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Creative Pultrusions, Inc. PowerPoint Presentation highlighting the SuperPile piling product line.
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SuperPile SuperPile Composite Composite Fender Pile Fender Pile
SystemSystem
Presented byPresented byDustin Troutman
Director of Marketing & Product Development
CREATIVE PULTRUSIONS, INC.
www.creativepultrusions.com
SuperPile AttributesSuperPile AttributesPultruded profiles are used extensively around the world, providing the lowest cost solutions, as part of engineered systems or stand alone products.
Benefits include:
• Light Weight
• High Strength
• Low Maintenance
• Ease of Fabrication
• Will not rot, corrode or spall
• Superior Dielectric Strength
• Lowest Installed Cost
• “Green” Low Embodied Energy
SuperPile Profiles SuperPile Profiles are Manufactured by the are Manufactured by the
Pultrusion ProcessPultrusion Process
SuperPile ProductionSuperPile ProductionHigh strength fiberglass is pulled into the heated die.
The fibers are injected with a high strength polyurethane resin and cure in a continuous process.
Finished product is pulled through the die and into the cut-to-length saw where it is cut and prepared for shipment to the job site.
SuperPile ConstructionSuperPile Construction High strength E-glass engineered reinforcements provide superior strength and stiffness in the 0°, +45°, -45° and 90° directions.
High pressure injected SUPURTUF™ polyurethane matrix provides the extraordinary strength and toughness of the SuperPile.
SUSUPURPURTUF™ Polyurethane TUF™ Polyurethane ResinResin
Traditional Resins vs. SUPURTUF Polyurethane
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
Tensile Strength(LW) ASTM
D638
Tensile Strength(CW) ASTM
D638
CompressiveStrength (LW)ASTM D695
CompressiveStrength (CW)
ASTM D695
InterlaminarShear (LW)
ASTM D2344
Test and Method
psi
Polyester
Polyester FR
Vinyl EsterSUPURTUF 4000
• Superior Strength
• Superior Chemical Resistance
• Superior Impact Strength
• Superior Toughness
• Superior Energy Absorption
SUSUPURPURTUF™ Polyurethane TUF™ Polyurethane UV PerformanceUV Performance
• 8,000 hours QUV testing.
• No significant change in compression strength.
• Exterior will fade over time and begin to chalk.
TR150.794 Test Results: Lengthwise Compression Strength vs. QUV Exposure Time
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
100,000
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
QUV Exposure
Str
en
gth
(p
si)
Test Results: No Paint
Test Results: Painted w/ SWSolar Reflective Walnut Brown
SuperPile Mechanical SuperPile Mechanical & Physical Properties & Physical Properties
Average values based on full
section testing performed at
WVU
Note: FLDOT has adopted the ultimate
strength at 80% of the average values.
SuperPile Mechanical SuperPile Mechanical & Physical Properties& Physical Properties
Specification Test Requirement
Standard TitleSuperPile by
Creative Pultrusions, Inc.
Creative Pultrusions, IncSupplied HDPE Sleeve
(when applicable)
Required Properties for Fiberglass Structurally Reinforced
Composite Lumber (SCL)
ASTM D792Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement
Density = 122.3 pcfVoid Content < 1%
59.9 pcf (tested D1505)
55-63 pcf
ASTM D570 Standard Test Method for Water Absorption of Plastics 0.15% (24hrs).01-.1%
(From www.matweb.com HDPE Extruded)
2hrs <1.0% weight increase24hrs <3.0% weight increase
ASTM D746Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact
Test using ASTM D7028 (DMA)Tan Delta Peak = 132°C
G' (-50°C) = 6.5 GPa
G' (25°C) = 5.29 GPa1
< -75-deg C Brittleness Temp < -40-deg C
ASTM D256Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics
90 ft-lb/in1.47-11.0 ft-lb/in
(From www.matweb.com HDPE Pipe Grade)
> 0.55ft-lb/in
ASTM D2240 Standard Test Method for Rubber Property—Durometer Hardness 85 Shore D 62 Shore D 44-75 (Shore D)
ASTM D4329 Standard Practice for Fluorescent UV Exposure of PlasticsNo measurable hardness
change after 1344hrs UV exposure500 hours < 10% change in Hardness
ASTM D4060Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber Abraser
0.0035 oz0.002 oz
(web search)
Weight Loss < 0.02ozCycles = 10,000Wheel = CS17
Load - 2.2lb
ASTM D756Practice for Determination of Weight and Shape Changes of Plastics Under Accelerated Service Conditions (Sea Water, Gasoline, No. 2 Diesel)
Sea Water = 0.32% Wt Increase2
Gasoline = 0.33% Wt Increase2
No. 2 Diesel = 0.14% Wt Increase2
Sea Water < 1.5% Weight IncreaseGasoline < 9.5% Weight Increase
No. 2 Diesel < 6.0% Weight Increase
ASTM D638 Standard Test Method for Tensile Properties of Plastics 136000 psi> 3,500psi
(yield)Min. 2,200 psi @ Break (Strength)
ASTM D695 Standard Test Method for Compressive Properties of Rigid Plastics 6.40E+06 psi> 175,000 psi
(Tested D638 Tension)Min. 40,000 psi @ Break (Modulus)
ASTM D1894Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting
0.207 0.2-0.25 Max. 0.25 Wet
ASTM D6117Standard Test Methods for Mechanical Fasteners in Plastic Lumber and Shapes
1,728 lb (1/4"-14 x 1.5" Long SS Hex Head
Self Drilling Screw)Min. 60lb
Full Section Bend TestFull Section Bend Test
• Full Section Four Point Bend to Failure per ASTM D6109.
