SuperPile SuperPile Composite Composite Fender Pile Fender Pile

SystemSystem

Presented byPresented byDustin Troutman

Director of Marketing & Product Development

CREATIVE PULTRUSIONS, INC.

www.creativepultrusions.com

SuperPile AttributesSuperPile AttributesPultruded 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

SuperPile Profiles SuperPile Profiles are Manufactured by the are Manufactured by the

Pultrusion ProcessPultrusion Process

SuperPile ProductionSuperPile ProductionHigh 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.

SuperPile ConstructionSuperPile Construction 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.

SUSUPURPURTUF™ Polyurethane TUF™ Polyurethane ResinResin

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

CompressiveStrength (LW)ASTM D695

CompressiveStrength (CW)

ASTM D695

InterlaminarShear (LW)

ASTM D2344

Test and Method

psi

Polyester

Polyester FR

Vinyl EsterSUPURTUF 4000

• Superior Strength

• Superior Chemical Resistance

• Superior Impact Strength

• Superior Toughness

• Superior Energy Absorption

SUSUPURPURTUF™ Polyurethane TUF™ Polyurethane UV PerformanceUV Performance

• 8,000 hours QUV testing.

• No significant change in compression strength.

• Exterior will fade over time and begin to chalk.

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

Str

en

gth

(p

si)

Test Results: No Paint

Test Results: Painted w/ SWSolar Reflective Walnut Brown

SuperPile Mechanical SuperPile Mechanical & Physical Properties & Physical Properties

Average values based on full

section testing performed at

WVU

Note: FLDOT has adopted the ultimate

strength at 80% of the average values.

SuperPile Mechanical SuperPile Mechanical & Physical Properties& Physical Properties

Specification Test Requirement

Standard TitleSuperPile by

Creative Pultrusions, Inc.

Creative Pultrusions, IncSupplied HDPE Sleeve

(when applicable)

Required Properties for Fiberglass Structurally Reinforced

Composite Lumber (SCL)

ASTM D792Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement

Density = 122.3 pcfVoid Content < 1%

59.9 pcf (tested D1505)

55-63 pcf

ASTM D570 Standard Test Method for Water Absorption of Plastics 0.15% (24hrs).01-.1%

(From www.matweb.com HDPE Extruded)

2hrs <1.0% weight increase24hrs <3.0% weight increase

ASTM D746Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact

Test using ASTM D7028 (DMA)Tan Delta Peak = 132°C

G' (-50°C) = 6.5 GPa

G' (25°C) = 5.29 GPa1

< -75-deg C Brittleness Temp < -40-deg C

ASTM D256Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics

90 ft-lb/in1.47-11.0 ft-lb/in

(From www.matweb.com HDPE Pipe Grade)

> 0.55ft-lb/in

ASTM D2240 Standard Test Method for Rubber Property—Durometer Hardness 85 Shore D 62 Shore D 44-75 (Shore D)

ASTM D4329 Standard Practice for Fluorescent UV Exposure of PlasticsNo measurable hardness

change after 1344hrs UV exposure500 hours < 10% change in Hardness

ASTM D4060Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber Abraser

0.0035 oz0.002 oz

(web search)

Weight Loss < 0.02ozCycles = 10,000Wheel = CS17

Load - 2.2lb

ASTM D756Practice for Determination of Weight and Shape Changes of Plastics Under Accelerated Service Conditions (Sea Water, Gasoline, No. 2 Diesel)

Sea Water = 0.32% Wt Increase2

Gasoline = 0.33% Wt Increase2

No. 2 Diesel = 0.14% Wt Increase2

Sea Water < 1.5% Weight IncreaseGasoline < 9.5% Weight Increase

No. 2 Diesel < 6.0% Weight Increase

ASTM D638 Standard Test Method for Tensile Properties of Plastics 136000 psi> 3,500psi

(yield)Min. 2,200 psi @ Break (Strength)

ASTM D695 Standard Test Method for Compressive Properties of Rigid Plastics 6.40E+06 psi> 175,000 psi

(Tested D638 Tension)Min. 40,000 psi @ Break (Modulus)

ASTM D1894Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting

0.207 0.2-0.25 Max. 0.25 Wet

ASTM D6117Standard Test Methods for Mechanical Fasteners in Plastic Lumber and Shapes

1,728 lb (1/4"-14 x 1.5" Long SS Hex Head

Self Drilling Screw)Min. 60lb

Full Section Bend TestFull Section Bend Test

• 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.• Five Piles of Each Series

Were Tested.Flexural Test, WVU

Full Section Bend Results Full Section Bend Results 12” dia. SuperPile 12” dia. SuperPile

Flexural Test, WVU

Full Section Bend Results Full Section Bend Results 16” dia. SuperPile16” dia. SuperPile

Full Section Transverse Full Section Transverse Pin BearingPin Bearing

• 1” diameter pin.

• Loaded to failure.

• Failure mode, bearing of FRP tube.

• Transverse bearing strength ≈ 23,000 psi.

Full Section Crush StrengthFull Section Crush Strength

• Crush strength based on compression loading a 10”x10” HDPE wale section into the SuperPile.

