)Manufacturing line for RD piles (RD90-RD220/12.5)

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Value adding and servicesVersatile value-adding and outfitting of piles(406.4 D 1220.0 mm)according to the requirements of EN1090 at Oulainen pile factory:

Rock shoesShear ringsInterlocksetc.

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Value adding and servicesOutstanding flexibility and service ability of value-adding and outfitting through extensive sub-contracting network in Finland and abroad

Manufacturing of accessoriesCuttingBevellingCoatingInterlock weldingetc.

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Value adding and servicesEfficient and cost effective logistical services

Truck deliveries straight from the factoriesVessels from Raahe, Turku & Hanko:

Hull (UK), Szczecin (POL), Pasajes (ESP), Ravenna (ITA), Antwerp (BEL), Halmstad(SWE) and Vejle (DEN)

Vessels to case-specific ports for direct project deliveries

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Case examples of SSAB’s global pile projectsNETHERLANDS

BAVO KademurenVSF/Jetties 1 & 2 BP RotterdamBAM Neste Oil Jetty Rotterdam

ESTONIA Vanasadama Cruise Quay Tallinn

NORWAYE18 Bommestad - Sky, Larvik tunnelE18 Bommestad - Sky, Farris bridge

SWEDENAkademiska sjukhuset, Uppsala

RUSSIAUst-Luga

NEW ZEALANDWaitaki Power Station

New Zealand

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Combi wall / BAVO Kademuren, Netherlands Fast and reliable deliveries over a longer period of time

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Combi wall / BAVO Kademuren, NetherlandsFast and reliable deliveries over a longer period of time

OUR SOLUTION

SSAB’s delivery of the primary piles provided with factory-welded interlocks for the combi walls in exact lengths. Solutionfor combi walls based on a high-strength steel grade S550J2Hincluding welded interlocks. Overall project costs were cut byreducing the total amount of steel used. Savings were totally385 ton.

CUSTOMER CASE

The industrial area in the Rotterdam harbor had to be expanded. For this a new area was reclaimed from the sea and new harbors and customer specific quay walls had to be build.

"We chose SSAB as supplier for the steel piles because it supplies good value for money and for the additional services it can provide" H. Dries, project manager of the BAVO Kademuren Maasvlakte 2 project.

Delivery (2010-2011):• ø 1.220 x 13.00 mm, S550J2H, 2126 ton (savings 14.20 mm 180 ton)• ø 1.220 x 17.60 mm, S550J2H, 125 ton (savings 20.00 mm 15 ton)• ø 1.220 x 14.20 mm, S550J2H, 1842 ton (savings 190 ton)• ø 1.620 x 20.00-24.00 mm, X-70, 550 ton • ø 1.016 x 12.50 mm, X-70, 295 ton• E21 interlocks 12,8 km and coating 674 m²

Co-operation partners:• Client: Maasvlakte 2 land reclamation project• Investor: Gemeentelijk Havenbedrijf Rotterdam • Main contractor: BAVO Kademuren (BAM and Volkerwessels)• Designer: BAM Infraconsult

Contact: [email protected]

Dolphin piles / VSF Jetties 1 & 2 BP Rotterdam, Netherlands Renovation fenders Jetties 1 & 2

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Dolphin piles / VSF Jetties 1 & 2 BP Rotterdam, Netherlands Renovation fenders Jetties 1 & 2

OUR SOLUTION

SSAB's supplied the ready to be installed Dolphins just in timeon site. Dolphins has been re-designed in higher steel grade(Optim 500ML) and has been supplied including coating. Alsoloose pile heads have been supplied for further processing bythe customer.

CUSTOMER CASEThe existing jetties 1 & 2 need to be renovated to suit futurevessel sizes. The work is executed in different phases and startswith demolishing the existing jetties. Each phase needs to beexecuted within only 3 weeks. As part of phase 1 two newdolphins need to be installed.

Absolutely essential is that the dolphins are supplied as agreed since heavy and expensive equipment has been scheduled according to the planning.

“We selected SSAB as the preferred supplier because they were able to delivery the dolphins within the requested time frame and budget” Arjan Joling, project manager Volker Staal en Funderingen b.v.

Delivery (2010):• 2 pcs. ø 2800,0 x 24.00 mm, S355J2H, L = 3700 mm• 2 pcs ø 2800.0 x 30.00/40.00/60.00/40.00/24.00 mm, Optim 500ML,

L = 44600 mm, weight 125553 kg• Coating 25 100 mm

Co-operation partners:• Client: BP Raffinaderij Rotterdam B.V.• Main contractor: Volker Staal en Funderingen b.v.


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Large diameter piles / BAM Neste Oil Jetty Rotterdam, NetherlandsExtremely long piles fast and reliably

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Large diameter piles / BAM Neste Oil Jetty Rotterdam, NetherlandsExtremely long piles fast and reliably

OUR SOLUTION

SSAB's supplied extremely long piles including coating fast andreliable

SSAB’s delivery includes all together 1,4 km large diameter steelpiles.