• 20:1 Span to Depth Ratio• Established EI.• Established Bending
Strength. • Established Energy
Absorption Characteristics.• Five Piles of Each Series
Were Tested.Flexural Test, WVU
Full Section Bend Results Full Section Bend Results 12” dia. SuperPile 12” dia. SuperPile
Flexural Test, WVU
Full Section Bend Results Full Section Bend Results 16” dia. SuperPile16” dia. SuperPile
Full Section Transverse Full Section Transverse Pin BearingPin Bearing
• 1” diameter pin.
• Loaded to failure.
• Failure mode, bearing of FRP tube.
• Transverse bearing strength ≈ 23,000 psi.
Full Section Crush StrengthFull Section Crush Strength
• Crush strength based on compression loading a 10”x10” HDPE wale section into the SuperPile.
• Crush Strength ≈ 27 kips.
Full Section Crush Strength Full Section Crush Strength EnhancementEnhancement
• Crush strength can be increased with the addition of an FRP insert.
• Crush Strength increase to 77 kips when needed.
SuperPile Bolt Pull Through SuperPile Bolt Pull Through StrengthStrength
• Bolt pull through strength bases on a 1” dia bolt with large. square curved washers
• Average 27 kips.
SuperPile Fatigue Testing SuperPile Fatigue Testing 12” dia. SuperPile 12” dia. SuperPile
• 200 cycles
• Max load 40% of ultimate
• Results, no significant decrease in strength or stiffness.
Fatigued Sample vs. Average12" SuperPile
0
20
40
60
80
100
120
Max Load (kips) Max Stress (psi) Bending MOE(Msi)
Test
Average of 5 SUPURTUF12" SuperPile
Fatigued Pile 200 cycles
SuperPile Fatigue Testing SuperPile Fatigue Testing 16” dia. SuperPile 16” dia. SuperPile
• 200 cycles.
• Max load 40% of ultimate.
• Results, no significant decrease in strength or stiffness.
Fatigued Sample vs. Average 16" dia SuperPile
0
20
40
60
80
100
120
Max Load (kips) Max Stress (psi) Bending MOE
Test
Average of 5 SUPURTUF16" SuperPile
Fatigued Pile 200 cycles
Fatigue of Pultruded Fatigue of Pultruded CompositesComposites
LRFD Pre-Standard LRFD Pre-Standard
• Δ S - ratio of the live load stress to that of the tensile failure stress.
• Below 4,000 cycles fatigue can be neglected.
S-N Curve For Tensile Stress Gross Section*
0
0.1
0.2
0.3
0.4
0.5
0.6
1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08
Number of Stress Cycles, Nf
Str
ess
Ran
ge,
DS
FDOT QPL FDOT QPL ApprovalApproval
Pile system was designed and approved based on FDOT Structures Manual Volume 1 January 2012.
FDOT QPL Approval FDOT QPL Approval
FDOT QPL Approval FDOT QPL Approval
FDOT QPL ApprovalFDOT QPL Approval
FDOT QPL Approval FDOT QPL Approval
Connection DetailsConnection Details
Connection DetailsConnection Details
• Stainless Steel Hardware.
• 6” Square Curved Washers.
• 50 lb-ft max. torque.
• Self drilling screws for attaching the cap.
Pile Splice OptionPile Splice Option
• Steel Pipe Splice Installed at VADot Rte. 3 Piankatank River Fender Project.
• Connection tested during PDA test by Crofton Diving.
• Bolted connection with three 1” dia bolts.
Pile Splice Testing Pile Splice Testing
• Three bolt connection tested with a vibratory hammer to test the pin bearing strength after excessive vibration.
