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
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PILE DETERIORATION
There are many causes for
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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
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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
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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®
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• Different levels of deterioration require
different repair or protection methods…
Choosing the Appropriate Repair Solution
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EXTREME DETERIORATION
PileCap® Marine Pile Restoration Systems for
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• 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.
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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.
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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.
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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.
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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
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SERIOUS DETERIORATION
PileForm™ F (FRP) Marine Pile Encapsulation Systems for
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• 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
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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.
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Square PileForm™ F (FRP) Fiberglass Jackets
Robert Moses Bridge
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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
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Engineers Drill Core Samples
Samples Display Full Penetration
and Superior Bonding
NEW PILES OR MODERATE
DETERIORATION
PileForm™ W Retrowrap™ Corrosion Control Systems for
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Provides splash zone and underwater corrosion protection to new and existing piles, pipelines and risers.
PileForm™ W Retrowrap™
Corrosion Control Systems
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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™
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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
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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
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PILE REPAIR PRODUCTS
Five Star Marine® Offers A Full Line of
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• 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
39 © 2013 Five Star Marine, Inc.
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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