SUPERPILE INSTALLATION MANUAL
Contents
1. gt SUPERPILE DISTALLATIGN MARONI i i E O RT q a Ha di Me a rine Contractors E ini instaliations SUPERPILE OVERVIEW SUPERPILE is a highly engineered com posite pile designed and manufactured i Resin Impregnator exclusively for fender mooring and com r Surfacing pression pile applications SUPERPILE is I i Forming amp ng Die Pulling System manufactured by the pultrusion process di si A continuous process in which resin and A Tia _ Cut Off Saw reinforcements are saturated and guided Ae J Va into a heated die where the curing process Continuous commences SS gt Preformer Caterpillar Pullers shown or Reciprocating Pullers Pultrusion Process Schematic 1 SUPERPILE is manufactured with a two compo nent polyol isocyanate polyurethane matrix with a fiberglass reinforcement architecture comprised of 11Msi Modulus 290 ksi tensile strength fiberglass manufactured to ASTM D578 specifications The outer layer is comprised of a 10 mil thick synthet ic UV protection vell SUPERPILE is environmentally friendly featuring a low carbon footprint SUPERPILE will not leach chemicals or harm the environment SUPERPILE TU460 16 Production SHIPPING AND RECEIVING SUPERPILE is shipped to the job Inc CPI to manufacture piles to Prior to shipping the contractor site via flatbed dedicated truck long lengths eliminating the need shall commu2. of time Many contractors and utilities have had success when utilizing the FGH series drill bits The bits will save time and drill thousands of holes before needing to be replaced FGH Series Fiberglass Pile Drillng Bit SUPERPILE can be field cut with a concrete skill or reciprocating saw An abrasive blade should always be used Concrete saws work the best and can be utilized with a standard concrete cutting blade During drill and sawing operations dust will be emitted The dust is considered a nuisance dust which can irritate your eyes and skin Therefore safety glasses gloves and long sleeve shirts are recommended during the cut ting and drilling process As documented by OSHA FRP dust millings have potential to cause eye skin and upper respiratory tract irritation e Cause mechanical irritant properties of the glass fibers e FRP particulate is Non Hazardous e FRP particulate is greater than 6 microns therefore it cannot reach Concrete Saw the alveoli e The International Agency for Research on Cancer IARC classified FRP particulate as non cancer causing in June of 1987 G3 CONNECTION DETAILS SUPERPILE connections should be made with galvanized or stain less steel connectors as designed and approved by the Engineer of Record EOR Holes should be drilled based on the nominal bolt diameter oversized by 1 16 Pin Bearing Strength Pin bear ing strengths are detailed in the technical data sh
3. d was re driven on the following date with dynamic test gauges attached to the pile Testing was performed to aid contractors in the selection of the appropriate impact hammers for installation of the SUPERPILES And to establish for Geotechnical Engineers the feasible soil resistances in which the piles may be driven without damage and to identify the allowable driving stress The rated capacity of each hammer is utilized in the PDA as follows Hammer Rated Driving Energy Typical Energy Expected to be Delivered to Pile Vulcan 01 L 15 kip ft 6 9 kip ft_ APE D30 32 74 kip ft 20 40 kip ft 6D PILE DYNAMIC ANALYSIS Cont d 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 The test pile driven with the larger APE D30 32 Impact Hammer was driven through the same soils at a blow count 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 After a one day set up period the pile was 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 co
4. e piles Normal wear and tear including abrasions and scuff marks are common and shall not cause concern The piles shall be free from delami nations Example of Delamination in a FRP Square Tube A delamination is a separation of two or more layers or plies of rein forcing material within a pultrusion The separation can be penetrated by a needle If the defect is over 3 8 wide it is a delamination and not a process shrinkage crack The piles shall be free from dry fiber a condition in which fibers are not fully encapsulated by resin during the pultrusion process Example of Fracture Damage Caused The piles shall be free from frac by Tow Motor Fork Impact ture caused by improper han dling during shipping Example of Dry Fiber in a Pultruded Panel NS DIMENSIONAL INSPECTION UPON DELIVERY Bow Piles shall be straight to within 020 ft of length measured by weight minimizing the bow Note Weight minimizing refers to the pile laying flat on the ground in contact with the flat ground and the bow measured at peak height Length Piles shall meet the specified length to 2 Wall thickness Shall be 15 of the nominal wall thickness DRILLING AND CUTTING INSTRUCTION SUPERPILE can be drilled with carbide tipped drill bits CPI recommends B amp A Manufacturing Company http www bamanufacturing com FGH series drill bits for applications that require multiple holes in a short period
5. eet for the vari ous SUPERPILE sections Note that the pin bearing strength varies based on the direction of the load The Length Wise LW bearing strength is normally higher than the Cross Wise CW pin bearing strength and must be considered during the design process In the event that signage conduits or other non structural append ages are required to be mounted to the FRP piles stainless steel self drilling screws should be utilized to make the connection as lag screws nails and staples cannot be utilized Torque Limits Proper care must be taken not to over torque the through bolts during construc tion The SUPERPILE like any hollow section is susceptible to damage due to over tightening and egg shaping or crushing the pile Therefore a maximum torque of 30 lb ft is recommended If a torque wrench is not available or utilized during construction tighten the nut until the compression spring washer has been collapsed and then turn the nut another turn This method has been utilized by the utility industry successfully for over 10 years Oversized Washers Connec tions should always be made with oversized washers that match the radius of the pile FRP piles are extremely strong However the Modulus of Elasticity is about 1 5th that of steel Therefore highly concentrated loads are required to Oversized Curved Washer be dissipated over a larger area of the pile section CPI recommend
