B.5 Special corner piles
B.5.1 General
Figure B.4 shows examples of the construction of special corner piles by welding a prefabricated connector to the sheet pile.
Legend
- α angle of ± 90°
- β angle of 90° to 135°
- a prefabricated connector
- b special corner pile (single or double)
- D weld
B.5.2 Type of welding
Weld D : intermittent weld with an effective weld thickness aeff of 5 to 6 mm. Total length of the intermittent weld being 30 % of the sheet pile length meaning three welds of 100 mm each per metre of sheet pile.
When there exists a possibility of serious corrosion, a continuous sealing weld may be necessary between the intermittent welds.
B.5.3 Assembly and welding procedure for the corner pile
- assemble the prefabricated connector and the sheet pile on horizontal supports. Generally the corner sections do not extend to the top of the special pile in order to allow for driving with a cap or clamps;
- position the connector at the appropriate angle (possible angles are 90º or from 90° to 135°);
- tack weld over the whole length;
- apply the final welds according to the procedure described for the junction pile.
B.5.4 Welding filler metals
As for junction piles (according to B.4.4).
B.6 Straight web junction piles
B.6.1 General
Fabrication of straight web junction piles is carried out by welding, special connectors or by bolting. Figures B.5 and B.6 show examples of the fabrication by welding and special connectors.
Legend
P1, P2 welds a sheet pile offcut
B.6.2 Type of welding for straight web junction piles
The weld is continuous with an effective weld thickness as shown in figure B.5.
B.6.3 Assembly and welding procedure for the straight web junction pile
The working procedure is as follows (see figure B.5):
- prepare and straighten either one or the three sheet pile offcut(s). Generally the width of the offcut(s) is half the width of a complete sheet pile;
- when necessary chamfer the offcut(s);
- assemble the offcut(s) and a complete sheet pile or the round bar on horizontal supports. The connecting angle a normally is 35° to 45°, the angle γ, 120°;
- tack weld the offcut(s) over the whole length of the complete sheet pile or the round bar;
- weld P1 : first weld at both ends, then in the centre of the junction pile length (over a length of about 1 000 mm).Then start the intermediate weld P1 at the centre and move by the back step method towards the ends of the junction pile (length of each pass about 1 000 mm);
- first weld P2: weld each offcut over the whole length at one side and then over the whole length at the opposite site;
- if the junction pile deforms during welding, straighten it with a torch or a press.
B.6.4 Welding filler materials
According to B.4.4 (junction piles).
B.7 Box piles
B.7.1 General
Figure B.8 shows an example of a box pile made out of two U-type sheet piles.
B.7.2 Type of welding
Weld 'C' : external continuous longitudinal weld with an effective weld thickness which is in accordance with the design (aeff ≥ 5 mm to 9 mm, depending on the thickness of the sheet pile section).
Weld 'R': internal longitudinal weld with an effective weld thickness aeff ≥ 5 mm normally over a length of 500 mm at the top and bottom of the box pile.
B.7.3 Assembly and welding procedure for a box pile
Stages for assembling and welding are :
- assemble the two single piles on horizontal supports;
- adjust any differences in width of the sheet piles with a chain-wrench or other means (see figure B.7);
- tack weld over the whole length;
- apply welds 'R' at both ends of the box pile (see figure B.8);
- apply welds 'C' over a length of about 1 000 mm, first at each end, then in the centre of the box pile (see figure B.8);
- finish weld 'C' by the back step method from the centre towards the ends of the box pile (length of each pass about 1 m);
- if the box pile deforms during welding, straighten it with a torch or a press.
Legend
- a U box pile
- b chain pull
- c assembling support
Legend
- * in accordance with the design
- a single pile
- b detail of "C" weld
- c detail of "R" weld (length : normally 500 mm on top and toe)
B.7.4 Welding filler metals
As for junction piles in accordance with B.4.4.
B.8 Sealing welds
An example of sealing by welding is shown in figure B.9.
Legend
- a excavation side
- B labyrinth weld at top and toe of the sheet pile
- C main weld
- D backside weld
- e main weld length = pile length
| Steelgrade hot rolled EN 10248-1:1995 | Steelgrade cold formed EN 10249-1:1995 | Steelgrade tubes for primary elements EN 10219-1:1997, tables A.1, B.1 and B.2 | EN 440:1994 |
| S 240GP S 270GP S 320GP S 355GP S 390GP S 430GP |
S 235JRC S 275JRC S 355JOC |
S 235xxx S 275xxx -- S 355xxx -- S 420xxx S 460xxx |
G2Si G2Si G2Si G2Si G3Si1 G3Si1 G3Si1 |
| Steel grade hot rolled EN 10248-1:1995 | Steel grade cold formed EN 10249-1:1995 | Steelgrade tubes for primary elements EN 10219-1:1997, tables A.1, B.1 and B.2 | EN 756:1995 |
| S 240GP S 270GP S 320GP S 355GP S 390GP S 430GP |
S 235JRC S 275JRC S 355JOC |
S 235xxx S 275xxx -- S 355xxx -- S 420xxx S 460xxx |
S1 S1 S2 S2Si S4 S2Ni 1 |
| Steel grades acc. to EN 10248-1:1995 EN 10249-1:1995 |
S 240 GP S 270 GP S 235 JRC S 275 JRC |
S 320 GP S 355 GP S 355 JOC |
S 390 GP S 430 GP |
||
| EN 10219-1:1997 | S 235xxx S 275xxx |
S 355xxx |
S 420xxx S 460xxx |
||
| Welding energy | ≥ 15 < 25 kJ/cm | 15 kJ/cm | 25 kJ/cm | 15kJ/cm | 25 kJ/cm |
| Thickness of the product (mm) 8 10 12 14 16 18 20 22 24 26 28 30 |
5 5 5 5 5 5 5 5 5 5 5 5 |
5 5 5 5 5 30 60 85 100 110 120 130 |
5 5 5 5 5 5 5 5 5 5 5 5 |
5 5 5 50 90 110 130 150 155 160 165 170 |
5 5 5 5 5 5 5 30 55 75 90 95 |