• Crush Strength ≈ 27 kips.

Full Section Crush Strength Full Section Crush Strength EnhancementEnhancement

• Crush strength can be increased with the addition of an FRP insert.

• Crush Strength increase to 77 kips when needed.

SuperPile Bolt Pull Through SuperPile Bolt Pull Through StrengthStrength

• Bolt pull through strength bases on a 1” dia bolt with large. square curved washers

• Average 27 kips.

SuperPile Fatigue Testing SuperPile Fatigue Testing 12” dia. SuperPile 12” dia. SuperPile

• 200 cycles

• Max load 40% of ultimate

• Results, no significant decrease in strength or stiffness.

Fatigued Sample vs. Average12" SuperPile

0

20

40

60

80

100

120

Max Load (kips) Max Stress (psi) Bending MOE(Msi)

Test

Average of 5 SUPURTUF12" SuperPile

Fatigued Pile 200 cycles

SuperPile Fatigue Testing SuperPile Fatigue Testing 16” dia. SuperPile 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 SUPURTUF16" SuperPile

Fatigued Pile 200 cycles

Fatigue of Pultruded Fatigue of Pultruded CompositesComposites

LRFD Pre-Standard 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

Str

ess

Ran

ge,

DS

FDOT QPL FDOT QPL ApprovalApproval

Pile system was designed and approved based on FDOT Structures Manual Volume 1 January 2012.

FDOT QPL Approval FDOT QPL Approval

FDOT QPL Approval FDOT QPL Approval

FDOT QPL ApprovalFDOT QPL Approval

FDOT QPL Approval FDOT QPL Approval

Connection DetailsConnection Details

Connection DetailsConnection Details

• Stainless Steel Hardware.

• 6” Square Curved Washers.

• 50 lb-ft max. torque.

• Self drilling screws for attaching the cap.

Pile Splice OptionPile Splice Option

• 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” dia bolts.

Pile Splice Testing 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.

PDA Analysis Performed PDA Analysis Performed by Atlantic Coast by Atlantic Coast EngineeringEngineering

Location: Crofton Services

Yard Portsmouth, VA

PDA AnalysisPDA Analysis

An 18” Dia. ½” thick steel

tube was bolted to the end

of the pile to increase the

driving resistance.

PDA Analysis Hammers PDA Analysis Hammers UsedUsed

• Vulcan 01 (5,000 lb ram

with a stroke of 3 ft.).

• APE D30-32 (6,600 lb

ram with a stroke of

11.25 ft.).

PDA Analysis SummaryPDA Analysis Summary• A 60’ SuperPile driven to refusal at 35’ with a

Vulcan 01 Hammer (120 blows/ft).

• Evaluated driving resistance 160 kips, energy 8

kip-ft, compressive driving stress 8 ksi.

• The pile was extracted and the steel toe plate

was removed.

• The pile was inspected.

PDA Analysis SummaryPDA Analysis Summary• A 60 ft SuperPile was driven to 50’ with an APE 30-32

Hammer (6-9 blows/ft).

• The next day the pile was driven an additional 2’ with a blow

count of (110 to 125 blows/ft) .

• Evaluated driving resistance 340-370 kips, energy transfer

30 kip-ft, compressive

driving stress 13-15 ksi.

PDA Analysis Summary PDA Analysis Summary ConclusionsConclusions

PDA Analysis Summary PDA Analysis Summary ConclusionsConclusions

Impact Hammer Impact Hammer Installation Options Installation Options Include:Include:

Air Hammer with a rated capacity of

15 to 35 kip-ft.

Diesel hammer with a rated capacity

of 15 to 35 kip-ft.

Vibratory Drive/Hammer System

Vibratory Compactor

Note: A driving cap is required.

Impact Hammer Impact Hammer Installation VideoInstallation Video

Vibratory Hammer Vibratory Hammer InstallationInstallation

Vibratory Hammer Vibratory Hammer InstallationInstallation

Why Specify SuperPile?Why Specify SuperPile?

• Installs 2x faster than solid piles.

• 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 40 years.

AccessoriesAccessories

• Thermoplastic caps

• FRP caps

• HDPE sleeves

• FRP sleeve ring

Important Design Important Design Considerations IncludeConsiderations Include

• Deflection

• Point Loads

• Drive Ability of the Piles Based on the Soil Profile Including Blow Counts

SuperPile™ the Green SuperPile™ the Green ChoiceChoice

• Inert, will not leach dangerous chemicals and pesticides or heavy metals into the environment.

Pile Splice OptionPile Splice Option

• Steel Pipe Splice Installed at VADot Rte. 3 River Fender Project.

• Connection tested during PDA test by Crofton Diving.

• Bolted connection with three 1” dia bolts.

Pile TipsPile Tips

• Cast iron pile tips are utilized for bearing piles.

Important Design Important Design Considerations IncludeConsiderations Include

• Deflection

• Point Loads

• Drive Ability of the Piles Based on the Soil Profile Including Blow Counts

Why Specify an FRP Why Specify an FRP SuperPile?SuperPile?

