Creative Pultrusions, Inc. SuperLoc™ Composite Sheet Pile System

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Creative Pultrusions, Inc. SuperLoc™ Composite Sheet Pile System

  1. 1. SUPERLOC™ COMPOSITE SHEETPILE www.creativepultrusions.com 814.839.4186 Toll Free: 888.CPI.PULL Fax: 814.839.4276 214 Industrial Lane, Alum Bank, PA 15521 Presented by Dustin Troutman 1
  2. 2. OUTLINE • Pultrusion Manufacturing Process and Materials • SuperLoc™ Profiles and Accessories • SuperLoc™ Engineering Analysis and Data • Green Solution • Installation Profiles • Creative Pultrusions Company Overview 2
  3. 3. SUPERLOC™ ATTRIBUTES PULTRUDED 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 3
  4. 4. Pultruded profiles are cut to length during the continuous manufacturing process. 4. Resin and glass fiber reinforcements are combined and formed into the shape of the die on a continuous process. 1. The resin is initiated by the thermal decomposition process. The initiator is heated until a chemical bond dissociation produces two radicals. The chain continues to build until the monomer is used resulting in a cured resin. 2. The profiles are pulled through a die. 3. SUPERLOC™ PROFILES ARE MANUFACTURED BY THE PULTRUSION PROCESS Pulling System* Cut-Off Saw Preformer Continuous Strand Mat Guide Plate Rovings Resin Impregnator Surfacing Veil Forming & Curing Die *Caterpillar Pullers (shown) or Reciprocating Pullers 4
  5. 5. SUPERLOC™ PRODUCTION High Strength Fiberglass is pulled into the heated die. The fibers are injected with a high strength thermoset resin, under high pressure, once in the die. 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. 5
  6. 6. WHY FRP COMPOSITES? Steel Rusts Wood Rots Concrete Spalls PVC deflects and requires additional walers 6
  7. 7. SUPERLOC™ SHEET PILING SYSTEM Top Caps SuperWale™ Corner Connector SuperWale™ Section SuperWale™ Corner Connector SuperWale™ Section SuperWale™ Corner Connector SuperLoc™ Series 1560/1580/1610 Sheet Pile SuperWale™ Section Top Caps SuperWale™ Corner Connector 7
  8. 8. SUPERLOC™ SHEET PILES Series 1610 Commercial/Residential (SS820) Series 1580 Residential/Commercial (SS860) Series 1560 Residential/Light Commercial (SS806) 8
  9. 9. TOP CAPS Series 1610 (CH995) Series 1560 (SS051) Series 1610 (CH995) Series 1560 (SS051) Series 1610 (CH995) Series 1560 (SS051) Series 1580 (CH980) Series 1610 (CH995) Series 1560 (SS051) 9
  10. 10. CONNECTORS Series 1610 (SS821) Series 1560 - 90°/180° (SS809) Series 1560 - 45°/90° (SS804) 10
  11. 11. SUPERWALE™ AND ACCESSORIES SuperWale™ Steel Washers (FAB384 or FAB385) SuperWale™ W-Corner Connector (FAB093 – 90° or FAB094 – 45°) SuperWale™ (SS810) SuperWale™ W-Splice (FAB095) 11
  12. 12. SUPERLOC™ ENGINEERING 12
  13. 13. 13 TEST THE DESIGN IN ONE OF OUR IN-HOUSE TEST FACILITIES FULL SECTION AND COUPON LEVEL TESTING
  14. 14. RESIN OPTIONS Series 1500/1525 POLYESTER (PE) RESINS – are manufactured for corrosion related applications. Polyester resins display excellent structural properties and are resistant to acids, salts, and many dilute chemicals at moderate temperatures. The standard 1525 series contains fire retardant additives that permit the profiles to pass UL94 with a (V0) rating and ASTM E84 with a class A rating. 14
  15. 15. RESIN OPTIONS Series 1625 VINYL ESTER (VE) RESINS – are based on bisphenol, an epoxy resin. VE resins provide resistance to a wide range of acids, alkalis, bleaches and solvents for use in many chemical environments. They also offer excellent toughness and fatigue resistance. The standard 1625 series contains fire retardant additives that permit the profiles to pass UL94 with a (V0) rating and ASTM E84 with a Class A rating. 15
