2. www.creativepultrusions.com 814.839.4186 Toll Free: 888.CPI.PULL Fax: 814.839.4276
214 Industrial Lane, Alum Bank, PA 15521
Presented by Dustin Troutman
SUPERPILE COMPOSITE PIPE PILES
3. Pultruded 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
SUPERPLIE ATTRIBUTES
4. Pultruded profiles are cut to
length during the continuous
manufacturing process.
4.
Resin and glass fiber
reinforcements are combined
and formed into the shape of
the die on a continuous
process.
1. The resin is initiated by the
thermal decomposition
process. The initiator is heated
until a chemical bond
dissociation produces two
radicals. The chain continues
to build until the monomer is
used resulting in a cured resin.
2.
The profiles are pulled
through a die.
3.
Pulling
System*
Cut-Off Saw
Preformer
Continuous
Strand Mat
Guide Plate
Rovings
Resin Impregnator
Surfacing Veil
Forming &
Curing Die
*Caterpillar Pullers (shown)
or Reciprocating Pullers
4
SUPERPILE PROFILES ARE MANUFACTURED
BY THE PULTRUSION PROCESS
5. SUPERPILE PRODUCTION
High 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.
6. 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.
SUPERPLIE CONSTRUCTION
7. 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
Compressive
Strength (LW)
ASTM D695
Compressive
Strength (CW)
ASTM D695
Interlaminar
Shear (LW)
ASTM D2344
Test and Method
psi
Polyester
Polyester FR
Vinyl Ester
SUPURTUF 4000
• Superior
Strength
• Superior
Chemical
Resistance
• Superior
Impact
Strength
• Superior
Toughness
• Superior Energy
Absorption
WHAT MAKES SUPERPILE PERFORM?
SUPURTUF™ POLYURETHANE RESIN!
8. • UV Light Absorbers Protect The Resin From UV Damage.
• 10 Mil Polyester Veil Encapsulates The Fiberglass To Eliminate Fiber Blooming.
• Additional UV Protection Is Available By Applying Hdpe Sleeves, Polyurea
Coatings And Polyester Powder Coatings.
SUPURTUF™ POLYURETHANE UV
PERFORMANCE
9. • 8,000 Hours QUV Testing.
• No Significant Change In
Compression Strength.
• Exterior Will Fade Over Time
And Begin To Chalk.
• Piles Can Be Coated With
HDPE Sleeve Or Powder
Coated With A UV
Optimized Polyester Powder
Coating.
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
Strength(psi)
Test Results: No Paint
Test Results: Painted w/ SW
Solar Reflective Walnut Brown
SUPURTUF™ POLYURETHANE UV
PERFORMANCE
11. SUPERPILE FRP PIPE PILE TESTING
• Tested Per ASTM D6109 Test Standards At West Virginia University (WVU).
• Method To Determine The Full Section Bending Modulus Of Elasticity And The
Full Section Bending Strength.
• Tested To Determine The Crush Strength, Pin Bearing Strength, Washer Pull
Through Strength And Connection Capacities Both At WVU And At Creative
Pultrusions, Inc. (CPI) Test Facility.
• Pile Dynamic Analysis (PDA) Performed By Atlantic Coast Engineering.
14. CHARACTERISTIC DESIGN
PROPERTIES ARE DETERMINED
PER ASTM D7290
WHY ASTM D7290 AND WHY SHUOLD I
CARE?
It is an internationally recognized standard for
evaluating material property characteristic values
for polymeric composites for civil engineering
structural applications.
The characteristic value is a statistically-based
material property representing the 80% lower
confidence bound on the 5th
percentile value of a
specified population.
14
The characteristic value allows you to use LRFD or
Allowable Stress Design techniques and it allows
you to fairly compare FRP to other types of piles.
15. ASTM D7290-06
• Companies With Good Process
Control And Quality Standards
Are Rewarded In That The
Published Characteristic Design
Values Are Higher.
• Places All Suppliers On An Even
Playing Ground.
