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Creative Pultrusions, Inc. SuperPile Marine Products

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Creative Pultrusions, Inc. PowerPoint Presentation highlighting the SuperPile piling product line.

Creative Pultrusions, Inc. PowerPoint Presentation highlighting the SuperPile piling product line.

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  • 1. 214 Industrial Lane, Alum Bank, PA 15521
  • 2. 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 SUPERPILE COMPOSITE PIPE PILES
  • 3. 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 SUPERPLIE ATTRIBUTES
  • 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. 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 SUPERPILE PROFILES ARE MANUFACTURED BY THE PULTRUSION PROCESS
  • 5. SUPERPILE PRODUCTION High 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.
  • 6. 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. SUPERPLIE CONSTRUCTION
  • 7. 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 Compressive Strength (LW) ASTM D695 Compressive Strength (CW) ASTM D695 Interlaminar Shear (LW) ASTM D2344 Test and Method psi Polyester Polyester FR Vinyl Ester SUPURTUF 4000 • Superior Strength • Superior Chemical Resistance • Superior Impact Strength • Superior Toughness • Superior Energy Absorption WHAT MAKES SUPERPILE PERFORM? SUPURTUF™ POLYURETHANE RESIN!
  • 8. • UV Light Absorbers Protect The Resin From UV Damage. • 10 Mil Polyester Veil Encapsulates The Fiberglass To Eliminate Fiber Blooming. • Additional UV Protection Is Available By Applying Hdpe Sleeves, Polyurea Coatings And Polyester Powder Coatings. SUPURTUF™ POLYURETHANE UV PERFORMANCE
  • 9. • 8,000 Hours QUV Testing. • No Significant Change In Compression Strength. • Exterior Will Fade Over Time And Begin To Chalk. • Piles Can Be Coated With HDPE Sleeve Or Powder Coated With A UV Optimized Polyester Powder Coating. 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 Strength(psi) Test Results: No Paint Test Results: Painted w/ SW Solar Reflective Walnut Brown SUPURTUF™ POLYURETHANE UV PERFORMANCE
  • 10. SUPERPILE FRP PIPE PILE PRODUCT BROCHURE
  • 11. SUPERPILE FRP PIPE PILE TESTING • Tested Per ASTM D6109 Test Standards At West Virginia University (WVU). • Method To Determine The Full Section Bending Modulus Of Elasticity And The Full Section Bending Strength. • Tested To Determine The Crush Strength, Pin Bearing Strength, Washer Pull Through Strength And Connection Capacities Both At WVU And At Creative Pultrusions, Inc. (CPI) Test Facility. • Pile Dynamic Analysis (PDA) Performed By Atlantic Coast Engineering.
  • 12. THERMOPLASTIC PILE AND HDPE SLEEVE COMPARISON
  • 13. Values are Published As Average and per ASTM D7290 SUPERPILE MECHANICAL & PHYSICAL PROPERTIES
  • 14. CHARACTERISTIC DESIGN PROPERTIES ARE DETERMINED PER ASTM D7290 WHY ASTM D7290 AND WHY SHUOLD I CARE? It is an internationally recognized standard for evaluating material property characteristic values for polymeric composites for civil engineering structural applications. The characteristic value is a statistically-based material property representing the 80% lower confidence bound on the 5th percentile value of a specified population. 14 The characteristic value allows you to use LRFD or Allowable Stress Design techniques and it allows you to fairly compare FRP to other types of piles.
  • 15. 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 On An Internationally Recognized Standard.
  • 16. PULTRUDED STRUCTURES DESIGN METHODOLOGY OPTIONS LRFD or ASD 16
  • 17. • Load & Resistance Factor Design (LRFD) Of Pultruded Fiber Reinforced Polymer (FRP) Structure. • Developed By The Pultrusion Industry Council (PIC) 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. 17 LRFD Design
  • 18. SUPERPILE 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 & Polyurethane /Polyester. – .95/.90 For Elastic Modulus For Vinyl Ester & Polyurethane /Polyester. λ – Time Effect Factor 0.4 For Permanent Load. φ – Resistance Factor For Local Buckling Controlled Design – .65.