  16. 16. SUPERLOC™ DATA SHEETS • ASTM 7290 Derived. • Can be Used for ASD or LRFD Design Basis. • Supports LRFD Pre-Standard. • Moment Capacity Derived via the LRFD Manual of Pultruded Fiber Reinforced Polymer Structures. 16
  17. 17. THE SUPERLOC™ SHEETPILE DATA SHEETS HAVE BEEN DEVELOPED BASED ON ASTM D7290 REQUIREMENTS Why ASTM D7290? The characteristic value is a statistically-based material property representing the 80% lower confidence bound on the 5th-percentile value of a specified population. It is an Internationally Recognized Standard for Evaluating Material Property Characteristic Values for Polymeric Composites for Civil Engineering Structural Applications. 17
  18. 18. ASTM D7290-06 • Companies With Good Process Control And Quality Standards Are Rewarded In That The Published Characteristic Design Values Are Higher. • Places All Suppliers On An Even Playing Ground. • Enhances The Confidence Level On The Product Performance. • All Design Data Is Reported Based An Internationally Recognized Standard. 18
  19. 19. Load & Resistance Factor Design (LRFD) of Pultruded Fiber Reinforced Polymer (FRP) Structures. Developed by the Pultrusion Industry Council and the American Society of Civil Engineers (ASCE). A design standard exists for the Pultrusion Industry. Our industry joins ranks with steel, wood, concrete and aluminum as a standard material of construction. 19
  20. 20. THE SUPERLOC™ DATA SHEETS AND LOAD & RESISTANCE FACTOR DESIGN (LRFD) THE CHARACTERISTIC VALUES WERE DEVELOPED FOR AN LRFD DESIGN APPROACH WHERE: The characteristic/reference strength values shall be adjusted per table 2.4-1 to account for moisture. – 0.85/.80 for strength for vinyl ester/polyester – .95/.90 for elastic modulus for vinyl ester/polyester. λ – Time effect factor 0.4 for permanent load. φ – Resistance factor for local buckling controlled design – 0.80 or .65. 20
  21. 21. THE SUPERLOC™ DATA SHEETS AND ALLOWABLE STRESS DESIGN (ASD) THE CHARACTERISTIC VALUES CAN BE USED FOR ASD OR LRFD DESIGN APPROACHES. Typical industry ASD safety factors include: - 2.0 to 2.5 in flexure - 2.0 to 3.0 in shear - 2.5 to 3.0 for connections 21
  22. 22. SUPERLOC™ SHEETPILE MOMENT CAPACITY HAS BEEN DEVELOPED BASED ON THE LRFD PRE-STANDARD AND VERIFIED WITH FULL SECTION TESTING. Testing Conducted at Penn State University Note: Critical Load capacity is controlled by Local buckling of the compression flange. 22
  23. 23. 1580 FULL SECTION TESTING Note: Critical Load capacity is controlled by Local buckling of the compression flange. The test results correlated well to the LRFD results. 23
  24. 24. IMPORTANT DESIGN CONSIDERATIONS INCLUDE • Deflection • Moment Capacity • Shear in Bending • Force on Wall Induced by Wale • Point Loads • Severe Abrasion Installations • Drive Ability of the Sheets Based on the Soil Profile Including Blow Counts 24
  25. 25. • Heavy Duty Sheet • Standard Charcoal Gray Color • Optimized UV Protection • Direct Inject Manufacturing Equates to High Strength and Stiffness 25
  26. 26. • Heavy/Medium Duty Sheet. • Available in PE or VE Resins. • Standard Charcoal Gray Color. • Optimized UV Protection. • Can be Driven in Pairs to Increase Production and Reduce Cost. 26
  27. 27. • Medium/Light Duty • Available in PE or VE Resins • Standard Charcoal Gray Color • Optimized UV Protection 27
  28. 28. • Available in PE or VE Resins • Standard Charcoal Gray Color • Optimized UV Protection • Replaces Wood, Steel and Concrete Wales • Pre-Engineered Load Tables. • Galvanized Accessories 28
  29. 29. • Galvanized Steel Splices. • Corner Connectors • Tie-Rod Washers. • Custom Corners Available for Unconventional Angles. 29
