Marine Pile Restoration and Corrosion Protection Systems · Marine Pile Restoration and Corrosion Protection Systems April 16, ... Provides splash zone and underwater corrosion protection

Association of Pacific Ports 2015

Presented by Tom Spear

Marine Pile Restoration and

Corrosion Protection Systems

April 16, 2013

• Protection vs Restoration -Reasons for Pile Repair

• Product Solutions

• Types of Pile Deterioration

• Choosing an Appropriate Repair Solution

– Extreme Deterioration

– Serious Deterioration

– Moderate Deterioration/Protection

• Other Products for Marine Pile Repair

– Cementitious Grouts

– Epoxy Grouts

– Adhesives & Sealants

Agenda

2 © 2013 Five Star Marine, Inc.

• Why Protection ??

• Why Restoration ??

Protection & Restoration


PILE DETERIORATION

There are many causes for


The challenging marine environment, weathering, and poor construction practice leads to concrete failure:

1) Corrosion of steel and the resulting expansive forces

2) Freeze-thaw deterioration

3) Sulfate attack

4) Alkali-silica reaction

5) Impact damage

CONCRETE Pile Deterioration


Shipworms are not worms at all, but rather a group of unusual saltwater clams with very small shells, notorious for boring into wooden structures that are in sea water.

WOOD Pile Deterioration


Hoboken, NJ – Teredos’ and Limnorias, ship worms, termites of the

sea… No matter what you call them, these mollusks are eating

away at the wooden piers in Hoboken.

A large portion of the walkway between Sinatra Field and the

Hudson River collapsed, another in a series of pier collapses along

the waterfront…

“Pier-eating monsters ‘Termites of the sea’

causing piers to collapse…”

Corrosion and

Oxidation are factors in

Steel Piles.

STEEL Pile Deterioration

SOLUTIONS

Five Star Marine®


• Different levels of deterioration require

different repair or protection methods…

Choosing the Appropriate Repair Solution


Ext

rem

e

Mo

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rate

Se

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us

EXTREME DETERIORATION

PileCap® Marine Pile Restoration Systems for


Ext

rem

e

• Five Star Marine® PileCap™ Marine Pile Restoration Systems

are capable of completely

restoring a damaged pile to 100%

structural load bearing integrity.

• All PileCap™ Systems are

designed with the client’s

individual needs in mind with

many applications requiring no

downtime or interruption to

the normal business activity.

PileCap™ Structural Repair Systems

PileCap™ Steel System

Designed to repair severely corroded or breached steel piling. The structural jacket becomes a permanent form for strength and durability by bearing the pile’s intended load while eliminating corrosion and preventing further damage to the pile.


PileCap™ Concrete System A 100% structural jacket designed to repair severely spalled and damaged sections back to full structural integrity. These structural jackets can also be injected with Five Star Marine® epoxy or cementitious Grouts to fill voids and damaged areas. Existing steel, reinforcing mesh, or rebar rods remain internal and require minimal preparation and thus less time and hardware for installation.


PileCap™ HP-Pile System

Fully restore the load bearing integrity to an existing HP-Pile by

removing the damaged portion and replacing it with a new portion. The

new section of piling is connected to the existing.


PileCap™ Timber System

Extends the life of existing wood piles by removing a portion of

damaged or deteriorated piling and installing new sections without

adding additional weight or causing further stress to the wood pile. The

wood piling is brought back to 100% structural integrity.


The PILECOAT System is a marine adapted,

polyurea spray elastomer coating, designed

specifically for use on jackets intended for

concrete, steel and timber surfaces.

PILECOAT is a cost-effective method of

corrosion mitigation providing properly

prepared substrates with 75(+) years of

serviceability.

PileCap™ PILECOAT

Cost effective alternative to driving

new piles

Patented friction coupler system

provides full restoration of structural

integrity

Provides an excellent barrier to

corrosive marine elements

Adds less weight when compared to

conventional repairs

Five Star Marine® professional

engineers will help you consider a

number of design elements for the

perfect custom solution

ADVANTAGES of the PileCap™ S Systems


SERIOUS DETERIORATION

PileForm™ F (FRP) Marine Pile Encapsulation Systems for


Se

rio

us

• PileForm™ F (FRP)

fiberglass jackets

provide protection for

piles in hostile

environments:

– Salt water

– Ice

– Floating debris

– Tidal action

– UV degradation

– Chemical pollutants

– Acids

– Oils

PileForm™ F (FRP) Fiberglass Jackets


1. Round

2. Square

3. H Shapes

4. Pile Capitals

5. Customized to your

designs

Come in a variety of shapes and custom sizes:

PileForm™ F (FRP) Fiberglass Pile Jackets

Round PileForm™ F (FRP) Fiberglass Jackets

Typical timber pile repairs utilizing PileForm™ F (FRP) jackets and

engineered fill materials.