  • 19. SUPERPILE & ALLOWABLE STRESS DESIGN 2.5 in Flexure 3.0 in Shear 3.0 for Connections • Material Properties Are Reduced To Satisfy An Appropriate Safety Factor. • Typical Safety Factors For Pultruded Structures. 19
  • 20. • 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. • Nineteen 12”x1/2” And Twelve 16”x1/2” Piles Were Tested To Failure. • Piles From Several Production Runs Were Tested. Flexural Test, WVU FULL SECTION BEND TEST
  • 21. Testing at Ft. Collins, CO ENERGY ABSORPTION • High Strength And Rather Low Modulus Values, As Compared To Steel, Equate To Very High Energy Absorption Capabilities. • Ideal For Dock And Bridge Fender Systems Where Energy Absorption Is Critical. • Derived By Calculating The Area Under The Load/Deflection Curve.
  • 22. BOLTED CONNECTIONS FOR FORCES APPLIED PARALLEL TO THE PILE • Characteristic Design Values Have Been Developed And Published Per ASTM D7290 • The Capacities Were Developed From Full Section Testing. • A 1.0” Diameter Bolt Was Used In The Test. • Failure Load Is Defined As The First Indication Of A Yield In The Load/Displacement Plot. • Chart Represents The Bolt Being Loaded On One Side Of The Pile.
  • 23. • 1” Diameter Pin. • Failure Mode, Pin Bearing Of Frp Tube. • Chart Represents The Bolt Capacity Loaded On One Side Of The Pile. BOLTED CONNECTIONS FOR FORCES APPLIED TRANSVERSE TO THE PROFILE
  • 24. FULL SECTION CRUSH STRENGTH • Crush Strength Derived By Applying A Transverse Load Into The SUPERPILE Through A 10”x10” Wale Section. • The Ultimate Load Is Defined As The First Yield Point On The Load Vs. Displacement Plot.
  • 25. FULL SECTION CRUSH STRENGTH ENHANCEMENT • Crush Strength Can Be Increased With The Addition Of An FRP Insert. • Crush Strength Can Be Increase To 74 Kips Or Higher When Needed. • The Addition Of Concrete, In Localized Sections, Can Be Used To Increase The Crush Strength. Testing Has Indicated That The Crush Strength Can Be Increased To 180+ Kips.
  • 26. SUPERPILE BOLT PULL THROUGH STRENGTH WITH CURVED WASHER • Average And Characteristic Washer Pull Through Strengths Have Been Developed. • The Values Are Based On 6”x1/2” And 6”x3/8” Curved Washers For The Round Piles And 4”x3/8” Washers For The Octagonal Piles. • Washers Can Be Used To Increase The Crush Resistance.
  • 27. SUPERPILE FATIGUE TESTING 12” DIA. SUPERPILE • 200 Cycles. • Max Load 40% Of Ultimate. • Results, No Significant Decrease In Strength Or Stiffness. Fatigued Sample vs. Average 12" SuperPile 0 20 40 60 80 100 120 Max Load (kips) Max Stress (psi) Bending MOE (Msi) Test Average of 5 SUPURTUF 12" SuperPile Fatigued Pile 200 cycles
  • 28. SUPERPILE FATIGUE TESTING 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 SUPURTUF 16" SuperPile Fatigued Pile 200 cycles
  • 29. FATIGUE OF PULTRUDED COMPOSITES 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 StressRange,∆S
  • 30. FDOT QPL APPROVAL Pile System Was Designed And Approved Based On FDOT Structures Manual Volume 1 January 2012.
  • 31. CONNECTION DETAILS
  • 32. • Stainless Steel Hardware. • 6” Square Curved Washers. • 50 Lb-ft Max. Torque. • Self Drilling Screws For Attaching The Cap. CONNECTION DETAILS
  • 33. • Connection Detail Decreases The Point Load Stress. • Hollow Composite Pipe Piles Require Attention To The Connection Details. • Excessive Point Loads Should Be Avoided. CONNECTION DETAILS PILE TO PIER CONNECTION
  • 34. COLUMN LOADS • Long Column Loading- SUPERPILE Follows Euler Buckling.
  • 35. PDA ANALYSIS PERFORMED BY ATLANTIC COAST ENGINEERING Location: Crofton Services Yard Portsmouth, VA
  • 36. PDA ANALYSIS • An 18” Dia. ½” Thick Steel Tube Was Bolted To The End Of The SUPERPILE To Increase The Driving Resistance. • A Vulcan 01 (5,000 Lb Ram With A Stroke Of 3 Ft.) Was Utilized To Drive The Piles To Refusal. • An Ape D30-32 (6,600 Lb Ram With A Stroke Of 11.25 Ft.) Was Utilized To Drive The Pile To Failure.