  30. 30. UV PERFORMANCE • Each sheet contains Hindered Amine Light Stabilizers (HALS). HALS function as long term thermal and light stability promoters. • Each sheet contains a 10 mil polyester surfacing veil that encapsulates the fiberglass and creates a resin rich surface. 30
  31. 31. LONG TERM DURABILITY Long term durability testing, based on the Arrhenius Principle, indicates that the SUPERLOC sheet pile will maintain 80% of the original compression strength for over 50 years. 1500 Series Resin Normalized Strength VS. Projected Service Life 0.50 0.60 0.70 0.80 0.90 1.00 1.10 0 10 20 30 40 50 60 70 80 90 100 Service Life (years) StrengthRetention Factor Tension Strength (Lengthwise) Compression Strength (Lengthwise) Compression Strength (Crosswise) Bearing Strength @ Yield (Lengthwise) Bearing Strength @ Yield (Crosswise) Linear (Tension Strength (Lengthwise)) Linear (Compression Strength (Lengthwise)) Linear (Compression Strength (Crosswise)) Linear (Bearing Strength @ Yield (Lengthwise)) Linear (Bearing Strength @ Yield (Crosswise)) 31
  32. 32. LONG TERM DURABILITY Long term durability testing, based on the Arrhenius Principle, indicates that the SUPERLOC sheet pile will maintain 90% of the original compression/tensile modulus for over 50 years. 1500 Series Resin Normalized Modulus VS. Projected Service Life 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 0 10 20 30 40 50 60 70 80 90 100 Service Life (years) ModulusRetention Factor Tension Modulus (Lengthwise) Compression Modulus (Lengthwise) Compression Modulus (Crosswise) Linear (Tension Modulus (Lengthwise)) Linear (Compression Modulus (Lengthwise)) Linear (Compression Modulus (Crosswise)) 32
  33. 33. SUPERLOC™ THE GREEN CHOICE • Inert, will not leach dangerous chemicals, pesticides or heavy metals into the environment. 33
  34. 34. SUPERLOC™ THE GREEN CHOICE Embodied Energy Comparison 0 20 40 60 80 SuperLoc™ Steel Aluminum PVC MJ/kgofmaterial 34
  35. 35. SUPERLOC™ THE GREEN CHOICE Co2 Footprint 0 2 4 6 8 10 12 14 SuperLoc™ PVC Steel Aluminum kgCo2/kgofmaterial 35
  36. 36. SUPERLOC™ THE GREEN CHOICE • Greenhouse Gas (kg CO2) .94 • Ozone Layer (kg CFC11) 1.5 × 107 • Acidification (kg SO2) 0.0032 • Eutrophication (kg PO4) 5.9 × 104 • Heavy Metals (kg Pb) 1.2 × 105 • Carcinogens (kg B(a)P) 3.9 × 108 • Summer Smog (kg C2H4) 4.1 × 104 • Winter Smog (kg SPM) 0.0024 • Energy Resources (MJ LHV) 11.0 36
  37. 37. INSTALLATION OPTIONS INCLUDE  Water jetting Equipment.  Jackhammer Equipment.  Vibro-Drive/Hammer System.  Vibratory Compactor. Can be Driven in Soils with a Blow Count of 20 or less without a mandrel. 37
  38. 38. VIBRO-HAMMER INSTALLATION Can be installed in soils with a blow count of 20 or less without a mandrel. 38
  39. 39. MASONBORO HARBOUR, WILMINGTON, NC 900 ft (274m) shoreline bulkhead 39
  40. 40. THE GLENRIDGE ON PALMER RANCH SARASOTA, FL 2,000 ft (609m) shoreline bulkhead 40
  41. 41. THE GLENRIDGE ON PALMER RANCH SARASOTA, FL 41
  42. 42. THE GLENRIDGE ON PALMER RANCH SARASOTA, FL 42
  43. 43. 3,280 ft (1000+ meters) Causeway AZERBAIJAN SERIES 1580 43
  44. 44. AZERBAIJAN PROJECT 3,280 ft (1000+ meters) Retaining Wall 44
  45. 45. AZERBAIJAN COMPLETE 45
  46. 46. DOWNTOWN FT. MEYERS FLORIDA Installed with an ICE Model 6E Vibratory Hammer 46
  47. 47. DOWNTOWN FT. MEYERS FLORIDA COMPLETE 47
  48. 48. DOWNTOWN FT. MEYERS FLORIDA 48
  49. 49. DOWNTOWN FT. MEYERS FLORIDA COMPLETE 49
  50. 50. WALDO POINT HARBOR, CALIFORNIA Currently under construction 50
  51. 51. KEYPORT, NJ 1,451 lineal ft. (427 m) wall photo taken after hurricane Sandy 2012. Installation 2006. 51
  52. 52. KEYPORT, NJ Photos of wall taken during Hurricane Sandy 52
  53. 53. KEYPORT, NJ Photo taken after Hurricane Sandy 2012 53