• Enhances The Confidence Level
On The Product Performance.
• All Design Data Is Reported
Based On An Internationally
Recognized Standard.
17. • Load & Resistance Factor
Design (LRFD) Of Pultruded Fiber
Reinforced Polymer (FRP) Structure.
• Developed By The Pultrusion
Industry Council (PIC) And The
American Society Of Civil
Engineers (ASCE).
• A Design Standard Exists For The
Pultrusion Industry. Our Industry
Joins Ranks With Steel, Wood,
Concrete And Aluminum As A
Standard Material Of
Construction.
17
LRFD Design
18. SUPERPILE DATA SHEETS AND LOAD & RESISTANCE
FACTOR DESIGN (LRFD)
THE CHARACTERISTIC VALUES WERE DEVELOPED
FOR AN LRFD DESIGN APPROACH WHERE:
The Characteristic/Reference Strength Values Shall
Be Adjusted Per Table 2.4-1 To Account For Moisture.
– 0.85/.80 For Strength For Vinyl Ester &
Polyurethane /Polyester.
– .95/.90 For Elastic Modulus For Vinyl Ester &
Polyurethane /Polyester.
λ – Time Effect Factor 0.4 For Permanent Load.
φ – Resistance Factor For Local Buckling Controlled
Design – .65.
19. SUPERPILE & ALLOWABLE STRESS
DESIGN
2.5 in Flexure
3.0 in Shear
3.0 for Connections
• Material Properties Are
Reduced To Satisfy An
Appropriate Safety Factor.
• Typical Safety Factors For
Pultruded Structures.
19
20. • 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.
• Nineteen 12”x1/2” And Twelve
16”x1/2” Piles Were Tested To Failure.
• Piles From Several Production Runs
Were Tested.
Flexural Test, WVU
FULL SECTION BEND TEST
21. Testing at Ft. Collins, CO
ENERGY ABSORPTION
• High Strength And Rather Low Modulus
Values, As Compared To Steel, Equate To
Very High Energy Absorption Capabilities.
• Ideal For Dock And Bridge Fender Systems
Where Energy Absorption Is Critical.
• Derived By Calculating The Area Under The
Load/Deflection Curve.
22. BOLTED CONNECTIONS FOR FORCES APPLIED PARALLEL
TO THE PILE
• Characteristic Design Values Have Been
Developed And Published Per ASTM D7290
• The Capacities Were Developed From Full
Section Testing.
• A 1.0” Diameter Bolt Was Used In The Test.
• Failure Load Is Defined As The First Indication
Of A Yield In The Load/Displacement Plot.
• Chart Represents The Bolt Being Loaded On
One Side Of The Pile.
23. • 1” Diameter Pin.
• Failure Mode, Pin Bearing Of Frp Tube.
• Chart Represents The Bolt Capacity
Loaded On One Side Of The Pile.
BOLTED CONNECTIONS FOR FORCES APPLIED TRANSVERSE
TO THE PROFILE
24. FULL SECTION CRUSH STRENGTH
• Crush Strength Derived By Applying A
Transverse Load Into The SUPERPILE
Through A 10”x10” Wale Section.
• The Ultimate Load Is Defined As The First
Yield Point On The Load Vs.
Displacement Plot.
25. FULL SECTION CRUSH STRENGTH ENHANCEMENT
• Crush Strength Can Be Increased With
The Addition Of An FRP Insert.
• Crush Strength Can Be Increase To 74
Kips Or Higher When Needed.
• The Addition Of Concrete, In Localized
Sections, Can Be Used To Increase The
Crush Strength. Testing Has Indicated
That The Crush Strength Can Be
Increased To 180+ Kips.
26. SUPERPILE BOLT PULL THROUGH STRENGTH WITH CURVED
WASHER
• Average And Characteristic Washer
Pull Through Strengths Have Been
Developed.
• The Values Are Based On 6”x1/2” And
6”x3/8” Curved Washers For The Round
Piles And 4”x3/8” Washers For The
Octagonal Piles.