  • 37. PDA Analysis SUMMARY The test pile driven with the Vulcan 01 Impact Hammer, to refusal, demonstrated a driving resistance of 160 kips, a driving energy of 8 kip-ft., and a compressive driving stress of 8 ksi. The pile was extracted, inspected and revealed no signs of damage.
  • 38. PDA ANALYSIS SUMMARY The test pile driven with the larger APE D30-32 impact hammer was driven through the same soils at a blowcount of 9 blows/ft. Ending at a blowcount of 12 blows/ft., which was evaluated to represent a resistance of 200 kips with a compressive stress of 11 ksi. No evidence of damage was observed.
  • 39. PDA ANALYSIS SUMMARY After a One Day Set Up Period, the Pile was Re-Driven with the APE D30-32 Impact Hammer at a Substantially Greater Resistance. At 235 blows/ft., a Driving Resistance of 340- 370 kips, an Average Energy Transfer of 30 ksi and a Recorded Compressive Driving Stress of 13-15 ksi, the Pile Head Split and the Pile Failed. Prior to the Pile Head Splitting, a CAPWAP® Analysis Indicated an Ultimate Axial Compressive Capacity of 350 kips.
  • 40. PDA ANALYSIS SUMMARY CONCLUSIONS • The PDA Testing Indicates that Impact Hammers with a Rated Energy of 15 to 35 kip-ft are Appropriate for the Installation of SUPERPILES. • Hammers with Rated Energies in the Range of 35 to 50 kip-ft Should be Used with Some level of Caution, and May Require a Pile Cushion to Reduce Driving Stresses. • Based on Observations Made During the Test Pile Program, It is Recommended that Dynamic Consultants Utilize a Model PAX PDA Unit (with a longer pretrigger buffer than the PAK unit) Due to the Longer Pre- Compression Time. • For Impact and Vibratory Installed SUPERPILES, CPI Recommends the use of a Wave-Equation Analysis and Driveability Study to Assess the Soil-Pile Interaction and Estimate Pile Driving Stresses During Installation Considering the Proposed Hammer Assembly and Site Soil Profile.
  • 41. IMPACT HAMMER INSTALLATION VIDEO
  • 42. VIBRATORY HAMMER INSTALLATION
  • 43. ACCESSORIES • Thermoplastic Caps • FRP Caps • HDPE Sleeves • Driving Tips • Custom Coatings
  • 44. ACCESSORIES – FRP STRUCTUTAL PROFILES, DECKING AND GRATING
  • 45. • 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” Diameter Bolts. PILE SPLICE OPTIONS
  • 46. 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.
  • 47. PULTRUSION THE GREEN CHOICE EMBODIED ENERGY COMPARISON 80 60 40 20 0 S U P ER LO C TM S TE E L A LU M IN U M P V C MJ/kgOFMATERIAL 47 Will Not Leach
  • 48. WHY SPECIFY SUPERPILE? • Installs 2x Faster Than Solid Piles.
  • 49. WHY SPECIFY SUPERPILE? • Energy Absorption Capacity
  • 50. WHY SPECIFY SUPERPILE? • Ease of Fabrication
  • 51. WHY SPECIFY SUPERPILE? • Environmentally Friendly
  • 52. WHY SPECIFY SUPERPILE? • Engineered Solution, Manufactured in a Climate Controlled Facility to Stringent QA Standards.
  • 53. WHY SPECIFY SUPERPILE? • Will Stand The Test Of Time. • 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 41 Years. • Will Not Rot, Spall Or Deteriorate. • Can Be Installed With Traditional Pile Driving Equipment.
  • 54. MARGATE BRIDGE, NJ 52 12” diameter FRP piles at 80 foot in length were used to construct the bridge fender.
  • 55. MARGATE BRIDGE, NJ Piles Ready to Ship Piles Delivered to the Job Site Piles Installed with a Vulcan V5C Vibro Hammer
  • 56. MARGATE BRIDGE, NJ COMPLETE FENDER
  • 57. VIRGINIA DOT TWIGG BRIDGE FENDER 116 16” diameter SUPERPILES used to construct the fender
  • 58. VIRGINIA DOT 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
  • 59. VIRGINIA DOT TWIGG BRIDGE FENDER FRP piles being installed with a Vulcan 01 5,000 lb hammer.