6. fabrication on the approved pile drawings In the event that a pile needs to be pulled a vibratory hammer can be The contractor is cautioned that on some occasions the pile may re quire an FRP insert for added com pression or pin bearing strength Therefore the interior diameter of the pile will change The contrac AMPLITUD CLAMPING FORCE J re j AAG y y Pa SL hi E q Le Li iin AHY ir rae I es la Example of Vibrato Hammer Steel Fabrication utilized to pull the piles Through bolt the pile and the drive head with three 1 diameter bolts spaced a minimum of 5 apart Vibrate the pile and pull tension until the pile begins to move Once the friction has broken pull the pile without the vibratory hammer engaged The vibratory hammer oscillation will cause the bolt holes to elon gate if engaged for an extended period of time 1 500 ko cm aa al 7 24 TIT Pe Maa INTE C si J 2 gt DL mm F illo n BI FAU mm 13 in MII cu a n if Mmm 7 200 lbs 100 ft Typical Vibratory Drive Hammer Specifications courtesy of RPI Construction Equipment IMPORTANT NOTICE In reference to the proper use of this equipment please be advised that job site conditions may vary due to a change in the geology of a par ticular area lt is always a good practice to consult with a geotechnical engineer prior to starting a project Also a good rule of thumb is to know your soil condition
7. mpressive driving stress of 13 15 ksi the pile head split and the pile failed 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 COMPRESSION LOADS compressive strengths and load Column Length Ultimate Compresssion Load Ibs carrying capabilities The following 16 x1 2 12 x1 2 12 x3 8 chart depicts the ultimate com Feet SUPERPILE SUPERPILE SUPERPILE pression loads that the piles can sustain during the driving process without buckling The loads are considered ultimate loads and should be factored accordingly en ra AIA 900 19 585 16 744 10 183 K 1 Pinned Pinned End conditions assumed FOR MORE DETAILS ON SUPERPILE CONTACT Richard McTavish ASSET Tel 44 0 1633 637513 Fax 44 0 1633290519 Email rich assetint co uk International Structured Solutions Stephenson Street Newport NP19 4XH UK Tel 44 0 1633637513 Fax 44 0 1633290519 www assetint co uk
8. nicate with CPI re The continuous manufacturing pro for splices garding the packaging and ship cess permits Creative Pultrusions ping method Considerations shall include but may not be limited to Length of piles Quantity of piles on the truck Weight of the pile packages Unloading method Dedicated Truck Hauling 80 piles to Margate New Jersey Gi PROPER HANDLING UPON DELIVERY Proper care should be taken during will reduce the chance of the pile handling The piles were pack aged and loaded on the flatbed with a tow motor Contact CPI for the weights of the piles and indi vidual packages Proper care should be taken when removing the tie down straps Although the piles are cradled in wood chalks never assume that the wood chalks will keep the piles from shifting The pultruded piles are smooth and can be very slippery if they be come wet Never use steel chok ers or chains to unload the piles A nylon strap preferably with a neo prene skin is recommended This sliding during the picking process CPI prefers to use Light pole handling slings made by Lift It http www lift it com The slings must be double wrapped and the manufacturers recommendations must be followed Lift It Sling Double Wrapped Around SUPERPILE VISUAL INSPECTION UPON DELIVERY Upon delivery of the piles the piles shall be inspected for damage that could affect the long term perfor mance of th
9. s that washers measuring 6 x 6 x 3 8 manufactured in galvanized or stainless steel be utilized for all bolted connections into the pile Note All testing was performed with 50 ksi 4 x 4 x 3 8 and 6 x 6 x 3 8 steel washers Point Loads SUPERPILE was designed for an ultimate crush strength of 27 kips spread over a nine inch length of the pile In the event the pile connection or im pact loads will be greater than the ultimate strength with the appro priate safety factors applied the crush strength can be increased by increasing the wall thickness of the pile Always consider the crush strength capacity when design ing the pile to dock connections The reaction loads may require a thicker pile with a saddle connec tion 7 INSTALLATION OPTIONS Vibratory Hammer SUPERPILE can be efficiently driven with a vibratory hammer When utilizing a vibratory hammer an adaptor shall be fabricated to connect the pile to the vibratory hammer The adaptor shall in clude an interior steel pipe that fits into the SUPERPILE to guide the pile The interior tube should be between 0 5 and 2 of the interior diameter of the FRP pile The interior pipe shall be welded onto a flat steel plate The steel plate will apply the compression force into the top of the pile The steel plate shall be connected to a beam that can be clamped by the vibratory hammer tor should base the vibratory adap tor
10. s before selecting pile driving equipment This can be accomplished by reviewing test soil borings before every project The above equipment is being used in a granular soil condition which is recommended when using vibratory driver extractors RPI Construction Equipment G5 INSTALLATION OPTIONS Air and Diesel Hammers Diesel and Air Hammers have been utilized to drive the 12 and 16 SUPERPILES A pipe insert driving head or steel pipe cap is required for driving the hollow FRP piles It is important that the piles are impacted so that the driving force is dissipated over the cross section of the top of the pile Vulcan 01 Impact Hammer Driving Example of Pipe Insert Driving Head 16 Diameter SUPERPILE for Driving Hollow Piles PILE DYNAMIC ANALYSIS CPI contracted to Crofton Construction Services Inc and to Atlantic Coast Engineering in order to have a Pile Dynamic Analysis PDA performed on SUPERPILE Crofton Construction Services Inc installed two SUPERPILES one with a Vulcan 01 Impact Hammer and one with an APE D30 32 Impact Hammer Both piles were driven with a steel toe plate bolted to the bottom of the pile in order to increase the driving resistance of the soils The pile driven with the Vulcan 01 Air Hammer was driven to refusal 120 blows ft at a depth of 35 feet and then extracted for visual inspection The pile driven with the APE D30 32 hammer was driven to a depth of 50 feet allowed to set overnight an
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