A Designer’s Introduction to Development, Design and Application of Vinyl and Composite Sheet Pile

Everlast Synthetic Products

Technical Support and Sales

David Wentland, P.E.Coastal Engineer

andESP Representative

Docks & Marinas, Inc.www.docks-marinas.com

davewentland@docks-marinas.com

1+920-621-3464 USAJanuary 2013

A major portion of the following information

provided by Carl Hazenberg, P.E.

Chief EngineerEverlast Synthetic Products

ESP Resources

Quality Products tested bythird part laboratoriesEngineering Support:

• Consulting• Preliminary Design• AutoCAD Details and Project Specifications• Involved in thousands of projects

worldwide.Installation Videos on Website and You

Tube

www.everlastseawalls.comwww.docks-marinas.com

Design Manuals and SoftwareWe Use

Naval Facilities Engineering CommandFoundations and Earth Structures

Many Uses for ESP Sheet Piling

• Seawalls and Bulkheads

• Wave Breaks• Cut-off Walls – Civil

and Environmental• Levee raising• Detention Ponds• Weirs

Some of OurCustomers

The Competitive Value of ESP Sheet Piling

Material Cost

Vinyl - $3.50/SF to $8.00/SFFRP Composite - $9.00/SF to $20/SF

Installation:Generally one to two times material cost

• 35,000 to 44,000 lbs per truck

• 400 LF to 800 LF of wall per truck (16’ long sheets)

The Competitive Value of ESP Sheet Piling

Weight and Freight

Standard bundle sizes to streamline manufacturing and shipping

Historyof

Sheet Pile

Examples of Composites

Timber

Reinforced Concrete

Fiber ReinforcedPlastic (FRP)

Why Plastic/Synthetics ?1) Durable - will not rust, rot, or be eaten2) Tough (Impact Modifiers)3) UV stabilized 4) Light Weight5) Attractive (available in grey and clay)6) Environmentally Friendly – inner core is

comprised of PVC recycled regrind7) Environmentally Friendly – will not leach heavy

metals or chemicals into the environment.8) Lowest Cost Hard Armoring System Available

Rusted Steel Replaced by Vinyl

Aluminum

Timber attacked byMarine Borers

Reinforced Concrete

ESP VinylExtrusion Process

Vinyl Thicker than 0.5” = BRITTLE

Here is One Problem Our Competitors Have

ShoreGuard 950 (0.65” thick)Crane Materials Industries (CMI) Product

ESP’s Selection of Vinyls

ESP’s Selection of Composites (EverComp 32.1, 40.1 and 80.5 not shown)

EverComp Fiber Reinforced Polymer(FRP) Composite ESP’s other synthetic productStronger than vinyl

• Cost: Usually cheaper than steel• Amortized cost: Much less than steel. No corrosion or

maintenance.• Aesthetics: No rust appearance. Variety of colors to

choose from.• Lengths: Up to 50 ft. Can make custom profiles for a

project.• Lead Times: In stock or 2 – 4 weeks. • Weight: Lighter than steel. Easier to transport and

install.

“Pulling” of glass fibers removes “slack” in reinforcement. Up to 8,000 lbs pull force provides for mobilization of reinforcement strength immediately when sheet pile is subjected to loading.

ESP’s EverComp Sheet PilingFor Very Demanding Wall Strength

1) Roving – bundle of continuous filament fibers running parallel together

2) Chop fibers – fibers that are cut or chopped and sprinkled onto a mat

3) Continuous Strand Mat (CSM or CFM) – swirled “spaghetti” like filaments

4) Mats – roving is stitched or woven to create mats with reinforcement in all directions

Creating ESP’s FRP Sheet PilingBeginning With the Glass Fiber

The Pultrusion Process

ESP’sEverComp FRP

HOCH2CH2O H + HO C CH = CH C OH

O O

_ H2O

O

OO

OH

EG FUMARIC ACID

C CH = CH CHOCH2CH2

ESTER GROUP

1) Polyester (PET) – most common - Isophthalic, terapthalic, or orthopthalic – least expensive, least chemically resistant, and brittle

2) Vinylester – better shear, impact, and durability than polyester – more expensive than polyester – most common resin for boats

3) Epoxy – most expensive and difficult to pultrude – utilized in “ultra high end” applications – defense, yacht racing, etc.

