Technical Specification

1200 - STRUCTURAL STEEL WORKS

Table of Contents
PAGE
1.

General ................................................................................................................... 3

2.

Codes and Standards............................................................................................ 3

3.

Material ................................................................................................................... 4

3.1

General............................................................................................................... 4

3.2

Steel Quality and Constructions ..................................................................... 4

3.2.1

Steel for Sheet Piles and Interlocks ........................................................... 4

3.2.2

Steel for Rod of Injection Pile ..................................................................... 4

3.2.3

Steel for Walings .......................................................................................... 4

3.2.4

Steel for Integration of Injection Pile / Anchor .......................................... 4

3.2.5

Steel for Horizontal Anchor Construction ................................................. 4

3.2.6

Steel for Dowels ........................................................................................... 5

3.2.7

Steel Capping Beam..................................................................................... 5

3.2.8

Steel for Edge Protection ............................................................................ 5

3.2.9

Steel for Guard Rails.................................................................................... 5

3.2.10

Steel for Opening Covers ............................................................................ 5

3.2.11

Steel for Drainage Cover ............................................................................. 5

3.2.12

Other Steel .................................................................................................... 6

3.3

Mounting, Bolts and Accessories ................................................................... 6

3.4

Transport and Storage ..................................................................................... 6

4.

Quality .................................................................................................................... 6

4.1

Certificate of Origin .......................................................................................... 6

4.2

Inspection .......................................................................................................... 7

4.3

Welding .............................................................................................................. 7

5.

Tolerances.............................................................................................................. 7

6.

Specification for Construction Works ................................................................. 8

6.1

General............................................................................................................... 8

6.2

Welding .............................................................................................................. 8

6.3

Fabrication and Erection.................................................................................. 8

6.4

Steelwork ........................................................................................................... 9

6.4.1

Sheet Piles - Weep Holes............................................................................. 9

6.4.2

Rainwater Outlet........................................................................................... 9

6.4.3

Waling............................................................................................................ 9

6.4.4

Integration of Injection Piles / Anchors.................................................... 10

6.4.5

Horizontal Anchor Construction............................................................... 10

6.4.6

Dowel between Quay Block....................................................................... 10

6.4.7

Burning off the Pile Tops........................................................................... 11

6.4.8

Closing of Sheet Wall Front / Capping Beams ........................................ 11

6.4.9

Edge Protection.......................................................................................... 11

6.4.10

Guard Rails ................................................................................................. 11

6.4.11

Opening Covers.......................................................................................... 11

6.4.12

Drainage Cover........................................................................................... 12

6.5

Preservative Coating ...................................................................................... 12

6.6

Equipotential Bonding / Earthing .................................................................. 12

7.

Measurement and Payment ................................................................................ 12

II

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Technical Specifications

Section 1200 STRUCTURAL STEEL WORKS

1.

General

The work covered under this Section consists of furnishing all necessary plant, labour,
equipment, appliances, materials, tests, workshop planning, etc. in performing all operations in
connection with all structural steel and miscellaneous metal work in accordance with the design
drawings and Specifications or assumed by the Contractor to be necessary as provisional
structure.
Included but not limited to this work are the following items:
piles for sheet pile walls (sheet piles and combined sheet pile walls (combi walls))
waling of sheet pile walls, incl. integration of injection piles
horizontal anchors
capping beams
edge protection
guard rails
rainwater outlet
weepholes for sheet pile walls
dowel between quay blocks
crane rail facilities and crane buffers
bollards and bollard anchoring
railway stop blocks
miscellaneous metal work, etc.
With the Tender the Tenderer shall sufficiently describe and explain in his Method Statements
the equipment and procedure, incl. welding selected by him to perform the works.
The Contractor shall prepare the complete workshop drawings and any supplemental structural
analyses required by him, for all structural steel works in accordance with the Drawings and
structural analyses of the main structural elements.
Main dimensions, clearances and other basic data shown in the Drawings shall be adhered to,
but the Contractor may adjust measurements in coordination with the Engineer to suit the
manufacturing and installation requirements.
2.

Codes and Standards

The work shall be carried out in accordance with the following codes and specifications:
DIN 18800
DIN EN10204
DIN EN 10025
DIN EN 287
DIN EN 729 - 1
DIN EN 719
DIN EN 10021
All Estonian Codes and Standards which may apply.

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3.