• Washers Can Be Used To Increase The
Crush Resistance.
27. SUPERPILE FATIGUE TESTING 12” DIA. SUPERPILE
• 200 Cycles.
• Max Load 40% Of
Ultimate.
• Results, No Significant
Decrease In Strength Or
Stiffness.
Fatigued Sample vs. Average
12" SuperPile
0
20
40
60
80
100
120
Max Load (kips) Max Stress (psi) Bending MOE
(Msi)
Test
Average of 5 SUPURTUF
12" SuperPile
Fatigued Pile 200 cycles
28. SUPERPILE FATIGUE TESTING 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 SUPURTUF
16" SuperPile
Fatigued Pile 200 cycles
29. FATIGUE OF PULTRUDED COMPOSITES
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
StressRange,∆S
30. FDOT QPL APPROVAL
Pile System Was Designed And Approved
Based On FDOT Structures Manual Volume
1 January 2012.
33. • Connection Detail Decreases
The Point Load Stress.
• Hollow Composite Pipe Piles
Require Attention To The
Connection Details.
• Excessive Point Loads Should
Be Avoided.
CONNECTION DETAILS PILE TO PIER CONNECTION
35. PDA ANALYSIS PERFORMED BY ATLANTIC COAST
ENGINEERING
Location: Crofton Services Yard
Portsmouth, VA
36. PDA ANALYSIS
• An 18” Dia. ½” Thick Steel Tube Was Bolted To The
End Of The SUPERPILE To Increase The Driving
Resistance.
• A Vulcan 01 (5,000 Lb Ram With A Stroke Of 3 Ft.)
Was Utilized To Drive The Piles To Refusal.
• An Ape D30-32 (6,600 Lb Ram With A Stroke Of 11.25
Ft.) Was Utilized To Drive The Pile To Failure.
37. PDA Analysis SUMMARY
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.
38. PDA ANALYSIS SUMMARY
The test pile driven with the larger
APE D30-32 impact hammer was
driven through the same soils at a
blowcount 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.
39. PDA ANALYSIS SUMMARY
After a One Day Set Up Period, the Pile was
Re-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 Compressive Driving Stress
of 13-15 ksi, the Pile Head Split and the Pile
Failed.
Prior to the Pile Head Splitting, a CAPWAP®
Analysis Indicated an Ultimate Axial
Compressive Capacity of 350 kips.
40. PDA ANALYSIS SUMMARY CONCLUSIONS
• 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, and May Require a Pile Cushion to Reduce Driving
Stresses.
• Based on Observations Made During the Test Pile Program, It is
Recommended that Dynamic Consultants Utilize a Model PAX PDA Unit (with
a longer pretrigger buffer than the PAK unit) Due to the Longer Pre-
Compression Time.
• For Impact and Vibratory Installed SUPERPILES, CPI Recommends the use of a
Wave-Equation Analysis and Driveability Study to Assess the Soil-Pile
Interaction and Estimate Pile Driving Stresses During Installation Considering
the Proposed Hammer Assembly and Site Soil Profile.
45. • 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”
Diameter Bolts.
PILE SPLICE OPTIONS
46. 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.
47. PULTRUSION THE GREEN CHOICE
EMBODIED ENERGY COMPARISON
80
60
40
20
0
S U P ER LO C TM
S TE E L A LU M IN U M P V C
MJ/kgOFMATERIAL
47
Will Not Leach
52. WHY SPECIFY SUPERPILE?
• Engineered Solution,
Manufactured in a
Climate Controlled
Facility to Stringent QA
Standards.
53. WHY SPECIFY SUPERPILE?
• Will Stand The Test Of Time.
• 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 41 Years.
• Will Not Rot, Spall Or Deteriorate.
• Can Be Installed With Traditional Pile Driving Equipment.
54. MARGATE BRIDGE, NJ
52 12” diameter FRP piles at 80 foot in length
were used to construct the bridge fender.
