SAWH Steel Piles and SSAW Steel Pipe Piles: A Comprehensive Guide
In the construction industry, steel piles play a crucial role in supporting structures and providing stability in various soil conditions. Among the different types of steel piles, SAWH (Submerged Arc Welded Helical) steel piles and SSAW (Spiral Submerged Arc Welded) steel pipe piles are widely used due to their exceptional strength and durability. In this comprehensive guide, we will explore the characteristics, manufacturing process, applications, and advantages of SAWH steel piles and SSAW steel pipe piles.
SAWH Steel Piles: Characteristics and Manufacturing Process
SAWH steel piles are known for their helical shape, which provides excellent load-bearing capacity and resistance to lateral forces. These piles are manufactured using the submerged arc welding process, where a continuous helical weld is formed between the steel plates. The plates are first formed into a cylindrical shape and then welded using a submerged arc welding machine. The welding process ensures a strong and seamless bond, resulting in a high-quality pile.
The SAWH steel piles are typically made from high-strength low-alloy (HSLA) steel or carbon steel. The choice of steel grade depends on the specific project requirements and the soil conditions at the construction site. The piles can be customized in terms of diameter, thickness, and length to meet the design specifications.
Standard | Specification |
ASTM A53 | Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless |
API 5L | Specification for Line Pipe(Two levels PSL 1 and PSL 2 of seamless and welded steel pipes for use in pipeline transportation systems in the petroleum and natural gas industries.) |
A252 | Standard Specification for Welded and Seamless Steel Pipe Piles |
A500 | Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes |
BS EN10219-1 | Cold formed welded structural hollow sections of non-alloy and fine grain steels – part1: Technical delivert conditions |
BS EN10219-2 | Cold formed welded structural hollow sections of non-alloy and fine grain steels – part2: tolerances dimmsions and sectional properties |
Advantages and Applications of SAWH Steel Piles
SAWH steel piles offer several advantages that make them suitable for a wide range of applications:
- High Load-Bearing Capacity: The helical shape of SAWH steel piles provides increased load-bearing capacity, making them ideal for supporting heavy structures and transferring loads to the underlying soil.
- Resistance to Lateral Forces: The helical design also enhances the resistance of SAWH steel piles to lateral forces, such as wind and seismic loads. This makes them suitable for projects in areas prone to high winds or earthquakes.
- Durability and Longevity: SAWH steel piles are highly durable and resistant to corrosion, ensuring their longevity even in harsh environmental conditions. This makes them a cost-effective choice for long-term projects.
- Versatility: SAWH steel piles can be used in various soil conditions, including soft soils, hard soils, and even marine environments. They can be installed using different methods, such as driven piles or drilled piles, depending on the project requirements.
- Cost-Effective: SAWH steel piles offer a cost-effective solution due to their long service life, minimal maintenance requirements, and ease of installation. They provide a reliable foundation system that reduces the risk of costly repairs or replacements in the future.
SAWH steel piles find applications in a wide range of construction projects, including:
- Bridge foundations
- Building foundations
- Wharf and jetty construction
- Offshore structures
- Retaining walls
- Transmission tower foundations
- Industrial structures
SAWH Steel Pipe Piles Manufacturing Process: Ensuring Quality and Precision
Manufacturing high-quality SAWH (Submerged Arc Welded Helical) steel pipe piles requires a specialized and optimized process to ensure the durability and reliability of the final product. In this section, we will delve into the manufacturing process of SAWH steel pipe piles, highlighting the steps involved and the technologies employed by market leader, abtersteel pipe Mobile.
![DECOILING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_01-decoiling.gif)
Coils are processed at a preparation stand where the lead end is cut square to remove any irregular shape. Coil identity is verified and measurements are recorded to verify material is within required tolerances. Coils are then loaded into the decoiling stand to feed into the mill.
![LEVELING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_02-leveling.gif)
The skelp is fed through a seven-roll flattener to provide a consistently flat strip for the forming process.
