Brooklyn Bridge Park Preventative Maintenance Plan Report
Brooklyn Bridge Park Preventative Maintenance Plan Report
Brooklyn Bridge Park Preventative Maintenance Plan Report
Report for
P R E V E N TAT I V E M A I N T E N A N C E P L A N
Presented to
Presented by
Table of Contents
Pages13
Section 2 Introduction
Pages45
Pages67
Pages814
Pages1519
Pages2024
Pages2529
Section 8 Conclusion
Page30
ThisreportwasdevelopedbyCH2MHILLEngineeringP.A.forthesolepurposeanduseby
BrooklynBridgeParkCorporation.Informationinthisreportbemaynotbeused,reproduced,
ordisclosedtoanyotherpartyforanyotherpurposewithouttheexpressedwrittenpermission
ofCH2MHILLEngineeringP.A.
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Section 1
Executive Summary
BrooklynBridgePark(BBP)providesflagshippublicwaterfrontaccessandexperiencesthroughthe
conversionofformerindustrialusewaterfrontfacilities,originallyconstructedinthe1950s/1960s,into
premierparkspace.BBPsmaritimeassetsinclude:
13,000timberpiles
11,000concretepileextensions
4,500linearfeetofconcreteandsteelbulkheads
830,000squarefeetofconcretepierdeck
3,200linearfeetofriprapornaturalshoreline
Photo 1-1. Deteriorated timber pile from marine borer attack at Pier 3
LocatedalongtheEastRiver,BBPswaterfrontassetsare
subjecttoinevitabledeteriorationasaresultofthe
harshmarineenvironmentinwhichtheyareinstalled.
Observedandexpecteddeteriorationisduetomarine
borersandrotfortimberelements,spalling,chemical
attack,andbreakdownforconcreteelements,and
corrosionforsteelelements.Ifthedeteriorationon
theseelementsareleftunabated,theirloadcarrying
capacitywilldecreaseovertimetothepointwherethe
structuremaybecomeunabletosafelysupportthe
Parksrequiredloadrating.Incaseswherethe
deteriorationissignificant,localizedfailuresofthe
structuremayalsobepossible.StructuresalongthePark
waterfrontwithreducedloadratingswillneedtobe
temporarilyclosedtothepublicuntilthenecessaryrepairscanbeimplementedandtheirloadcarrying
capacityisrestored.ThemajorityoftherepairworkatBBPwillinvolvebothaboveandunderwater
repairstothetimberpilessupportingthewaterfrontstructures.UndertakingworkalongtheParks
waterfrontischallengingduetotheharshmarineenvironment,theunderwaterrepairwork,limited
access,andtheneedtominimizedisruptionstoongoingParkoperations.Allthesefactorsmakethe
maintenanceoftheParkswaterfrontinfrastructurefarmoredifficultandcostlythanatypicalpublic
park.
BBPiscommittedtoensuringthattheParkremainsinastateofgoodrepairwellintothefutureandhas
activelyallocatedfundingfortheimplementationofacosteffective,sustainable,andresponsible
maintenanceplanfortheParkswaterfrontinfrastructure.Therearetwoapproachestowaterfront
facilitymaintenance,reactiveandproactive.Reactiverepairsareperformedwhenstructuralelements
becomestructurallyinadequateduetodeterioration,andmayincludestructuralconcreteencasements
oftimberpilestorestoreitsloadcarryingcapacity.Proactive,orpreventativerepairsareinstalledprior
toloadcarryingcapacityreductionsduetodeterioration,andmayconsistofepoxy(nonstructural)
encasementsoftimberpilestoarrestdeterioration.
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Since2010,emergencystructuralrepairshavebeentheonlyoptionatBBPduetosignificant
deteriorationofthemarinestructures.TheserepairswereinstalledtorestoretheloadratingofeachPier
andtosupportParkloads.NowthatthepiershavebeenrepairedtosatisfytheParksrequiredload
rating,BBPisatacrossroadstodecidewhethertoeithercontinuewiththesamereactivemaintenance
approachortoinsteadshifttoaproactive,preventativemaintenanceplanforthetimberpiles.
Theproposedpreventativemaintenanceplanfortheexistingtimberpilesisanepoxygroutencapsulation
system.Thisproductissoldbyseveralmanufacturersandhasbeenusedformarineapplicationsfor30
years.IthasbeensuccessfullyusedinNewYorkHarborbyentitiessuchasNYCEDC,theHudsonRiver
Park,BatteryParkCityAuthority,andinotherapplicationsbothdomesticallyandaroundtheworld.The
LakePontchartrainCausewayinsouthernLouisiana,whichistheworldslongestbridgeoverwater,has
reliedonthisepoxygroutencapsulationsystemsince1988toprotectover1,300ofits54in.diameter
concretepiles.HereinNewYork,thepassengershipterminalontheWestSideofManhattanhas
installedover2,300epoxygroutencasementssincetheearly2000sonitstimberpilestoprotectthem
fromfurtherdeterioration.CH2MHILL(CH2M),asBBPsmarineinfrastructureconsultantwithover35
yearsofmaritimedesignexperienceworkinginNewYorkHarbor,recommendstheepoxygrout
encapsulationsystemasthemostreliable,proven,andcosteffectiverepairmethodforthetimberpiles.