• Installs 2x faster than solid piles.

• Can be field fabricated.

• Will not leach chemicals

• Will absorb more energy than concrete and

wood piles.

• Will not rot, spall or deteriorate.

• Can be installed with traditional pile driving

equipment.

• Lowest installed cost.

Margate Bridge, NJ Margate Bridge, NJ

52 12” diameter FRP piles at 80 foot in length were used to construct the bridge fender.

Margate Bridge, NJ Margate Bridge, NJ

Piles Ready to Ship Piles Delivered to the Job Site

Piles Installed with a Vulcan

V5C Vibro Hammer

Margate Bridge, NJ Margate Bridge, NJ Complete FenderComplete Fender

Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender

116 16” diameter SuperPiles used to construct the fender

Virginia DOT Virginia DOT TWIGG Bridge Fender 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

Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender

FRP piles being installed with a Vulcan 01 5,000 lb hammer.

Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender

Divers had to locate the piles around a buried electric cable

Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender

Driven piles with polymer wales attached

Virginia DOT Virginia DOT TWIGG Bridge Fender TWIGG Bridge Fender

Completed Fender

Pinellas Bayway Bridge Pinellas Bayway Bridge Florida DOT Florida DOT

Pinellas Bayway Bridge Pinellas Bayway Bridge Florida DOT Florida DOT

104 16” diameter 67’ long SuperPiles used to construt the fender

Pinellas Bayway Bridge Pinellas Bayway Bridge Florida DOT Florida DOT

104 16” diameter 67’ long SuperPiles used to construct the fender

Statue of Liberty Project Statue of Liberty Project FHWA Project FHWA Project

198 piles 12” in diameter by 48’ long

Statue of Liberty Project Statue of Liberty Project FHWA Project FHWA Project

Craney Island Portsmouth, VA Craney Island Portsmouth, VA Fuel Pier U.S. NavyFuel Pier U.S. Navy

95’ piles, HDPE sleeves, filled with concrete, FRP ring.

Craney Island Portsmouth, VA Craney Island Portsmouth, VA Fuel Pier U.S. NavyFuel Pier U.S. Navy

FRP ring permits the sleeve to slide

Wharf Charlie, Mayport FloridaWharf Charlie, Mayport FloridaU.S. NavyU.S. Navy

72’ piles, HDPE sleeves, FRP Insert

San Francisco West Harbor San Francisco West Harbor Renovation ProjectRenovation ProjectSan Francisco, CASan Francisco, CA

47 feet of 12” SuperPile (including 15 foot thin wall HDPE sleeve)

Long Beach New York Long Beach New York Hurricane Sandy Repair and Hurricane Sandy Repair and

Protection Protection

Long Beach New York Long Beach New York Hurricane Sandy Repair and Hurricane Sandy Repair and

Protection Protection

Long Beach New York Long Beach New York Hurricane Sandy Repair and Hurricane Sandy Repair and

Protection Protection

Long Beach New York Long Beach New York Hurricane Sandy Repair and Hurricane Sandy Repair and

Protection Protection

Facilities Overview

Facilities Facilities (Sq. Ft)(Sq. Ft) 160,000160,000

Production MachinesProduction Machines 18 18

EmployeesEmployees 148148

DLR: 04.25.13

Creative Pultrusions, Inc. was established in 1973 Creative Pultrusions, Inc. was established in 1973 and is located in Alum Bank, Pennsylvania.and is located in Alum Bank, Pennsylvania.

Hill & Smith Review of 2012

Creative is Owned by:Creative is Owned by:Hill & Smith Holdings PLCHill & 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 and Galvanizing Services.

• Revenue 2011 £406.2m

Creative’s Platform Creative’s Platform Experience Midlands, U.K. Experience Midlands, U.K.

Platform ExtensionPlatform 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!

Creative’s Platform Creative’s Platform Experience NYCTA Experience NYCTA

Elevated RailElevated Rail

• 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!

Product LinesProduct LinesFactory Built HS-25 Rated Factory Built HS-25 Rated Bridge DecksBridge Decks

Why: 200’x60’ Installed in 14 hours!

Product LinesProduct LinesFiberglass Decking / Flooring / Grating and Panels

Tuf-dek™ Flooring

SuperPlank™ Decking Flowgrip® Flooring Panel SuperDecking

Heavy Duty Plank

Product LinesProduct LinesFiberglass Decking / Flooring / Grating and Panels

Supergrate™ Pultruded Grating

Supergrate™ Molded Grating

SUPERPANEL PA004

SUPERPANEL Wall Panel CT066

SUPERPANEL CP150 Superdeck™

Superdeck™ Rail Platform Panel

Product LinesProduct LinesUtility ProductsUtility Products

• Distribution Poles

• Cross Arms

Product LinesProduct LinesCooling Tower ComponentsCooling Tower Components

287kV Live installation 287kV Live installation transmission arms for BC transmission arms for BC HydroHydro

Over 1,000 Pedestrian Over 1,000 Pedestrian Bridges built with our Bridges built with our materialsmaterials

Questions Questions and and

AnswersAnswers