  54. 54. O’QUINN MARINE SERIES 1580 200 ft (61m) shoreline bulkhead 54
  55. 55. O’QUINN MARINE SERIES 1580 100 ft (31m) shoreline bulkhead 55
  56. 56. O’QUINN MARINE SERIES 1580 100 ft (31m) shoreline bulkhead 56
  57. 57. O’QUINN MARINE SERIES 1580 100 ft (31m) shoreline bulkhead 57
  58. 58. RESIDENTIAL INSTALLATION WRIGHTSVILLE BEACH, NC 125 ft (38m) shoreline bulkhead 58
  59. 59. MAGNOLIA BAY WATERFRONT DEVELOPMENT BILOXI, MS 125 ft (38m) shoreline bulkhead 59
  60. 60. SEABROOK SHIPYARD SEABROOK, TX 1,000 ft (304m) shoreline bulkhead 60
  61. 61. PIRATES COVE MARINA MANTEO, NC 700 ft (213m) shoreline bulkhead 61
  62. 62. PORTOFINO HARBOR MARINA CLEAR LAKE SHORES, TX 3,000 ft (914m) shoreline bulkhead 62
  63. 63. HAMPTON MARINA HAMPTON, VA 1,300 ft (396m) shoreline bulkhead 63
  64. 64. STAR FLEET MARINA CLEAR LAKE SHORES, TX 1,300 ft (396m) shoreline bulkhead 64
  65. 65. GRANDPAPPY POINT MARINA DENNISON, TX 1,000 ft (304m) shoreline bulkhead 65
  66. 66. KETEWOMOKE YACHT CLUB HUNTINGTON, NY 120 ft (36m) shoreline bulkhead 66
  67. 67. BOBBY JONES GOLF COMPLEX SARASOTA, FL 200 ft (61m) shoreline bulkhead 67
  68. 68. LITTLE MINERAL MARINA POTTSBORO, TX 700 ft (213m) shoreline bulkhead 68
  69. 69. CAROLINE COUNTY RECREATION AND PARKS GREENSBORO, MD 350 ft (106m) shoreline bulkhead 69
  70. 70. LOUISIANA DEPARTMENT OF NATURAL RESOURCES MANDALAY BANK PROTECTION DEMO TERREBONNE PARISH, LA 3,800 ft (1158m) shoreline bulkhead 70
  71. 71. RESIDENTIAL INSTALLATION MATTITUCK, NY 90 ft (27m) retaining wall 71
  72. 72. ELEVATED BRIDGE APPROACH SOUTHAMPTON, NY 120 ft (36m) Bridge Approach Walls 72
  73. 73. 2,100 ft (640m) shoreline bulkhead THE SHORES DEVELOPMENT SOUTH PADRE ISLAND, TX 73
  74. 74. THE SHORES DEVELOPMENT SOUTH PADRE ISLAND, TX 2,100 ft (640m) shoreline bulkhead 74
  75. 75. THE SHORES DEVELOPMENT SOUTH PADRE ISLAND, TX 2,100 ft (640m) shoreline bulkhead 75
  76. 76. MARSHALL FORD MARINA AUSTIN, TX 234 ft (71m) Breakwater 76
  77. 77. UNITED STATES NAVY PIER, CHOLLAS CREEK, SAN DIEGO, CA 1,200 ft (365m) shoreline bulkhead 77
  78. 78. MARTINEZ MARINA MARTINEZ, CA 400 ft (121m) shoreline bulkhead 78
  79. 79. FACILITIES OVERVIEW Creative Pultrusions, Inc. was established in 1973 and is located in Alum Bank, Pennsylvania. PRODUCTION MACHINES = 18 FACILITIES (SQ. FT) = 160,000 EMPLOYEES = 148 79
  80. 80. 80 HILL & 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 & Galvanizing Services. • 2013 Revenue of £444.5m • Infrastructure – 71% Roads - 25% Utilities - 46% • Galvanizing - 29% £316.9m £127.6m
  81. 81. 81 WHERE HILL & SMITH OPERATES UNITEDSTATES FRANCE UNITED KINGDOM SWEDEN THAILAND INDIA CHINA AUSTRALIA V • AUSTRALIA: New office in Queensland for the development of our wire rope and safety barrier products. • CHINA: Manufacturing and trading facilities located in the Jiangsu province for the further expansion of our pipe support business. • FRANCE: The locations of France Galva and Conimast, where we have ten galvanizing plants and a lightning column business. • INDIA: New manufacturing facility for pipe supports and also offices for development of our Hill & Smith infrastructure product business. • SWEDEN: Location of ATA Bygg-och Marckprodukter AB, the road safety barrier and signage business. • THAILAND: Location of part of our pipe supports manufacturing capability, where we have plants near Bangkok. • UK: Head office and various group site locations covering our main infrastructure products business and network of UK galvanizing plants. • USA: Our V&S galvanizing and utilities plants are situated on the East Coast along with the Bergen and Carpenter & Paterson pipe support business and the fiber reinforced composite profiles business, Creative Pultrusions.