Technical Specifications

Material

3.1

General

Structural steel work shall be fabricated from killed and specially killed steel complying with DIN
EN 10025 and DIN EN 10250-1,2 and shall be of the grades shown in the Drawings, the Bill of
Quantities or the Specifications.
The Contractor may propose alternative grades and sizes of structural steel for use in the
Works. Such alternative shall satisfy the requirements of DIN EN 10025, DIN EN 10250-1,2 or
any other approved standard for the specified grade, and shall have section properties and
material thickness at least equal to those of the specified sizes. Alternative sections shall only
be used with the approval of the Engineer.
3.2
3.2.1

Steel Quality and Constructions

Steel for Sheet Piles and Interlocks

The steel qualities for steel piles, sheet piles and interlocks are described in Section 800,
Subsection 3 - Material.
3.2.2

Steel for Rod of Injection Pile

The steel quality of the rod of the injection piles shall be according to the technical approval of
the building authority or to a technical approval of an international admitted building institute
witch is a member in the European Organisation for Technical Approvals (i.g. German Institute
DIBt) (refer to Section 900 - Subsection 3 - Material).
3.2.3

Steel for Walings

Steel quality for all types of walings shall be according to the Drawings, i.e. S355J2G3.
3.2.4

Steel for Integration of Injection Pile / Anchor

Steel quality for the integration of the injection piles to the sheet pile wall shall be as stated in
the Drawings.
The design and proof of the anchorage detail shall be performed by the Contactor according to
the choice of type of injection pile, the technical approval of building authority or to a technical
approval of an international admitted building institute witch is a member in the European
Organisation for Technical Approvals and with respect to the guidelines of the Drawings.
3.2.5

Steel for Horizontal Anchor Construction

The steel sheets at the corner / connection of the waling shall be of grade S355J2G3 and shall
be guaranteed without longitudinal splitting.
The horizontal anchors (3 1/2") incl. turning buckle shall be made out of steel S355J0.
The material for the steel ground plates connected to the bearing piles shall be chosen by the
Contractor according requirements of his design.

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3.2.6

Technical Specifications

Steel for Dowels

Dowels shall be made of steel pipes ( 219,1 x 16) of grade S355J2G3.

3.2.7

Steel Capping Beam

The capping beam and the associated angle profile shall be 10 mm thick and of grade S235JR.
The top surface of the capping beam shall be such that hawsers run over will not be damaged.
No sharp protrusions are allowed.
In order to prevent slipping the water side portion of the capping beam shall be slightly above
the surface of the quay, as shown in the Drawings. Wedge-shaped grooves for drainage shall
be provided in the bulge at least every 3 m. Furthermore, the horizontal surface shall be a nonskid, e.g. studded, checkered or similarly treated according to EAU R95.
The capping beams shall receive a coating according to the protective paint system as
described in Section 1400.
3.2.8

Steel for Edge Protection

The edge protection shall be constructed of rounded steel plates (radius abt. 125 mm) of grade
S235JR with steel claws (L abt 20 cm) for anchorage at the back side.
All welds concerning the anchors shall be made prior to corrosion protection.
The edge protection shall receive a corrosion protection by hot-dip galvanising as described in
Section 1400.
3.2.9

Steel for Guard Rails

The guard rails shall be constructed of steel pipes ( 101,6 x 6,3) and plates (min t = 10 mm) of
grade S355J2G3.
All welds shall be made prior to corrosion protection.
The guard rails shall receive a corrosion protection by hot-dip galvanising as described in
Section 1400.
3.2.10 Steel for Opening Covers
The quality of steel shall be according to static requirements and choice of the Contractor. It
shall be at least of grade S235JP.
All opening covers shall receive a coating according to the protective paint system as described
in Section 1400.
3.2.11 Steel for Drainage Cover
The drainage openings (DN 100) in the slab of the quay structure shall be covered by perforated sheet (200 x 200 x 3 mm) of quality 1.4565 (steel V4A according to DIN EN 100888-1).

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Technical Specifications

The drainage openings (DN 50) in the slab of the installation channel shall be covered by perforated sheet (100 x 100 x 3 mm) of quality 1.4565 (steel V4A according to DIN EN 100888-1).
3.2.12 Other Steel
Structural steel not mentioned above, e.g. for auxiliary or provisional structures shall be at least
of grade S235JP or according to static requirements.
3.3