![SKELP END WELDING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_03-Skelp.gif)
New coils are joined to the previous coil by submerged arc welding to provide a continuous strip.
![SKELP AND EDGE ULTRASONIC TESTING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_04-Skelp.gif)
The skelp is tested for laminar imperfections along both edges and across the full width of the strip using a series of normal beam ultrasonic probes.
![EDGE TRIMMING AND BEVELING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_05-edge.gif)
The strip is fed through a series of milling machines that give the material the proper width, and machine the strip edges with the specific bevel shape for optimal welding.
![FORMING AND TACK WELDING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_06-forming.gif)
The strip is pushed through a three-roll bending stand and formed into a spiral, with the two edges of the strip meeting after the forming process. The required pipe diameter is obtained by adjusting the feed angle based on the width of the strip, and the orientation of the three roll bending sets to form the ideal radius. The edges of the strip are tack welded together using a continuous single wire gas metal arc welder. Fine tuning of the pipe diameter and strip edge offsets are continually monitored and controlled.
![FLYING CUTOFF](https://www.avatur.com/wp-content/uploads/2024/01/sawh_07-flying.gif)
The continuous pipe is then cut into individual pieces to the specified length up to 80 ft. The cut is made without stopping the forming process by a travelling carriage clamped to the moving pipe and an oxygen plasma torch moved around the periphery of the pipe on a rotating frame.
![INSIDE CLEANING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_08-insidecleaning.gif)
The inside of the pipe is cleaned of loose mill scale and tack welding slag by a rotating brush and vacuum system.
![TACK WELD INSPECTION](https://www.avatur.com/wp-content/uploads/2024/01/sawh_09-tackweldinginspection.gif)
The full-length tack weld is visually inspected to ensure it is properly prepared for submerged arc welding. In order to promote a sound weld along the entire pipe, run-on and run-off tabs are welded on to the pipe ends. This allows any defects caused by instability in the start or stop of the welding process to be cut off with the tabs and discarded.
![INTERNAL AND EXTERNAL SUBMERGED-ARC WELDING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_10-welding.gif)
Pipe is welded on one of three welding stands using a three-wire inside pass followed by a two-wire outside pass. The deposits overlap to provide a full penetration weld. The welding process is computer controlled and weld alignment is automatically adjusted by a laser tracking system. The weld wires are submerged in a layer of granular flux which provides shielding to weld puddle from the ambient air and allows impurities to float out of the weld before it solidifies. Unused loose flux is recycled into the system, while hard fused flux is separated and discarded.
![INSIDE CLEANING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_11-insidecleaning.gif)
The run-on and run-off tabs are removed and the pipe is cleaned using a vacuum system to remove any residual material from the welding process.
![INSPECTION OF SUBMERGED-ARC WELDING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_12-inspection.gif)
Each pipe is measured for dimensional conformance to the specifications and each weld is visually inspected before the pipe is allowed to continue through the production line.
![REPAIR WELDING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_13-repairwelding.gif)
Defects identified during testing and inspection are removed, and the weld is repaired and re-tested and inspected to ensure complete removal of the defect.
![SAMPLING AND DESTRUCTIVE TESTING](https://www.avatur.com/wp-content/uploads/2024/01/16-destructivetesting.gif)
The mill computer system indicates any required testing and pipe rings for mechanical testing samples are secured. The mechanical properties of the base metal and the weld are measured in accordance with agreed specifications.
![WELD SEAM REMOVAL AT PIPE ENDS](https://www.avatur.com/wp-content/uploads/2024/01/sawh_15-weldseamremoval.gif)
To ensure that the pipe can easily be girth welded in the field, the inside and outside weld caps on each end are ground flush with the pipe body.
![BEVELING OF PIPE ENDS](https://www.avatur.com/wp-content/uploads/2024/01/sawh_16-beveling.gif)
Each pipe end is machined with a bevel for field welding according API 5L standards or customer specifications.