  • 60. VIRGINIA DOT TWIGG BRIDGE FENDER Divers had to locate the piles around a buried electric cable
  • 61. VIRGINIA DOT TWIGG BRIDGE FENDER Driven piles with polymer wales attached
  • 62. PINELLAS BAYWAY BRIDGE FLORIDA DOT 104 16” diameter 67’ long SUPERPILES used to construct the fender
  • 63. APPLICATION PROFILE PINELLAS BAYWAY BRIDGE PIPE PILE FENDER INSTALLATION 63
  • 64. PINELLAS BAYWAY BRIDGE FLORIDA DOT 104 16” diameter 67’ long SUPERPILES used to construct the fender
  • 65. STATUE OF LIBERTY PROJECT FHWA PROJECT 198 piles 12” in Diameter by 48’ Long Bearing Piles
  • 66. STATUE OF LIBERTY PROJECT FHWA PROJECT
  • 67. STATUE OF LIBERTY PROJECT FHWA PROJECT
  • 68. STATUE OF LIBERTY PROJECT FHWA PROJECT
  • 69. CRANEY ISLAND PORTSMOUTH, VA FUEL PIER U.S. NAVY 95’ piles, HDPE sleeves, filled with concrete, FRP ring
  • 70. CRANEY ISLAND PORTSMOUTH, VA FUEL PIER U.S. NAVY FRP ring permits the sleeve to slide
  • 71. WHARF CHARLIE, MAYPORT FLORIDA U.S. NAVY 72’ piles, HDPE sleeves, FRP Insert
  • 72. SAN FRANCISCO WEST HARBOR RENOVATION PROJECT SAN FRANCISCO, CA 47 feet of 12” SUPERPILE (including 15 foot thin wall HDPE sleeve)
  • 73. LONG BEACH, NEW YORK HURRICANE SANDY REPAIR AND PROTECTION
  • 74. LONG BEACH, NEW YORK HURRICANE SANDY REPAIR AND PROTECTION
  • 75. LONG BEACH, NEW YORK HURRICANE SANDY REPAIR AND PROTECTION
  • 76. LONG BEACH, NEW YORK HURRICANE SANDY REPAIR AND PROTECTION
  • 77. 77 QUALITY The Quality Management System has been modeled per the requirements of the ISO9000:2008 International Standard. In 2012, Creative reinforced their commitment of providing the highest Quality of products and services with the addition of a certified LEAN / Six Sigma Black Belt who manages related Quality initiatives.
  • 78. 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 78
  • 79. 79 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
  • 80. 80 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.
  • 81. 81 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
  • 82. MASS TRANSIT DECKS 82 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!
  • 83. APPLICATION PROFILE MASS TRANSIT ELEVATED PLATFORM DECKS FOR NYCTA 83 • 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!
  • 84. PRODUCT LINES FACTORY BUILT HS-25 RATED BRIDGE DECKS Why: 200’x60’ Installed in 14 hours!
  • 85. DECKING PRODUCTS SUPERGRATETM PULTRUDED GRATING SUPERDECKTM SUPERPANEL PA004 SUPERPANEL CP150 85
  • 86. SUPERDECKTM RAIL PLATFORM PANEL SUPERGRATETM MOLDED GRATING SUPERPANEL WALL PANEL CT066 DECKING PRODUCTS SUPERPLANKTM DECKING 86
  • 87. SUPERDECKING TUF-DEKTM FLOORING HEAVY DUTY PLANK DECKING PRODUCTS FLOWGRIP® FLOORING PANEL 87
  • 88. FRP DISTRIBUTION AND TRANSMISSION POLES AND CROSSARMS 88
  • 89. CUSTOM PULTRUSIONS 89
  • 90. BC HYDRO 287kV TRANSMISSION CHANNEL DESIGNED BY CPI TESTED BY POWERTECH LABS INSTALLED AND VETTED BY BC HYDRO APPLICATION PROFILES 90
  • 91. APPLICATION PROFILE PEDESTRIAN BRIDGE 91
  • 92. CELEBRATING OVER 41 YEARS OF PROVIDING PULTRUSION SOLUTIONS QUESTIONS? www.creativepultrusions.com