Mounting, Bolts and Accessories

All mountings, bolts, washers, nuts and related accessories are to be supplied hot-galvanized
according to DIN 267-2,13,29, DIN EN 20898-2, DIN EN ISO 3269, DIN EN ISO 4759-1, DIN
ISO 8992.
If required or recommended by the Contractor / supplier, bolts, washers, nuts etc. may as well
be made of seawater resistant stainless steel, which shall at least comply with material number
1.4462 (German Steel lndustry)
Bolts, nuts and washers shall comply with the relevant European standard.
The heads of bolts shall be forged out of solid. All bolts shall have hexagonal heads and nuts.
All bolts and nuts shall be completed with washers.
The nuts and shanks of bolts shall be cleanly cut with standard threads and the nuts shall fit the
bolts accurately and sufficiently tightly that they can just be screwed down by hand. Samples
shall be submitted to, and approved by the Engineer before any bolts, nuts or washers are used
in the Works.
Foundation bolts for steel work shall be provided under the Contract and built into prepared
pockets or cast into the concrete foundations by use of suitable templates. The foundation bolts
shall be set to permit adjustments to the level of the steelwork in the event of differential
settlement of the foundations.
3.4

Transport and Storage

All steel work shall be efficiently and sufficiently protected against damage during transportation
and at site.
Steel work which is to be stored prior to erection shall be stacked clear of the ground with
packing between parts. The stacks shall be arranged so as to avoid the accumulation of dirt and
water on the surface and if cover is provided it shall be ventilated.
4.
4.1

Quality
Certificate of Origin

Ladle and product analyses according to DIN EN 10025 or DIN EN 10250-1,2 for the structural
steel incorporated in the Works shall be included in the certificate of origin, which shall be
submitted to the Engineer.
Upon arrival at Site the manufacturer, quality (steel grade, No. of Certificate of origin), date of
delivery, size and assignment of the material shall be clearly indicated by a works certificate /
delivery note on each bundle.
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4.2

Technical Specifications

Inspection

Plates shall be absolutely free of doubling. Appropriate test certificates shall be submitted to the
Engineer.
Anchoring devices/plugs shall be of a type licensed for use in construction works by a
competent building authority or equivalent testing institute, subject to Engineer's approval.
Mounting bolts are to be hexagonal bolts and units as per dimensions and standards indicated
in the Drawings and Bill of Quantities.
Wherever specified, the fixing material shall be supplied galvanized in accordance with DIN EN
ISO 1461 with supplement.
4.3

Welding

The soundness of the welding procedure selected by the Contractor shall be confirmed by trial
welds and tests to the satisfaction of the Engineer.
Test and inspection protocols shall be compiled by the Contractor and submitted to the
Engineer prior to installing the respective steel item in the work.
The standards of acceptability by which welding will be judged shall be as per DIN EN 729, DIN
EN 719. The Quality of weldings shall be inspected according to DIN 6653.
All bearing welds are to be checked through damage-free tests. X-ray or ultrasonic method shall
be applied to all major and most critical welds, whereas magnetic particle or colour penetration
tests or equivalent methods shall be used for all other bearing welds. The proposed methods of
inspection as well as the Contractors shop drawing showing the approximate location of all
critical weIds shall be submitted to the Engineer well in time before starting the welding works.
Rejection of welds may be made on the basis of the following factors: inadequate penetration,
incomplete fusion, burned through areas, sIag incursion, gas pockets, cracking and
undercutting. No weld containing cracks regardless of size shall be acceptable.
lf the Engineer believes that a defect exists in any weld or pass, the Contractor shall use
appropriate test methods to determine the soundness of the welds. If the weld proves to be
defective, it shall be repaired to the complete satisfaction of the Engineer.
5.

Tolerances

Manufacturing tolerances shall meet the applicable Standards relative to the individual steel
items.
All steel work shall be set accurately to the agreed lines and levels and must be plumb and
level.

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6.
6.1

Technical Specifications

Specification for Construction Works

General

The Contractor shall supply all labour and materials, haulage, storage and all services
necessary for the erection of the steel structures complete.
The Contractor shall be responsible for the stability of the structures at all stages of their
erection on Site and shall take all necessary measures, by the addition of temporary bracings
and guys, to ensure adequate resistance to wind.
6.2

Welding

The Contractor or the manufacturer of steel constructions is obligated to submit the proof of
competence to weld structural steel as per DIN 18800.
All welding work shall only be carried out by well trained welders qualified and certified
according to DIN 8560 and DIN EN 287 or equivalent standards for the type of welding to be
executed. Relevant certificates are to be submitted to the Engineer.
Welding electrodes, as well as welding method and sequence are to be coordinated with the
manufacturer(s) of the steel material. Relevant statements and/or recommendations are to be
submitted to the Engineer, well in time before starting the welding works.
Surfaces to be welded shall be free from loose scale, slag rust, grease, paint and any other
foreign material. The surface before welding shall be cleaned of rust, loose scale, oil and dirt,
sIag and spatter of each pass shall be cleaned from all welds, after completion.
All welds shall develop the strength and energy absorption characteristics specified for the
material being welded. All butt welds shall attain 100% penetration. All welds forming
connections between steel of different grades shall develop the strength specified for the higher
steel and shall develop the maximum energy absorption characteristics specified for either steel
being joined. Skip welding will not be permitted unless specifically mentioned on the drawings.
Down vertical welding is not acceptable.
All structural welds shall be continuous and shall be property sized to develop the full strength
of the smaller of the two members being joined.
All fillet welds are to be measured as per DIN 18800 and shall have a thickness of at least a =
6 mm, should they not be thicker for static reasons.
6.3