![HYDROSTATIC TESTING](https://www.avatur.com/wp-content/uploads/2024/01/sawh_17-hydrostatic.gif)
Each pipe is filled with water, sealed and pressurized according to the time and pressure requirements of the relevant specification. A pressure versus time graph is generated for each test cycle and computer archived with the pipe number.
![ULTRASONIC TESTING OF SPIRAL WELD](https://www.avatur.com/wp-content/uploads/2024/01/sawh_18-ultrasonictesting.gif)
The automated ultrasonic testing station inspects each pipe utilizing a computerized system with up to 12 shear wave probes looking for both longitudinal and transverse defects. Probe alignment is automatically adjusted by a laser tracking system. A test map recording all indications for each test is generated and computer archived. All indications that exceed the alarm level are recorded in the mill computer system and sent to manual ultrasonic testing for final disposition.
Manual ultrasonic testing is performed on each indication exceeding alarm level at the automated ultrasonic testing station. The mill computer system requires that disposition of each individual indication is completed before a pipe can be accepted. In addition, the complete circumference of each pipe end is tested for laminar discontinuities using a straight beam probe.
![X-RAY WELD INSPECTION/FILMLESS RADIOGRAPHY](https://www.avatur.com/wp-content/uploads/2024/01/sawh_19-xrayweld.gif)
Each pipe end is tested for a minimum of 8 inches of weld length using computed radiography. In addition, any defects detected by ultrasonic inspection are inspected to provide additional information for repairs and to aid in process changes to improve weld quality.
![FINAL INSPECTION](https://www.avatur.com/wp-content/uploads/2024/01/sawh_20-finalinspection.gif)
All required dimensional properties of the pipe are checked for conformance with the specification. Routine measurements are recorded in the mill computer system, verified against process limits, and utilized for data analysis. The pipe is visually examined full-length over the entire inside and outside surface, as well as both ends. Once the pipe passes visual and dimensional requirements, the data is entered into the mill computer system. The system verifies that passing tests have also been recorded for hydrotest, ultrasonic testing of the weld and pipe ends, and radiographic testing before the pipe can be accepted as a prime pipe.
![SHIPMENT](https://www.avatur.com/wp-content/uploads/2024/01/sawh_21-shipment.gif)
Pipes will be safely loaded on rail cars, truck beds, barges, or ocean going vessels depending on customer requirements and destination.
![GENERATIONS OF CERTIFICATES](https://www.avatur.com/wp-content/uploads/2024/01/image-asset.png)
Once all production and inspection steps have been carried out and all specification requirements have been fulfilled, the customer documentation is prepared. All results are listed, and certificates are produced.
FAQ: Frequently Asked Questions
- What is the difference between SAWH steel piles and SSAW steel pipe piles?
- SAWH steel piles are helically shaped and manufactured using submerged arc welding, while SSAW steel pipe piles are spiral welded cylindrical pipes. The choice between the two depends on the specific project requirements and soil conditions.
- Are SAWH steel piles and SSAW steel pipe piles suitable for marine environments?
- Yes, both SAWH steel piles and SSAW steel pipe piles are suitable for marine environments. They are designed to withstand corrosion and provide a reliable foundation in coastal and offshore construction projects.
- Can SAWH steel piles and SSAW steel pipe piles be customized in terms of diameter and length?
- Yes, both types of piles can be customized in terms of diameter, thickness, and length to meet the design specifications of the project. This allows for flexibility in adapting to different construction requirements.
- What are the advantages of using SAWH steel piles and SSAW steel pipe piles?
- The advantages include high load-bearing capacity, resistance to lateral forces, durability, longevity, versatility, and cost-effectiveness. These piles provide a reliable foundation system for various construction projects.
- How are SAWH steel piles and SSAW steel pipe piles installed?
- SAWH steel piles can be installed using methods such as driven piles or drilled piles, depending on the project requirements. SSAW steel pipe piles can be driven into the ground using pile driving equipment or installed using drilling methods.
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