Coating system:

Shot blasted as per Sa 2½ 1 layer Sigmacover primer , 75 µm (grey) 1 layer Sigmacover DTM coating 150 µm (light grey) 1 layer Sigmacover DTM coating , 150 µm (black RAL 9017

CUSTOMER CASENeste Oil built a renewable diesel plant in Rotterdamcompleted in 2011.

The challenge for the customer was to find a partner with theability to deliver extremely long piles up to 46 meter longaccording to customer’s needs fast and reliably.

Delivery (2010-2011):• RR660/12,8, S355J2H, L=15.3…45.3 m (156 ton) incl. coating 6.3…22.9

m (40…70%)• RR914/16,4, S355J2H, L=33.7…45.9 m (229 ton) incl. coating 22.9 m

(50…70%)

Co-operation partners:• Investor: Neste Oil• Main contractor: Technip Italy• Sub contractor: BAM Infra Zuidwest


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Vanasadama Cruise Quay in Tallinn, EstoniaUp to 46 m long steel pipe piles of two different wall thicknesses

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Vanasadama Cruise Quay in Tallinn, EstoniaUp to 46 m long steel pipe piles of two different wall thicknesses

OUR SOLUTION

SSAB was able to produce and deliver special designed pilesquickly and just in time taking into account any changes withthe specification and time of delivery during the project.

Piles were delivered up to 46 m long and of two different wallthicknesses: 12.5mm lower part and 16.00mm upper part. Allpiles were fitted with an extra inside ring to increase pilebearing capacity. As it is a jetty type quay, delivery also includedhorizontal pipes.

CUSTOMER CASETallinn is among the most popular destination for the cruiseindustry. To be able to handle the increasing number of cruisevessels the Vanasadama Cruise area had to be expanded and anew Cruise Quay had to be build.

The biggest challenge was to install very long 46 m inclinedpiles, 3:1, in one piece and within a very short time frame inopen sea conditions.

“We chose SSAB to supply the steel piles because it provides good value, fast and flexible delivery, and because of its range of additional services” Rauno Kõiv, BMGS, Project manager

Delivery (2013):• 1016 x 12.50mm (S355J2H), 817 ton • 1016 x 16.00mm (S355J2H), 971 ton• 1220 x 12.50mm (S355J2H), 437 ton• 1220 x 16.00mm (S355J2H), 608 ton

Co-operation partners:• Client/Main contractor: BMGS Estonia branch • Investor: Port of Tallinn • Designer: Corson OÜ


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RD Pile wall / E18 Bommestad - Sky, Larvik tunnel, NorwayPreparing safe, stiff and watertight retaining walls for new tunnel

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RD pile wall / E18 Bommestad - Sky, Larvik tunnel, Norway Preparing safe, stiff and watertight retaining walls for new tunnel

OUR SOLUTION

SSAB's high strength steel RDs320/10 pilewalls were installed tosecure 2 stiff and watertight parallell constructions through clayand moraine. Traffic could continue safely next to the site, andthe soil could be excavated between the 2 walls.

CUSTOMER CASEStatens vegvesen is building 7 km new E18 in Larvik, next toboth existing highway and the vulnerable Lake Farris. One of thetwo tunnels in the project, Larvik tunnel, consist of 2800 mtunnel in rock and 310 m tunnel in soil.

The challenge was to find a secure and reliable way to excavatethe 310 m pit for tunnel in soil, without interfering with trafficor the lake. The soil being very complex with both soft clay anddense moraine, it was hard to solve this with only sheetpiles asretaining walls for the excavation.

Drilling of RDs320/10 with RM/RF interlocks, sealed withbituminous sealant, was done to required depths to secure stiffand watertight retaining walls, before excavation.

Delivery (2014-2015):• 9600 m RDs320/10 incl. RM/RF-interlocks• 5000 m RDs320/10• 5800 m RDs220/12.5 with threaded sleeves• 953 ton PU32 and 125 ton GU16N

Co-operation partners:• Project owner: Statens vegvesen• Main contractor: Skanska Norge AS• Piling contractor: Entreprenørservice AS• Geotechnical designer: Rambøll Norge AS


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RD pile wall / E18 Bommestad – Sky, Farris bridge, NorwayDeep foundations in moraine close to highway and Lake Farris

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RD pile wall / E18 Bommestad - Sky, Farris bridge, Norway Deep foundations in moraine and close to highway and Lake Farris

OUR SOLUTION

SSAB's RD-pilewalls, in combination with sheet piles, was thebest way to make “boxes” for 8 of the 10 foundations, close tothe highway and in coarse and dense soil.