4) Polyurethane(PU) – performance is between vinylester and epoxy – best impact strength available – more expensive than vinylester - pure PU is difficult to pultrude

5) PU/Vinylester Hybrid – combine benefits of PU and vinylester into a resin system that can commercially be manufactured cost effectively – BEST VALUE FOR THE $$$$

Resin Types

Effect on Resin Physical Properties

EverComp Resin• Tg = 170° C (high glass

transition temp.)• Tough (high impact)• Durable• High shear properties• Superior bond to reinforcing

elements• Exceptional weatherablility• Exceptional chemical resistance

1)Glass – least expensive ($1 - $3/lb) - GFRP

2)Carbon – high tensile strength and modulus, no benefit in compression, and weak in shear. ($15+/lb) - CFRP

3)Aramid (Kevlar) – high tensile and shear strength, low modulus, and high impact. ($15/lb)

4)Boron – Exceptional performance in compression and low density ($1000/lb)

Types of Fiber Reinforcement

3D Finite Element Modeling -10 psi Uniform Load

Max Stress

3,526 psi

ESP 4.1 ShoreGuard 525(A competitor’s product)

Max Stress4,262 psi

ESP Has a Lower Resulting Tensile Stress with the Same Loading

Stress vs. StrainNo ductile zone

Interlaminar Shear Strength LengthwiseUtilizing Identical Fiber Architecture

by ASTM D2344-84(psi)

0

1,000

2,000

3,000

4,000

5,000

6,000

PolyesterEverComp

EverComp Resin Impact Strength vs. Polyesters ASTM D256

0

10

20

30

40

50

60

Izod Impact(ft-lbs/in)

PolyesterEverComp

Impact Strength (ASTM D6110) – Summary

• PVC sheets are brittle for thicknesses > 0.5”• FRP has better impact strength in extremely cold

weather

Room Temp

-30 F

0

2

4

6

8

10

12

14

16

18

EverComp

ShoreGuard 950

Impact Strength – Room Temperature

ShoreGuard 950

EverComp 26.1

Impact Strength – -30 degrees F (-30 degrees C)

ShoreGuard 950EverComp 26.1

U.S. Navy Durability StudyResin and Specific Glass Fiber Matrix:

• Freeze Thaw• Diesel Fuel• UV• pH up to 12• Salt Water

Small Boat Basin – Norfolk, VA

Interlock Flow TestingBy Independent Certified

Laboratory

Length of Interlock not SealedTo Measure Water Flow Rate Through Interlock

At Various Hydraulic Gradients

Design Criteria:• Durability and weatherability:

Longevity similar to vinyl• Impact resistance:

High impact strength• Stiffness:

High modulus of elasticity• Strength:

High tensile and flexural properties• Economy:

Must be competitively priced in the marketplace

EverComp 26.1 driven in South Carolina

Structural Limit of Vinyl Sheet Pile – Single Wale

ExampleESP 8.5 Profile Wall at North Myrtle

Beach, SCAbout 11.5 ft. from Mud Line to Top of Wall

Wale

• Deflection• E = 380,000 psi• Navy Style: Typically spans up to 15 ft. – lowest wale to

mudline.

ExampleCambridge, MD State MarinaESP 8.5 – 36 ft. sheet lengths

Structural Limitof

Vinyl Sheet Pile Wall Using Navy Style Design

Cantilever WallFree standing with

no tie-backs or deadmen

Form built for cast-in-placeConcrete cap

Timber cap

Navy Style WallSupport pileson outboard face of wall

Navy Style Wall

Exterior support piles

Multiple wales

Typical Section View of Tie-back Wall

Typical Plan View of Tie-back Wall

Typical Elevation View of Tie-back Wall

Typical Deadman Detail of Tie-back WallShowing Concrete Deadman in this Example

Example ofa Shallow Water Tie-back Wall Design

Helical AnchorsOne Method of Tying Back a Wall

LeveesNon Compliant

Potential Issues:• Additional R.O.W.• Foundation/Settlement• Global/Slope Stability

Advantages:• No Additional R.O.W. required• Less Disruption in populated

areas• Additional seepage protection• Protection against burrowing

animals

Traditional Expansion

Seepage Control – Dams and Levees

EarthEmbankment

ESP Vinyl or Composite Sheet

Pile

Advantages:• No additional R.O.W. required• Less disruption in populated areas• Additional seepage protection• Protection against burrowing animals

Alternative #2ESP sheet pilewith vertical

extension using gravity cell

configuration

Alternative #1ESP sheet pile

with short cantileverfor vertical extension

Additional Advantages:• Less dependent on poor foundation soils• Sheet lengths can be shorter• Can support roadway on top• Structurally can achieve taller structures