Fabrication and Erection

Fabrication and/or erection shall not start until the Contractor's drawings have been approved
by the Engineer. All dimensions shall be verified at the Site and the Contractor shall be
responsible for the accuracy and fit of all materials supplied.
Generally, work shall be shop assembled as far as possible. Exposed faces of work shall be
free of warps, dents, buckles or other distortions. Corners shall be accurately formed to profiles
shown, and joints shall be tightly fitted and made neat in appearance. Steel sheets shall be
stiffened or reinforced as far as required. Finished work shall be free from defects detrimental to
appearance and performance.
Weld splices shall be full penetration butt welds, ground flush where required.
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Technical Specifications

Tack welds, which are not part of the welds shown in the Drawings, will not be allowed at stress
transfer points such as splice plates and gusset plate connections.
Any material used in splices shall conform to the specification of the material which shall be
spliced.
All sharp edges and corners shall be chamfered and left without sharp lines, burrs shall be
removed.
Members distorted by the heat of welding or hot galvanizing process may be straightened by
mechanical means which do not damage the material. The suggested method shall be agreed
by the Engineer.
Temporary bracings shall be used where necessary to prevent collapse or distortion of the
structure during erection, and to maintain the correct position at all stages of the work.
Where metals of differing types are in contact with one another they shall be electrically
separated by using special isolating tape or by painting the connecting surfaces using bitumen
base paint or by other means as approved by the Engineer.
6.4
6.4.1

Steelwork
Sheet Piles - Weep Holes

Prior to installation of the sheet pile walls all intermediate sheet piles of the combi walls shall be
furnished with filter weep holes according to the Drawings.
The slots shall be covered with filter-stable geotextile, which shall be bonded across its full
length with a form-stable fixing according to Contractor's choice.
The slots shall be well rounded to prevent tear of the geotextile.
If necessary, the natural soil resp. the landfill shall be excavated down to - 2.0 m in order to
prevent tearing of the geotextile during the installation of the piles (see Section 700 - Secondary
Dredging).
6.4.2

Rainwater Outlet

Prior to installation of the sheet pile walls the connections for rainwater outlets shall be placed to
the respective sheet piles.
If necessary, the natural soil resp. the landfill shall be excavated down to abt. -1.5 m in order to
prevent damage of the structure during the installation of the piles (see Section 700 - Secondary
Dredging).
After completion of the rainwater outlet pipe the opening in the sheet pile wall shall be cut by
divers.
6.4.3

Waling

All sheet pile walls shall be furnished with waling.

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Technical Specifications

The combi walls shall receive a waling of 2 x U260, which shall be fixed in grooves at the top of
the bearing piles (at double piles) resp. on additional plates being mounted at both sides of
single piles.
The sheet pile walls (U-Profile) shall be furnished with a waling of 2 x U-350 profiles with
spacers in between. The waling shall be mounted on consoles and shall be fixed to the sheet
piles with waling bolts according to the Drawings.
The additional waling in the reach of the horizontal anchor is described in subsection 6.4.5.
6.4.4

Integration of Injection Piles / Anchors

At the combi walls the injection pile shall be led between both waling profiles as well as through
a hole burned into the flange of the double pile resp. the recess in the flange and web of a
single bearing pile according to the Drawings.
The Contractor has to prepare a detailed design for the integration of the injection piles to the
steel sheet pile wall according to the system chosen by the Contractor.
The head of the injection pile shall be fixed on top of the waling according to the detailed design
of the Contractor (see section 1000).
At the sheet pile walls (U-Profiles) the injection pile shall lead through a hole burned into the
landside flange of the sheet pile profile. The head of the injection pile shall be fixed within the
valley of the sheet pile using e.g. front plates, pipe sockets, etc. according to the detail design of
the Contractor.
The head and fixture of the injection pile shall be designed by the Contractor according to the
chosen pile system and shall be submitted to the Engineer for approval.
6.4.5