CUSTOMER CASEStatens vegvesen is building 7 km new E18 in Larvik, next toboth existing highway and the vulnerable Lake Farris. The newFarris Bridge is a separate contract with all its complexity. Thebridge is 570 m long and 28 m wide, consisting of 10foundations.

The challenges consist of different aspects: the vicinity toexisting highway and Lake Farris, and the depths to bedrock (20-80 m) in combination with the varying soil conditions.

SSAB’s customer made 8 “boxes” (see picture) with differentcombinations of RD-pilewalls and sheet piles depending on soilconditions. Within each “box” RR-piles and drilled piles wereinstalled to take the future loads of the new bridge.

Delivery (2014-2015):• 4500 m RD400/8 incl. RM/RF-interlocks• 1800 m RR900/20 incl. 94 pcs. rockshoes• 3200 m RD300/6.3 casings• 128 ton GU21N and 602 ton AZ18

Co-operation partners:• Project owner: Statens vegvesen• Main contractor: Bilfinger• Piling contractors: Kynningsrud Fundamentering AS and Hallingdal

Bergboring AS


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RR-piles / Akademiska Sjukhuset UppsalaRestrictions due to water catchment area and demanding deliveries

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RR-piles / Akademiska Sjukhuset Uppsala Restrictions due to water catchment area and demanding deliveries

OUR SOLUTION

SSAB’s extensive delivery included 34 km of RR220/10 pileelements. SSAB answered the demand from it’s customerHercules Grundläggning AB; supplying large amount of piles andaccessories quickly by using special flat trucks.

CUSTOMER CASEThe project is included in investment for the University Hospitalthat will double the base by 50% in 7 years. Land contract wasone of the largest in modern times in the county.

The challenge for the customer was that the project was inUppsala water catchment area which led to restrictions onequipment and materials.

Limited space and high production rate meant many machineunits that occasionally prevented the other. This also put greatdemands on the exact material supplies.

The project expanded by about 40% when the average lengthwas 17 m instead of the tendered 12 m.

Client’s demand included dimensioning of piles to manage loadcapacity of 1550 kN and dimensioning of sheet piles forexcavation depths between 5-14 m. Sheet piles were deliveredby Thyssenkrupp Bautechnik, total area of approximately 4 000m².

Delivery (2015-2016):• SSAB’s delivery content RR220/10 L=12 m pile elements approx.

34 000 m for approx. 2200 piles including rock shoes and bearing plates. Average pile length 17 m.

Co-operation partners:• End customer: Akademiska Hus (County Council of Uppsala)• General contractor land: SH-Bygg• Foundations contractor: Hercules Grundläggning AB


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Break water in Ust-Luga, RussiaPile/pile wall with special interlocks and inclined piles

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Break water in Ust-Luga, RussiaPile/pile wall with special interlocks and inclined piles

OUR SOLUTION

SSAB's pile/pile wall with special interlocks and inclined pileswas a reliable solution in terms of availability and schedule.

All piles for each stage have been loaded in dedicated vesselsfor delivery straight into Ust-Luga.

CUSTOMER CASEThe harbor in Ust-Luga need to be protected from the sea.

The break water will be completed in stages between 2013 and2017.

The challenge for the customer was to build a break water in ashort period of time due to challenging ice conditions.

“We have chosen SSAB because of the convenient location of the pipe production and short delivery time” Tatjana Detzel, TKBT

DELIVERY (2014-2015):• SSAB pile / pile wall and inclined piles• 560 LPB 180 interlocked piles ø 1020 x 12,00 mm, 12 880 m in total• 520 ø 1220 x 12,00 mm, 12 040 m in total

Co-operation partners:• Client: ThyssenKrupp Bautechnik GmbH• Main contractor:• Developer: Rosmorport• Piling subcontracting:• Design:


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RD® pile wall / Waitaki Power Station, New ZealandInstallation in restricted area with light equipment

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RD® pile wall / Waitaki Power Station, New ZealandInstallation in restricted area with light equipment

OUR SOLUTION

RD® pile wall system was installed with relatively small and lightequipment. Also installation involved less drilling work thaninitial solution with secant piles (no soft piles to drill out).

SSAB delivered complete retaining wall structures includingsteel pipe piles with welded interlocks

CUSTOMER CASEOld sluice pier of Waitaki Power Station had been undermined.This pier separates the sluice water drawn from the dam andthe turbine tailrace. The access to the pier is very restricted andconfined causing challenges regarding the installation withheavy equipment.

Delivery (2014-2015):• RD320/8 with RM/RF interlocks L= 15 m, in total 1 000 m

Co-operation partners:• Designer and general contractor: McConnell Constructors Ltd


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Summary

SSAB can supply piles to all destination in the world by utilizing:

full potential of own steel production including high steel gradesown pipe production including tailor-made dimensionsown value adding networkpiles in full lengths ready-to-be-installedefficient and cost effective logistical routes

Proven track record of successful deliveries and projects

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Any questions?

Documents

SSAB’s European pile projects