• Bolt holes were scrutinized for pin bearing damage.
PDA Analysis Performed PDA Analysis Performed by Atlantic Coast by Atlantic Coast EngineeringEngineering
Location: Crofton Services
Yard Portsmouth, VA
PDA AnalysisPDA Analysis
An 18” Dia. ½” thick steel
tube was bolted to the end
of the pile to increase the
driving resistance.
PDA Analysis Hammers PDA Analysis Hammers UsedUsed
• Vulcan 01 (5,000 lb ram
with a stroke of 3 ft.).
• APE D30-32 (6,600 lb
ram with a stroke of
11.25 ft.).
PDA Analysis SummaryPDA Analysis Summary• A 60’ SuperPile driven to refusal at 35’ with a
Vulcan 01 Hammer (120 blows/ft).
• Evaluated driving resistance 160 kips, energy 8
kip-ft, compressive driving stress 8 ksi.
• The pile was extracted and the steel toe plate
was removed.
• The pile was inspected.
PDA Analysis SummaryPDA Analysis Summary• A 60 ft SuperPile was driven to 50’ with an APE 30-32
Hammer (6-9 blows/ft).
• The next day the pile was driven an additional 2’ with a blow
count of (110 to 125 blows/ft) .
• Evaluated driving resistance 340-370 kips, energy transfer
30 kip-ft, compressive
driving stress 13-15 ksi.
PDA Analysis Summary PDA Analysis Summary ConclusionsConclusions
PDA Analysis Summary PDA Analysis Summary ConclusionsConclusions
Impact Hammer Impact Hammer Installation Options Installation Options Include:Include:
Air Hammer with a rated capacity of
15 to 35 kip-ft.
Diesel hammer with a rated capacity
of 15 to 35 kip-ft.
Vibratory Drive/Hammer System
Vibratory Compactor
Note: A driving cap is required.
Impact Hammer Impact Hammer Installation VideoInstallation Video
Vibratory Hammer Vibratory Hammer InstallationInstallation
Vibratory Hammer Vibratory Hammer InstallationInstallation
Why Specify SuperPile?Why Specify SuperPile?
• Installs 2x faster than solid piles.
• An ANSI Code of standard practice exists for the
pultrusion industry.
• An LRFD Pre-Standard exists for the pultrusion
industry.
• Our design values are backed by extensive
independent testing.
• CPI has been providing infrastructure solutions
for 40 years.
AccessoriesAccessories
• Thermoplastic caps
• FRP caps
• HDPE sleeves
• FRP sleeve ring
Important Design Important Design Considerations IncludeConsiderations Include
• Deflection
• Point Loads
• Drive Ability of the Piles Based on the Soil Profile Including Blow Counts
SuperPile™ the Green SuperPile™ the Green ChoiceChoice
• Inert, will not leach dangerous chemicals and pesticides or heavy metals into the environment.
Pile Splice OptionPile Splice Option
• Steel Pipe Splice Installed at VADot Rte. 3 River Fender Project.
• Connection tested during PDA test by Crofton Diving.
• Bolted connection with three 1” dia bolts.
Pile TipsPile Tips
• Cast iron pile tips are utilized for bearing piles.
Important Design Important Design Considerations IncludeConsiderations Include
• Deflection
• Point Loads
• Drive Ability of the Piles Based on the Soil Profile Including Blow Counts
Why Specify an FRP Why Specify an FRP SuperPile?SuperPile?
• Installs 2x faster than solid piles.
• Can be field fabricated.
• Will not leach chemicals
• Will absorb more energy than concrete and
wood piles.
• Will not rot, spall or deteriorate.
• Can be installed with traditional pile driving
equipment.
• Lowest installed cost.
Margate Bridge, NJ Margate Bridge, NJ
52 12” diameter FRP piles at 80 foot in length were used to construct the bridge fender.
Margate Bridge, NJ Margate Bridge, NJ
Piles Ready to Ship Piles Delivered to the Job Site
Piles Installed with a Vulcan
V5C Vibro Hammer
Margate Bridge, NJ Margate Bridge, NJ Complete FenderComplete Fender
Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender
116 16” diameter SuperPiles used to construct the fender
Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender
PDA Analysis was conducted to verify that the FRP pile could penetrate the Yorktown Shale formation prior to approval of the FRP Fender Pile for the TWIGG Bridge
Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender
FRP piles being installed with a Vulcan 01 5,000 lb hammer.
Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender
Divers had to locate the piles around a buried electric cable
Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender
Driven piles with polymer wales attached
Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender
Completed Fender
Pinellas Bayway Bridge Pinellas Bayway Bridge Florida DOT Florida DOT
Pinellas Bayway Bridge Pinellas Bayway Bridge Florida DOT Florida DOT
104 16” diameter 67’ long SuperPiles used to construt the fender
Pinellas Bayway Bridge Pinellas Bayway Bridge Florida DOT Florida DOT
104 16” diameter 67’ long SuperPiles used to construct the fender
Statue of Liberty Project Statue of Liberty Project FHWA Project FHWA Project
198 piles 12” in diameter by 48’ long
Statue of Liberty Project Statue of Liberty Project FHWA Project FHWA Project
Craney Island Portsmouth, VA Craney Island Portsmouth, VA Fuel Pier U.S. NavyFuel Pier U.S. Navy
95’ piles, HDPE sleeves, filled with concrete, FRP ring.
Craney Island Portsmouth, VA Craney Island Portsmouth, VA Fuel Pier U.S. NavyFuel Pier U.S. Navy
FRP ring permits the sleeve to slide
Wharf Charlie, Mayport FloridaWharf Charlie, Mayport FloridaU.S. NavyU.S. Navy
72’ piles, HDPE sleeves, FRP Insert
San Francisco West Harbor San Francisco West Harbor Renovation ProjectRenovation ProjectSan Francisco, CASan Francisco, CA
47 feet of 12” SuperPile (including 15 foot thin wall HDPE sleeve)
Long Beach New York Long Beach New York Hurricane Sandy Repair and Hurricane Sandy Repair and
Protection Protection
Long Beach New York Long Beach New York Hurricane Sandy Repair and Hurricane Sandy Repair and
Protection Protection
Long Beach New York Long Beach New York Hurricane Sandy Repair and Hurricane Sandy Repair and
Protection Protection
Long Beach New York Long Beach New York Hurricane Sandy Repair and Hurricane Sandy Repair and
Protection Protection
Facilities Overview
Facilities Facilities (Sq. Ft)(Sq. Ft) 160,000160,000
Production MachinesProduction Machines 18 18
EmployeesEmployees 148148
DLR: 04.25.13
Creative Pultrusions, Inc. was established in 1973 Creative Pultrusions, Inc. was established in 1973 and is located in Alum Bank, Pennsylvania.and is located in Alum Bank, Pennsylvania.
Hill & Smith Review of 2012
Creative is Owned by:Creative is Owned by:Hill & Smith Holdings PLCHill & Smith Holdings PLC
• Hill & Smith Holdings PLC is an international group with leading positions in the design, manufacture and supply of infrastructure products and galvanizing services to global markets. It serves its customers from facilities principally in the UK, France, USA, Thailand, Sweden and China.
• The Group's operations are organized into two main business segments: Infrastructure Products and Galvanizing Services.
• Revenue 2011 £406.2m
Creative’s Platform Creative’s Platform Experience Midlands, U.K. Experience Midlands, U.K.
Platform ExtensionPlatform Extension
• Creative engineered and manufactured the FRP platform system in conjunction with sister company
• Manufactured in Alum Bank, PA and installed in the UK. • Why did Network Rail specify an FRP platform? Speed of
installation and corrosion resistance!
Creative’s Platform Creative’s Platform Experience NYCTA Experience NYCTA
Elevated RailElevated Rail
• Creative engineered and manufactured the FRP platform deck system.
• Manufactured in Alum Bank, PA and installed in New York • Why did NYCTA specify an FRP platform? Speed of
installation and corrosion resistance!
Product LinesProduct LinesFactory Built HS-25 Rated Factory Built HS-25 Rated Bridge DecksBridge Decks
Why: 200’x60’ Installed in 14 hours!
Product LinesProduct LinesFiberglass Decking / Flooring / Grating and Panels
Tuf-dek™ Flooring
SuperPlank™ Decking Flowgrip® Flooring Panel SuperDecking
Heavy Duty Plank
Product LinesProduct LinesFiberglass Decking / Flooring / Grating and Panels
Supergrate™ Pultruded Grating
Supergrate™ Molded Grating
SUPERPANEL PA004
SUPERPANEL Wall Panel CT066
SUPERPANEL CP150 Superdeck™
Superdeck™ Rail Platform Panel
Product LinesProduct LinesUtility ProductsUtility Products
• Distribution Poles
• Cross Arms
Product LinesProduct LinesCooling Tower ComponentsCooling Tower Components
287kV Live installation 287kV Live installation transmission arms for BC transmission arms for BC HydroHydro
Over 1,000 Pedestrian Over 1,000 Pedestrian Bridges built with our Bridges built with our materialsmaterials
Questions Questions and and
AnswersAnswers