Horizontal Anchor Construction

In the reach of the outer edges of sheet pile walls, i.e. at the intersection of axes III and IV resp.
III and X, the sheet pile walls shall receive horizontal anchors in addition to the injection piles.
The last three sections of a combi wall at each wing shall be braced with waling (2 x U 260)
according to the Drawings.
Ground plates shall be installed at each of the outer two steel piles according to Contractor's
choice. The ground plates shall be furnished with a hole to bear the horizontal anchors (3 1/2"),
including turnbuckles.
6.4.6

Dowel between Quay Block

Dowels have to be placed in the joint between two quay blocks, wherever crane rails are
crossing the joint. The location and design is shown in the Drawings.
The dowels shall be fixed in the formwork and shall be concrete-casted in the first block to be
poured. After installation of the joint filler the second half of the dowel shall be covered with two
layers of bituminous paint (2 x abt. 1 mm). At the end of the dowel additional joint filler (fibre
plate) shall be placed. The dowel shall be completely filled with concrete or mortar, e.g. by
injection.

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6.4.7

Technical Specifications

Burning off the Pile Tops

The top of all bearing piles and sheet piles shall be cut off at level according to design as
preparation for coping with capping beams or concrete structure. The tolerance shall be
according to the requirements of further work, i.e.
max. 20 mm at sections with concrete coping
max. 5 mm at sections with capping beams.

6.4.8

Closing of Sheet Wall Front / Capping Beams

All sheet pile walls which will not be covered by concrete coping shall receive a cover of steel
sheets (capping beams) according to the Drawings.
Prior to installation of the capping beams at + 3,0 m the sheet pile wall shall be extended to this
elevation, wherever the bearing piles do not reach this level, i.e. at the blocks 2.4, 3.24, 4.10
and 9.12.
The front above these bearing piles shall be closed by inserting and welding steel sheet plates
between the outer interlocks of the intermediate piles as shown in the Drawings.
Wherever necessary, the top of the sheet pile wall has to be cut to level (according to
subsection 6.4.7) to enable a levelled fixing of the capping beams. The capping beams shall
continuously be welded on top of the piles.
6.4.9

Edge Protection

The top edges of the reinforced concrete structure shall be furnished with edge protection in
order to protect both the edge, as well as the hawsers running over it. The edge protection shall
carefully be aligned, placed in the formwork and securely fastened.
The edge protection shall be concreted flush towards the concrete surfaces. All inner surfaces
shall be completely covered with concrete.
6.4.10 Guard Rails
Guard rail shall be installed over the full length of the berths.
Mounting plates with blind nuts and anchors shall carefully be aligned, placed in the formwork
and securely fastened.
6.4.11 Opening Covers
Opening Covers shall be installed at all openings of:
Installation channel
Access box for the crane connection
Access box for electric and telecom.
All opening covers shall be furnished with opening aids, e.g. pneumatic spring system
(DICTATOR or equivalent).
The workshop design shall be executed by the Contractor according to the Drawings.

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Technical Specifications

6.4.12 Drainage Cover

The perforated sheets shall be fixed with bolts drilled into the concrete slab.
Furthermore, the drainage openings (DN 100) in the slab of the Quay structure shall be
protected by geotextile (Terrafix 609 or equivalent) and a gravel filter (according to the
Drawings) placed on top of the perforated sheet.
6.5

Preservative Coating

Corrosion protections shall be according to Section 1400 and as per type specified in the Bill of
Quantities.
The following items shall be furnished with preservative coatings:

Capping beams:
Guard rails:
Edge protections:
Opening covers:

protective paint system

hot-dip galvanized
hot-dip galvanized
protective paint system

The costs for corrosion protection shall be included in the costs of the respective items to be
protected.
6.6

Equipotential Bonding / Earthing

All edge protection, guard rails, opening covers and the sheet pile wall shall be connected to the
equipotential bonding / earthing as described in Section 1100 (subsection 6.3). The expenses
shall be included in the unit costs.
7.

Measurement and Payment

All unit rates or lump sum prices of the steel items shall include the costs for preparing the shop
drawings and any supplemental calculations, designs, materials, manufacture, installations,
welding, tests etc., complete in every respect.
The costs for corrosion protection shall be included in the costs of the respective items to be
protected.
Measurement and payment will be made per weight or by number as indicated in the Bill of
Quantities, in accordance with the Drawings and the Contractor's approved shop drawings.
The weight shall be the theoretical steel weight based on 7.85 t/m. Surcharges for rolling
tolerances, wastage, connection elements and the like will not be considered. However, a 3 %
welding seam surcharge on the weight will be taken into account.
Structural steel or other appropriate measures required by the Contractor for the proper
guidance, adjustment and support of prefabricated elements during installation will not be paid
for separately and shall therefore to be included in the prices for the installation of such items.

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