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FRP jackets refurbish timber piles
Applications news
FRP jackets refurbish timber piles THE STRUCTURAL integrity of the New York City Passenger Ship Terminal (PST) piers at the Port of New York, on the Hudson River, have been restored using a fibre reinforced plastic (FRP) pile encapsulation system. The project was part of the New York City Economic Development Corp’s US$50 million PST improvement plan. The timber piles of the PST’s three, approximately 1000 ft long and 125 ft wide, finger piers, had been eroded by wood-boring marine worms. Because of the amount of passengers using the port restoration of the piles was the best solution to the problem, rather than replacement and an expensive, lengthy shutdown. The encapsulation system chosen comprises a moulded FRP jacket, epoxy grout and aggregate mix. Divers abrade and clean each pile and then place the jackets around them. Epoxy grout and aggregate mix is then pumped by the divers from the bottom up, displacing the seawater. The aggregate mix enhances the bond as it scours the substrate further. The FRP jackets are durable in seawater,
lightweight and relatively easy to install, and provide maintenance-free protection for long periods of time. In Phase II of the project, awarded to Trevcon Construction Co Inc, Liberty Corner, New Jersey, Trevcon evaluated the condition of the pilings and decided to experiment with different epoxies and pile sleeves to maximise savings, assembly time and seam strength. MFG Construction Products Co, Independence, Kansas, was selected to supply the FRP pile sleeves. MFG provided its one-piece FRP pile repair sleeve. Designed to leave in place, the sleeves are chemically resistant to acids, alkalis and most solvents, thus providing long-lasting, reliable protection. They are made from chop strand mat and woven roving, providing better physical properties so the jackets meet or exceed specifications. For underwater assembly, the MFG sleeves offer a slip joint closure designed to make the divers’ jobs easier. Standard diameters are available in 12-36 inches and custom sizes can be accommodated. Lengths
Each year nearly 1 million passengers pass through the PST, which located a few blocks west of Times Square in the heart of Manhattan.
6
REINFORCEDplastics
January 2006
A composite pile encapsulation system was chosen for the New York City Passenger Ship Terminal project.
are produced to specifications and ultraviolet resistance accommodations are available. The MFG sleeve also offered a peal-away liner design seam and a resin bond finish to the jacket, eliminating the need to sandblast for chemical adhesion to work in conjunction with the epoxy used. “MFG was recommended and chosen based upon service and the fact that they could provide the required length and diameter of pile sleeves needed for the project; thus avoiding costly custom-built sleeves,” according to Trevcon president Ron Treveloni. He adds that the MFG jackets’ rough finish also strengthened the bonding epoxy, which was supplied by Sika Corp, Lyndhurst, New Jersey, to the shell. After testing concrete epoxy solutions, which were too heavy and would result in unnecessary weight added to the piers, Sika devised an epoxy resin solution. SIKA USA’s Sikadur 35, Hi-Mod LV/LTL epoxy resin adhesive is a two-component system with a long pot life which increases working time.
MFG also provided a prototype sleeve that was tested by Trevcon divers. “After the test they requested a design change: increase dimension by ¼” between the tongue and grove, explains Jim Williams, MFG Construction Products’ plant manager/project leader. “The additional space was needed because of the limited sight issues posed by the Hudson River during installation.” After MFG modified its design, a total of 1500-2000 jackets were produced for the project, which began in 2004 and is scheduled to be completed by the end of 2006. “We established our pile jacket effort approximately three years ago and it represents a growing business segment for us,” Williams says. “With new installations and private label/ joint encapsulation partnerships growing, we’re poised to capture 15% of the pile sleeve market in the near future.” Jim Williams, Molded Fiber Glass Companies; tel: +1-800-225-5634; e-mail: [email protected]; www.mfgcp.com
FRP jackets refurbish timber piles THE STRUCTURAL integrity of the New York City Passenger Ship Terminal (PST) piers at the Port of New York, on the Hudson River, have been restored using a fibre reinforced plastic (FRP) pile encapsulation system. The project was part of the New York City Economic Development Corp’s US$50 million PST improvement plan. The timber piles of the PST’s three, approximately 1000 ft long and 125 ft wide, finger piers, had been eroded by wood-boring marine worms. Because of the amount of passengers using the port restoration of the piles was the best solution to the problem, rather than replacement and an expensive, lengthy shutdown. The encapsulation system chosen comprises a moulded FRP jacket, epoxy grout and aggregate mix. Divers abrade and clean each pile and then place the jackets around them. Epoxy grout and aggregate mix is then pumped by the divers from the bottom up, displacing the seawater. The aggregate mix enhances the bond as it scours the substrate further. The FRP jackets are durable in seawater,
lightweight and relatively easy to install, and provide maintenance-free protection for long periods of time. In Phase II of the project, awarded to Trevcon Construction Co Inc, Liberty Corner, New Jersey, Trevcon evaluated the condition of the pilings and decided to experiment with different epoxies and pile sleeves to maximise savings, assembly time and seam strength. MFG Construction Products Co, Independence, Kansas, was selected to supply the FRP pile sleeves. MFG provided its one-piece FRP pile repair sleeve. Designed to leave in place, the sleeves are chemically resistant to acids, alkalis and most solvents, thus providing long-lasting, reliable protection. They are made from chop strand mat and woven roving, providing better physical properties so the jackets meet or exceed specifications. For underwater assembly, the MFG sleeves offer a slip joint closure designed to make the divers’ jobs easier. Standard diameters are available in 12-36 inches and custom sizes can be accommodated. Lengths
Each year nearly 1 million passengers pass through the PST, which located a few blocks west of Times Square in the heart of Manhattan.
6
REINFORCEDplastics
January 2006
A composite pile encapsulation system was chosen for the New York City Passenger Ship Terminal project.
are produced to specifications and ultraviolet resistance accommodations are available. The MFG sleeve also offered a peal-away liner design seam and a resin bond finish to the jacket, eliminating the need to sandblast for chemical adhesion to work in conjunction with the epoxy used. “MFG was recommended and chosen based upon service and the fact that they could provide the required length and diameter of pile sleeves needed for the project; thus avoiding costly custom-built sleeves,” according to Trevcon president Ron Treveloni. He adds that the MFG jackets’ rough finish also strengthened the bonding epoxy, which was supplied by Sika Corp, Lyndhurst, New Jersey, to the shell. After testing concrete epoxy solutions, which were too heavy and would result in unnecessary weight added to the piers, Sika devised an epoxy resin solution. SIKA USA’s Sikadur 35, Hi-Mod LV/LTL epoxy resin adhesive is a two-component system with a long pot life which increases working time.
MFG also provided a prototype sleeve that was tested by Trevcon divers. “After the test they requested a design change: increase dimension by ¼” between the tongue and grove, explains Jim Williams, MFG Construction Products’ plant manager/project leader. “The additional space was needed because of the limited sight issues posed by the Hudson River during installation.” After MFG modified its design, a total of 1500-2000 jackets were produced for the project, which began in 2004 and is scheduled to be completed by the end of 2006. “We established our pile jacket effort approximately three years ago and it represents a growing business segment for us,” Williams says. “With new installations and private label/ joint encapsulation partnerships growing, we’re poised to capture 15% of the pile sleeve market in the near future.” Jim Williams, Molded Fiber Glass Companies; tel: +1-800-225-5634; e-mail: [email protected]; www.mfgcp.com