Examples of Wall Caps

Aluminum, Wood and Concrete

and Accessories

Important Design and Construction Information

• Permit review and approvals - designs details and possible PE stamp and seal based on jurisdictional requirements

• Soil borings or available boring records – proper spacing and proximity to the wall alignment for a credible design

• Known and design parameters for designing the wall– Height– Tides– Slopes/grades– Loading and surcharge

• Input parameters for ESP sheet pile profilesESP EverComp 26.1 are:– σ all = 25,000 psi– τ all = 2,700 psi– Aweb = 2.33 in^2– Z = 13 in^3/ft– I = 52 in^4/ft– E = 4,200,000 psi

Wall Design Primer

Free Body Diagram (generalized)

Free Earth Support: H=11.75 ft

Fixed Earth Support: H=11.75 ft

Reduce Deflection and Reactions by “fixing” Toe of the Sheet Piling

Check Bending(flexural) StressMmax = 7,490.9 ft-lbs/ft

1. 7490.9 lbs-ft/ft * 12 in/ft = 89,890.8 lbs-in/ft2. σmax = Mmax / Z = 89,890.8 lbs-in/ft /13 in^3/ft =

6,914.7 psi3. σall = 25,000 psi >6,914.7 psi Okay

Check Shear StressVmax = 2,468.7 lbs/ft

1. Vweb=2,468.7 lbs/ft * 1.5ft/web = 3,703 lbs/web

2. τmax = Vweb/Aweb = 3,703 /2.33 in = 1,589 psi

3. τall = 2,700 psi >1,589 psi Okay

Check Deflection for Serviceability

Max Deflection = 1.0 inches1. Allowable deflection is 2% to 3% of the span2. Span = Distance from lowest support to

mudline, hence,Allow Deflection =(11.75ft – 3 ft) * 2% = 2.1

inches

Okay

Resultsfor

Fixed Earth Support

• Mmax = 7,490.9 ft-lbs/ft• Vmax = 2,468.7 lbs/ft• Max Deflection = 1.0 inches• Wale Load = 2,166 lbs/ft• Sheet Length = 24 ft• F.S. (toe kick) = 6.6

Size Wale, Deadman, and Tie-rods as Usual

Deflection and Shear Usually Control the DesignBackfill with flowable fill or lean concrete can be

used to increase shear and stiffness

A few of the several thousand projects

where ESP’svinyl and composite sheet piling

has been used

U.S. Navy DockNorfolk, VA

ESP EverComp Wall

Wall Height =17 ft.240 kip point load 5 ft. behind wall

U.S. ArmyCorps of Engineers (Wilmington, NC

District)

Harker’s Island, NCESP 4.1 Vinyl Sheet PileDriven through black rock

U.S. Army Corps

Galveston District

Wallisville Dam

ESP Vinyl Sheet PileCut-off Wall Installation

U.S. Army Corps Albuquerque District

Rio Jemez Flood ControlSanta Ana Indian

Reservation

ESP Vinyl Sheet Pilefor Flood Wall and Weir

Site PlanRio Jemez Flood Control

Weir

Sunrise SunsetCondominiumsCape San Blas, FL

Complete Engineering Design

Including stamped and sealed

Plans and specifications

Leidse RijnCity of Utrecht, The Netherlands

2 km of ESP 8.5 Euro Browntied back with

earth anchors driven 30 feet

Cherkarsy, Ukraine

Having suffered from 30 ft. of shoreline erosion over the past

several years

ESP EverComp Composite Walls

Cranberry MarinaSeaside Heights, NJ

Seawall and BoardwalkSlammed by Northeastern Storms and

IceCity of Keyport, NJ

Patchogue Ferry Terminal

Patchogue, NY

Height of Wall = 11 ft.

Mmax = 3,098.5 ESP 8.5, Section Modulus = 31 in^3/ft

Max Bending Stress = 1,199.4 psi

Design AnalysisPatchogue Ferry Terminal

Patchogue, NY

Assateague National Seashore

Assateague, VA

City of Sebastian, FLDesign/Build

2.1 miles tied back with earth anchors

Before After

Chautauqua Lake, NY

Installed by:C&E Crete SystemsSherman, NYMarch 2012

Location

Long Island, NY

Rippling WaterwayMajor drainage runoff from U.S. 1 in Florida

Weir 1failed 3 times before replaced 10+ years ago

with ESP vinyl sheet piling

Weir 110 + years later with ESP vinyl sheet piling

And with the success of Wier 1 other

weirs on the network are now being rebuilt with

ESP vinyl sheet piling.