55. MARGATE BRIDGE, NJ
Piles Ready to Ship
Piles Delivered to the Job Site
Piles Installed with a Vulcan V5C Vibro
Hammer
58. VIRGINIA DOT
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
77. 77
QUALITY
The Quality Management System has
been modeled per the requirements of
the ISO9000:2008 International Standard.
In 2012, Creative reinforced their
commitment of providing the highest
Quality of products and services with the
addition of a certified LEAN / Six Sigma
Black Belt who manages related Quality
initiatives.
78. FACILITIES OVERVIEW
Creative Pultrusions, Inc. was
established in 1973 and is located
in Alum Bank, Pennsylvania.
PRODUCTION MACHINES = 18
FACILITIES (SQ. FT) = 160,000
EMPLOYEES = 148
78
79. 79
HILL & 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 & Galvanizing Services.
• 2013 Revenue of £444.5m
• Infrastructure – 71%
Roads - 25%
Utilities - 46% • Galvanizing - 29%
£316.9m £127.6m
80. 80
WHERE HILL & SMITH OPERATES
UNITEDSTATES
FRANCE
UNITED
KINGDOM
SWEDEN
THAILAND
INDIA
CHINA
AUSTRALIA
V
• AUSTRALIA: New office in Queensland for
the development of our wire rope and
safety barrier products.
• CHINA: Manufacturing and trading
facilities located in the Jiangsu province
for the further expansion of our pipe
support business.
• FRANCE: The locations of France Galva
and Conimast, where we have ten
galvanizing plants and a lightning
column business.
• INDIA: New manufacturing facility for
pipe supports and also offices for
development of our Hill & Smith
infrastructure product business.
• SWEDEN: Location of ATA Bygg-och
Marckprodukter AB, the road safety barrier
and signage business.
• THAILAND: Location of part of our pipe
supports manufacturing capability, where
we have plants near Bangkok.
• UK: Head office and various group site
locations covering our main infrastructure
products business and network of UK
galvanizing plants.
• USA: Our V&S galvanizing and utilities
plants are situated on the East Coast along
with the Bergen and Carpenter & Paterson
pipe support business and the fiber
reinforced composite profiles business,
Creative Pultrusions.
81. 81
HILL & SMITH REVIEW OF 2012
INFRASTRUCTURE PRODUCTS
The division is focused on supplying
engineered products to the roads
and utilities markets in geographies
where there is a prospect of
sustained long term investment in
infrastructure.
In 2012 the division accounted for
73% (2011: 68%) of the Group’s
revenue and 43% (2011: 48%) of the
Group’s underlying operating profit.
UTILITIES
The requirements for new power generation in emerging
economies and replacement of aging infrastructure in developed
countries provide an excellent opportunity for the Group’s utilities
businesses.
Revenues increased to £205.7m (2011: £167.0m), which after
adjusting for acquisitions and currency impacts, reflects 13%
organic growth of £22.5m. Underlying operating profit increased
by £1.9m to £13.4m (2011: £11.5m) with acquisitions contributing
£0.9m of the growth.
The organic growth was driven mainly by our US based businesses,
V&S Utilities and Creative Pultrusions, which benefitted from a
more active USA utilities market.
delivering a number of large projects in the transmission, rail and cooling tower markets. Over the year, we
further developed high value products for niche markets.
These products are lightweight, corrosion resistant and offer improved installation times, thereby substituting
traditional materials. There is a growing demand for composite products and this was evident in the supply of
85 railway platform extensions for the upgrade to the Wessex Line in the UK.
CREATIVE PULTRUSIONS
ACHIEVED A RECORD PERFORMANCE
82. MASS TRANSIT DECKS
82
CREATIVE’S PLATFORM EXPERIENCE MIDLANDS, U.K.
PLATFORM 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!
83. APPLICATION PROFILE
MASS TRANSIT ELEVATED
PLATFORM DECKS FOR NYCTA
83
• 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!