Square PileForm™ F (FRP) Fiberglass Jackets

Robert Moses Bridge


Easy installation

Lightweight for easy maneuvering by divers

Non-corrosive

High strength

Excellent solvent and chemical resistance

High abrasion and impact resistance

Five Star Marine® professional engineers will help you consider a number of design elements for the perfect custom solution

ADVANTAGES of the PileForm™ F Systems

Engineered Fill Systems Are a Permanent Fix


Engineers Drill Core Samples

Samples Display Full Penetration

and Superior Bonding

NEW PILES OR MODERATE

DETERIORATION

PileForm™ W Retrowrap™ Corrosion Control Systems for


Mo

de

rate

Provides splash zone and underwater corrosion protection to new and existing piles, pipelines and risers.

PileForm™ W Retrowrap™

Corrosion Control Systems


The system will withstand attack from environmental UV, ozone

and temperature variations while providing permanent protection

in service, by resisting wave and current forces.

Components which

combine to form the Five

Star Marine® PileForm™ W

Retrowrap™ system are

resistant to long term

immersion in both seawater

and fresh water, and to

biological and chemical

attack.

Easy one-piece installation; no primer, filler or tapes

Minimal surface preparation

Full-length flange closure for easy installation

Easy removal & replacement for reinspection

Provides active protection with environmentally safe corrosion inhibitors

Abrasion-resistant

UV-resistant

May be fitted with corrosion rate monitoring

PileForm™ W Retrowrap™


Multilayer, heavy-duty

construction

Does not require substrate

shotblast preparation

Provides the highest

abrasion resistance

Full-length closure flanges

for easy installation

Easy removal and

replacement for reinspection

Provides active protection

with environmentally safe

corrosion inhibitors

Hoop tension forces created

within the outer skin resist

high wave suction forces

PileForm™ W Retrowrap™ HD


One-piece construction

UV-stable

High abrasion resistance

Easily removable for reinspection

Custom-designed

Conforms to any size and shape

10-year manufacturer's warranty

Five Star Marine® professional support engineers will help you consider a number of design elements for the perfect custom solution

ADVANTAGES of the PileForm™ W Systems


PILE REPAIR PRODUCTS

Five Star Marine® Offers A Full Line of


• Five Star Marine® offers solutions for the structural repair and rehabilitation of above-water and underwater structures:

– Structural Concrete Underwater HP

• Perfect for small volume hand placements with minimal washout underwater.

– Structural Concrete Underwater PG

• Excellent pumping properties and minimal washout during large volume placements. Provides increased corrosion protection of steel reinforced structures with migrating corrosion inhibitor.

– Splash Zone Epoxy Compound

• 100% solids, two component epoxy compound .

– Waterproof Plug

• Fast-setting hydraulic cement that stops active leaks.

Structural Repair Products

• Epoxy Pile Jacket Grouts

– FSM Pile Jacket Epoxy Grout HP

– FSM Pile Jacket Epoxy Grout

– FSM Pile Jacket Epoxy Grout LPL

• Cementitious Pile Jacket Grouts

– FSM Structural Concrete UW PG

– FSM Cementitious Underwater Grout

– FSM Cementitious Underwater High-Strength

Grout

Engineered Fill Materials

Engineered Epoxy Grout Overview

Design Considerations

• Components supplied as a system

• Superior bond, tensile and compressive strength

• Minimal water absorption

• High impact resistance

• Excellent freeze-thaw resistance

• Lower weights added to existing piles

• Greatly improved long term durability

• Greatest return on investment

Limiting Considerations

• Perceived cost factor

• Pre-conditioning is required in cold weather applications

Engineered Cementitious

Grout Overview

Design Considerations

• Engineered product with

Quality Control pre-

determined

– vs. field mix

grout/concrete

• Wide temperature range

– (40-90o F)

• Extendable with coarse

aggregate

Limiting Considerations

• Freeze/thaw deterioration

• Larger Annulus requires: – Larger Jacket

– Increased Weight

• Requires quality course aggregate for extension

Erosion Control Products

• Tidal/Wave action and flooding cause erosion and the undermining of structures:

– PileForm™ ABM

• PileForm™ ABM mats are useful tools for underpinning and slope stabilization.

– PileForm™ SPB

• Scour Protection Bags represent a revolutionary step forward in the technology of underwater scour protection.

• Five Star Marine® offers everything needed to

successfully complete your marine rehabilitation or

repair project:

– High Performance Adhesives, Crack Injection & Anchorages:

• UW Epoxy Gel

• HP Anchor Gel Adhesive

• Epoxy Adhesive LV

• RS Anchor Gel Adhesive

• Splash Zone Compound

• PileForm™ Joint Filler

• Injection Gel Adhesive

Adhesive & Coating Products

• Five Star Marine® has all the support material needed to specify and install any marine pile stabilization, rehabilitation and protection project:

– Datasheets

– MSDS

– Design-A-Spec™ Guides

– Installation Guides and Videos

– Detail Drawings

Support Materials


Thank you for your time!

Schrader Co Sales LLC

www.schraderco.com/ 5Star-Marine.com

Tom Spear-Brian Jones 425-377-1550

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http://www.schraderco.com/

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Marine Pile Restoration and Corrosion Protection Systems · Marine Pile Restoration and Corrosion Protection Systems April 16, ... Provides splash zone and underwater corrosion protection