Drainage and Canal NetworkPalm Coast, FL

ESP Vinyl Sheet Pile Flood WallSeven ft. Height

Benecia, CA

Detention and Retention Pond Walls

• 1,500 LF cantilever wall• ESP 8.5 Vinyl – 22 ft.

lengths• Driven 18 ft. into the

ground• Superior solution over

cast-in-place or modular block wall

Before

After

BeforeHurricane

AfterHurrican

e

ESP Vinyl Sheet Piling

Shore Protection

Daytona Beach, FL

ESP EverCompComposite

Sheet Piling

Daytona Beach, FL

Before

After

Before

After

Shore ProtectionFlorida Coast

ESP EverComp

Sheet Piling

City of Palm Coast, FL 15 ft. Wall Height

Shoreline Development

ESPEverComp

Sheet Piling

Two Mile Eco-passage (Critter Wall)Florida DOT - U.S. 27

Tallahassee, FL

ESP 4.1 VinylSheet Piling

Nascar MarinaDaytona Beach, FL

Design/Build ESP EverComp 26.1

Bridge Abutment Scour Protection

Kings BridgeCity of Neptune Beach, FLValue Engineering vs. PZ 27

Cantilever31 ft. length ESP EverComp Sheets

Canal RestorationCity of Sebastian, FL

Design/Build ProjectTwo Miles ESP Vinyl Sheet Piling

with Earth Anchor Tie-backs

Innsbrook Golf Course

Plymouth, NC

Seven miles ESP 3.5 Vinyl Sheet Piling

Shoreline RestorationMyrtle Beach, SC

ESP EverComp 26.1Free-standing

Cantilever Wall

BeforeAfter

Coquina Pointe Yacht Club

Myrtle Beach, SC

ESP EverComp 26.1 Sheet Piling

Coquina Pointe Yacht Club

Myrtle Beach, SC

November 9, 2008

Types of Tools and

Installation Equipment

• Vibratory hammer• Rail Jet• Water jet• Collins Hammer• Drop Hammer• Trenching• Mandrel

Recommended SupplierOf Driving Hammers

For Rent or Sale

ESP Sheet Piling

Cut-off Wall for Two Dams

Sheeting Set in Toeof Mandrel

Hurricane Protection

U.S. 98Ft. Walton, FL

Method of Driving Vinyl and Composite Sheet Pilingin Very High Blowcount Material

¾” Thick Annealed Steel

Other ESP Products

FRP Round Piles

FRP Rectangular Tube/Wale

FRP Rectangular Tube/Wale Countersunk

• Corners• Adapters to other

sheet pile products• Wall caps• Splices• Stainless & HDG

fasteners• Plastic coated wood

piles and timber

ESP EverDrain Weep DrainsQuick Installation on the Outside of the

WallManufactured by Jet Filter

Technical Support and SalesDavid Wentland, P.E.Coastal EngineerDocks & Marinas, Inc.www.docks-marinas.comdavewentland@docks-

marinas.com920-621-3464 USA

ESP Representative1. Consider vinyl and composite as a

viable alternative on certain projects2. Talk to us about potential applications3. Permit “Value Engineering” of vinyl

and composite on qualified projects4. Consider service life and maintenance

costs as well as initial cost5. Vinyl – Insist on Co-extrusion and

creep data6. FRP Composites – Insist on

Polyurethane based resin systems7. Attend a webinar. Certificates of

continuing education provided. Photo Location: Cape San Blas, Florida

David Wentland, P.E.

Contact us if you want a certificate for this presentation

EXAMPLE FROM A PREVIOUS PRESENTATION

ESP Resources

Quality Products tested bythird part laboratoriesEngineering Support:

• Consulting• Preliminary Design• AutoCAD Details and Project Specifications• Involved in thousands of projects

worldwide.Installation Videos on Website and You

Tube

www.everlastseawalls.comwww.docks-marinas.com

A Designer’s Introduction to Development, Design and Application of Vinyl and Composite Sheet Pile

Everlast Synthetic Products

Technical Support and Sales

David Wentland, P.E.Coastal Engineer

andESP Representative

Docks & Marinas, Inc.www.docks-marinas.com

davewentland@docks-marinas.com

1+920-621-3464 USAJanuary 2013