Creative Pultrusions, Inc. SuperLoc™ Composite Sheet Pile System PowerPoint.

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. 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. 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. 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. 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. WHY FRP COMPOSITES?
Steel Rusts
Wood Rots
Concrete Spalls
PVC deflects and requires
additional walers
6

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. SUPERLOC™ SHEET PILES
Series 1610
Commercial/Residential
(SS820)
Series 1580
Residential/Commercial
(SS860)
Series 1560
Residential/Light Commercial
(SS806)
8

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. CONNECTORS
Series 1610
(SS821)
Series 1560 - 90°/180°
(SS809)
Series 1560 - 45°/90°
(SS804)
10

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. SUPERLOC™ ENGINEERING
12

13. 13
TEST THE DESIGN IN ONE OF
OUR IN-HOUSE TEST FACILITIES
FULL SECTION AND COUPON LEVEL TESTING

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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. • Heavy Duty Sheet
• Standard Charcoal Gray
Color
• Optimized UV Protection
• Direct Inject
Manufacturing Equates to
High Strength and Stiffness
25

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. • Medium/Light Duty
• Available in PE or VE
Resins
• Standard Charcoal
Gray Color
• Optimized UV
Protection
27

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. • Galvanized Steel Splices.
• Corner Connectors
• Tie-Rod Washers.
• Custom Corners Available
for Unconventional
Angles.
29

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. 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. 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. SUPERLOC™ THE GREEN CHOICE
• Inert, will not leach dangerous chemicals, pesticides or heavy metals into the
environment.
33

34. SUPERLOC™ THE GREEN CHOICE
Embodied Energy Comparison
0
20
40
60
80
SuperLoc™ Steel Aluminum PVC
MJ/kgofmaterial
34

35. SUPERLOC™ THE GREEN CHOICE
Co2 Footprint
0
2
4
6
8
10
12
14
SuperLoc™ PVC Steel Aluminum
kgCo2/kgofmaterial
35

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. 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. VIBRO-HAMMER
INSTALLATION
Can be installed in soils with a
blow count of 20 or less
without a mandrel.
38