  82. 82. 82 HILL & SMITH REVIEW OF 2012 INFRASTRUCTURE PRODUCTS The division is focused on supplying engineered products to the roads and utilities markets in geographies where there is a prospect of sustained long term investment in infrastructure. In 2012 the division accounted for 73% (2011: 68%) of the Group’s revenue and 43% (2011: 48%) of the Group’s underlying operating profit. UTILITIES The requirements for new power generation in emerging economies and replacement of aging infrastructure in developed countries provide an excellent opportunity for the Group’s utilities businesses. Revenues increased to £205.7m (2011: £167.0m), which after adjusting for acquisitions and currency impacts, reflects 13% organic growth of £22.5m. Underlying operating profit increased by £1.9m to £13.4m (2011: £11.5m) with acquisitions contributing £0.9m of the growth. The organic growth was driven mainly by our US based businesses, V&S Utilities and Creative Pultrusions, which benefitted from a more active USA utilities market. delivering a number of large projects in the transmission, rail and cooling tower markets. Over the year, we further developed high value products for niche markets. These products are lightweight, corrosion resistant and offer improved installation times, thereby substituting traditional materials. There is a growing demand for composite products and this was evident in the supply of 85 railway platform extensions for the upgrade to the Wessex Line in the UK. CREATIVE PULTRUSIONS ACHIEVED A RECORD PERFORMANCE
  83. 83. 83
  84. 84. MASS TRANSIT DECKS 84 CREATIVE’S PLATFORM EXPERIENCE MIDLANDS, U.K. PLATFORM 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!
  85. 85. APPLICATION PROFILE MASS TRANSIT ELEVATED PLATFORM DECKS FOR NYCTA 85 • 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!
  86. 86. SAN FRANCISCO WEST HARBOR RENOVATION PROJECT SAN FRANCISCO, CA 47 feet of 12” SUPEPILE (including 15 foot thin wall HDPE sleeve) 86
  87. 87. VIRGINIA DEPT. OF TRANSPORTATION 80 foot of SuperPile 12” diameter Bridge Fender System 87
  88. 88. VIRGINIA DEPT. OF TRANSPORTATION Bridge Fender System 88
  89. 89. FLORIDA DOT BRIDGE FENDER Bridge Fender System 89
  90. 90. AIR HAMMER INSTALLATION 90
  91. 91. PRODUCT LINES FACTORY BUILT HS-25 RATED BRIDGE DECKS Why: 200’x60’ Installed in 14 hours! 91
  92. 92. DECKING PRODUCTS SUPERGRATETM PULTRUDED GRATING SUPERDECKTM SUPERPANEL PA004 SUPERPANEL CP150 92
  93. 93. SUPERDECKTM RAIL PLATFORM PANEL SUPERGRATETM MOLDED GRATING SUPERPANEL WALL PANEL CT066 DECKING PRODUCTS SUPERPLANKTM DECKING 93
  94. 94. SUPERDECKING TUF-DEKTM FLOORING HEAVY DUTY PLANK DECKING PRODUCTS FLOWGRIP® FLOORING PANEL 94
  95. 95. FRP DISTRIBUTION AND TRANSMISSION POLES AND CROSSARMS 95
  96. 96. CUSTOM PULTRUSIONS 96
  97. 97. BC HYDRO 287kV TRANSMISSION CHANNEL DESIGNED BY CPI TESTED BY POWERTECH LABS INSTALLED AND VETTED BY BC HYDRO APPLICATION PROFILES 97
  98. 98. APPLICATION PROFILE PEDESTRIAN BRIDGE 98
  99. 99. CELEBRATING OVER 40 YEARS OF PROVIDING PULTRUSION SOLUTIONS QUESTIONS? www.creativepultrusions.com

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