Marine Pile Restoration and Corrosion Protection...

Prepared for: Association of Pacific Ports

2017 Winter Conference

Marine Pile Restoration and

Corrosion Protection Systems

• Who is Five Star Marine, Inc.?

• 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 © 2015 Five Star Marine, Inc.

• Five Star Marine, Inc. is a worldwide provider

of high-performance marine pile

encapsulation and protection systems

specifically designed for the rehabilitation

and structural stabilization of marine facilities

and underwater structures.

Who is Five Star Marine?


• Our PileForm™ Systems provide piling

restoration, corrosion protection and pile

rehabilitation jacket systems. In addition, Five

Star Marine® offers cementitious and epoxy

fill materials, plus protective sealants and

adhesives, providing a total solution to pile

repair needs.



• Our products are designed and tested by

commercial divers and engineers with an

emphasis on ease of installation, reliability,

safety and consistency.

• Our staff of committed, experienced

personnel is available for job site assistance

whenever you need it.



• Five Star Marine, Inc. is an affiliate of Five

Star Products, Inc., a top-tier supplier of high-

performance cement and epoxy-based

products for the industrial, infrastructure,

commercial and marine markets since 1955.



Growing With the Industry

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1981 – FSP Cementitious Waterproofing System

1990 – FSP Special Grout 120 w/Anti-Washout

1994 – FSP Cementitious Underwater HP & PG

2004 – FSP Pile Jacket Grout

Underwater Cementitious Pile Jacket Grout

Pile Jacket Epoxy Grout HP

2009 – Five Star Marine, Inc. is launched

Launched PileForm™ F (FRP) Jacket Repair Systems

2012 – Partners with PILECAP, Inc.

Launched PileForm™ S Structural Repair Systems and Marine Coatings

2013 – Partners with Corrosion Control International

Launched PileForm™ W Retrowrap™ Corrosion Control Systems

© 2015 Five Star Marine, Inc.

From Full Structural Repair Systems To

Heavy-Duty Protective Wraps

• Cementitious & Epoxy Fill Materials

• Fiberglass (FRP) & Nylon Pile Jackets

• Marine Coatings, Adhesives & Gels

• Marine Repair Mortars

• Marine Pile Restoration & Corrosion Control

Systems

Five Star Marine® Product Solutions


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


Three elements are

required for corrosion

to exist:

1. A protected metal

2. A corroded metal

3. A current-conducting

medium between the

two (electrolyte).

STEEL Pile Deterioration


SOLUTIONS

Five Star Marine®


• 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.


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

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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


Ketchikan, AK– Tident Seafoods had deteriorating piles

beneath processing facility and we were able to repair

without interrupting the use of the structure. This was of

paramount importance to the owner.

“Pier-eating monsters ‘Termites of the sea’

causing piers to collapse…”


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.


Engineered Fill Systems Are a Permanent Fix


Engineers Drill Core

Samples

Samples Display Full

Penetration and

Superior Bonding

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


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 the

attendant 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


• 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


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Thank you for your time!

www.5Star-Marine.com

1-203-336-7900

Represented on West Coast by

Schrader Co. Sales, LLC

425-377-1550

www.schraderco.com

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