39. MASONBORO HARBOUR,
WILMINGTON, NC
900 ft (274m)
shoreline bulkhead
39

40. THE GLENRIDGE ON PALMER RANCH
SARASOTA, FL
2,000 ft (609m)
shoreline
bulkhead
40

41. THE GLENRIDGE ON PALMER RANCH
SARASOTA, FL
41

42. THE GLENRIDGE ON PALMER RANCH
SARASOTA, FL
42

43. 3,280 ft
(1000+ meters)
Causeway
AZERBAIJAN SERIES 1580
43

44. AZERBAIJAN PROJECT
3,280 ft
(1000+ meters) Retaining Wall
44

45. AZERBAIJAN COMPLETE
45

46. DOWNTOWN FT. MEYERS FLORIDA
Installed with an
ICE Model 6E
Vibratory Hammer
46

47. DOWNTOWN FT. MEYERS FLORIDA COMPLETE
47

48. DOWNTOWN FT. MEYERS FLORIDA
48

49. DOWNTOWN FT. MEYERS FLORIDA COMPLETE
49

50. WALDO POINT HARBOR, CALIFORNIA
Currently under
construction
50

51. KEYPORT, NJ
1,451 lineal ft.
(427 m) wall
photo taken
after hurricane
Sandy 2012.
Installation
2006.
51

52. KEYPORT, NJ
Photos of wall taken
during Hurricane Sandy
52

53. KEYPORT, NJ
Photo taken after Hurricane Sandy 2012
53

54. O’QUINN MARINE SERIES 1580
200 ft (61m)
shoreline
bulkhead
54

55. O’QUINN MARINE SERIES 1580
100 ft (31m)
shoreline
bulkhead
55

56. O’QUINN MARINE SERIES 1580
100 ft (31m)
shoreline
bulkhead
56

57. O’QUINN MARINE SERIES 1580
100 ft (31m)
shoreline
bulkhead
57

58. RESIDENTIAL INSTALLATION
WRIGHTSVILLE BEACH, NC
125 ft (38m)
shoreline
bulkhead
58

59. MAGNOLIA BAY
WATERFRONT DEVELOPMENT
BILOXI, MS
125 ft (38m)
shoreline
bulkhead
59

60. SEABROOK SHIPYARD
SEABROOK, TX
1,000 ft (304m)
shoreline
bulkhead
60

61. PIRATES COVE MARINA
MANTEO, NC
700 ft (213m)
shoreline
bulkhead
61

62. PORTOFINO HARBOR MARINA
CLEAR LAKE SHORES, TX
3,000 ft (914m)
shoreline
bulkhead
62

63. HAMPTON MARINA
HAMPTON, VA
1,300 ft (396m)
shoreline
bulkhead
63

64. STAR FLEET MARINA
CLEAR LAKE SHORES, TX
1,300 ft (396m)
shoreline bulkhead
64

65. GRANDPAPPY POINT MARINA
DENNISON, TX
1,000 ft (304m)
shoreline
bulkhead
65

66. KETEWOMOKE YACHT CLUB
HUNTINGTON, NY
120 ft (36m)
shoreline bulkhead
66

67. BOBBY JONES GOLF COMPLEX
SARASOTA, FL
200 ft (61m)
shoreline
bulkhead
67

68. LITTLE MINERAL MARINA
POTTSBORO, TX
700 ft (213m)
shoreline
bulkhead
68

69. CAROLINE COUNTY RECREATION AND PARKS
GREENSBORO, MD
350 ft (106m)
shoreline
bulkhead
69

70. LOUISIANA DEPARTMENT OF NATURAL RESOURCES
MANDALAY BANK PROTECTION DEMO TERREBONNE
PARISH, LA
3,800 ft (1158m)
shoreline
bulkhead
70

71. RESIDENTIAL INSTALLATION
MATTITUCK, NY
90 ft (27m)
retaining wall
71

72. ELEVATED BRIDGE APPROACH
SOUTHAMPTON, NY
120 ft (36m)
Bridge
Approach Walls
72

73. 2,100 ft (640m) shoreline
bulkhead
THE SHORES DEVELOPMENT
SOUTH PADRE ISLAND, TX
73

74. THE SHORES DEVELOPMENT
SOUTH PADRE ISLAND, TX
2,100 ft (640m)
shoreline
bulkhead
74

75. THE SHORES DEVELOPMENT
SOUTH PADRE ISLAND, TX
2,100 ft (640m) shoreline
bulkhead
75

76. MARSHALL FORD MARINA
AUSTIN, TX
234 ft (71m)
Breakwater
76

77. UNITED STATES NAVY PIER,
CHOLLAS CREEK, SAN DIEGO, CA
1,200 ft (365m)
shoreline bulkhead
77

78. MARTINEZ MARINA
MARTINEZ, CA
400 ft (121m) shoreline bulkhead
78

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
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
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
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

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. 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. SAN FRANCISCO WEST HARBOR RENOVATION PROJECT
SAN FRANCISCO, CA
47 feet of 12” SUPEPILE
(including 15 foot thin wall HDPE sleeve)
86

87. VIRGINIA DEPT. OF TRANSPORTATION
80 foot of SuperPile
12” diameter
Bridge Fender System
87

88. VIRGINIA DEPT. OF TRANSPORTATION
Bridge Fender System
88

89. FLORIDA DOT BRIDGE FENDER
Bridge Fender System
89

90. AIR HAMMER INSTALLATION
90

91. PRODUCT LINES
FACTORY BUILT HS-25 RATED BRIDGE DECKS
Why: 200’x60’ Installed in 14 hours!
91

92. DECKING PRODUCTS
SUPERGRATETM
PULTRUDED GRATING
SUPERDECKTM
SUPERPANEL PA004
SUPERPANEL CP150
92

93. SUPERDECKTM
RAIL PLATFORM PANEL
SUPERGRATETM
MOLDED GRATING
SUPERPANEL WALL PANEL CT066
DECKING PRODUCTS
SUPERPLANKTM
DECKING
93

94. SUPERDECKING
TUF-DEKTM
FLOORING
HEAVY DUTY PLANK
DECKING PRODUCTS
FLOWGRIP®
FLOORING PANEL
94

95. FRP DISTRIBUTION AND
TRANSMISSION POLES
AND CROSSARMS
95

96. CUSTOM PULTRUSIONS
96

97. BC HYDRO 287kV TRANSMISSION CHANNEL
DESIGNED
BY CPI
TESTED BY
POWERTECH
LABS
INSTALLED AND
VETTED BY BC
HYDRO
APPLICATION PROFILES
97

98. APPLICATION PROFILE
PEDESTRIAN BRIDGE
98

99. CELEBRATING OVER 40 YEARS OF PROVIDING PULTRUSION SOLUTIONS
QUESTIONS?
www.creativepultrusions.com