Thetechnicalattributesofbothproactiveandreactivemaintenancestrategieswerecompared,as
summarizedbelow:
Attribute
Reactive
Proactive
RecommendedOption
Unitcostof
installation
Complicatedinstallation;
$1,100perlinearfoot
Straightforwardinstallation;
$475perlinearfoot
Proactivelesscostlythan
Reactiveapproach
Riskoffuture
costescalation
Significantescalation(>40%)
overthepastfiveyears.
Opportunitytolockinall
inclusivecostsandminimize
futureescalationrisk
Proactivelessriskofcost
escalation
Servicelife/
durability
Structuralsteelwillcorrode,
longtermdurabilityishighly
reliantuponworkmanship
Nocorrosivematerials;
straightforwardinstallation
sequence;onlyknown
potentialfailuremechanism
iseasilymitigated
Proactivelesssusceptible
tofailure
Warrantyof
work
Limited,shortterm(1to3
years)warrantyoptions
Plannedtoincorporatea
minimumof35year
warrantyoninstallation
ProactiveWarrantyperiod
issignificantlylonger
Stagingof
construction
operations
Permittingand
environmental
Requirescostlymitigation
Nomitigationrequired
ProactiveLeast
environmentalimpact
Additional
structuralload
>600lb/linearfootinstalled.
Mayaffecttheloadratingor
repairapproachinthefuture
duetoadditionaldeadload
fromrepair
<50lb/linearfootinstalled.
Nodeadloadconsiderations
duetominimalincreasein
deadload
ProactiveDoesnotreduce
pierloadrating
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AlifecyclecostanalysiswasalsoperformedtocomparethelongtermcostsassociatedwithBBPs
reactiveandproactivemaintenancestrategies.Theresultsoftheanalysisindicatethataproactive
approachwillyieldapproximately$85millioninsavingsoverthe50yearplanninghorizon(using2015
dollars).Thisisbasedontheassumptionthatthereactiverepaircostsarenotescalatedduringthis
period.
Thepreventativemaintenanceapproachismoreadvantageousthanthereactiveapproachfroman
engineering,environmental,andfinancialpointofview.Bytakingadvantageoflowerunitcostsandlower
riskofcostescalations,thepreventativemaintenanceapproachcansaveapproximately$85millionover
a50yearperiodwhencomparedwiththereactiveapproach.Moreimportantly,thetimberpiles
supportingtheParkswaterfrontinfrastructurewillbeprotectedfromfuturedeteriorationnowrather
thaninthefutureandensuresthattheParkremainsopentothepublic.Withthereactiveapproach,
thereisahigherriskoftemporaryclosurestotheParkduetopotentialreductionsinthepierloadratings
andlocalizedstructuralfailuresasaresultoftheinherentintervalsbetweenthecyclicalinspectionsand
theactualimplementationoftherecommendedrepairstothedeterioratedelements.Inaddition,
comparedtothereactiveapproach,thepreventativeapproachminimizesimpactontheenvironmentand
bothcurrentandfutureParkoperations.
Typically,thedriverforchoosingthetypeofrepairsformarinestructuresisdrivenbyavailablefunding.
Oftenpublicagencieshavelimitedfundingandcanrepaironlywhatisabsolutelynecessarytokeepthe
structurestanding(reactiveapproach).Iftheentitycontrollingthemaritimeassetswillbeinplaceona
longtermbasis(publicentity)andfundingisavailable,preventativemaintenancebecomesthepreferred
option.BrooklynBridgeParkisinasomewhatuniquelyadvantageoussituationwherepreventative
maintenanceisfinanciallyviableforamajorityoftheparkassets.
Forallthesereasons,CH2Mrecommendsthepreventativemodelforthemaintenanceofmarine
structuresatBrooklynBridgePark.Welookforwardtotheopportunitytoworkwithyouonthislandmark
project.ThisinvestmentwillensureopenvenuesandexperiencesforthepeopleofNewYorkforyearsto
come.
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SECTION 2 Introduction
Section 2
Introduction
BrooklynBridgePark(BBP)islocatedontheeastbankoftheLowerEastRiverinBrooklyn,NewYork.The
parkiscomprisedofapproximately85acresover1.3milesofwaterfrontandismanagedbytheBrooklyn
BridgeParkCorporation(BBPC).Historically,themajorityofthislandwascontrolledbythePortAuthority
ofNewYorkandNewJersey(PANYNJ)andusedasacommercialportforthetransferofgoodsfromship
toshore.ThemaritimeassetscontrolledbytheBBPCincludethefollowing(quantitiesareapproximate):
13,000timberpiles
11,000concretepileextensions
4,500linearfeetofconcreteandsteelbulkheads
830,000squarefeetofconcretepierdeck
3,200linearfeetofriprapornaturalshoreline
Theoriginalpierswereinstalledinthelate1950sandearly1960s,withadditionsanddeletionsmadeup
untilthecurrenttimeperiod.Thevastmajorityoftheexistingfoundationelementsandpierdecksremain
inplacetoday.
In2004,MichaelVanValkenburghAssociates(MVVA)createdamasterplanfortheparkarea,which
ultimatelyleadtothecreationoftheGeneralParkPlan(GPP)in2005.AsapartoftheGPP,theparkwas
mandatedtooperateinaneconomicallyselfsufficientmannerwithregardtoalloperationsand
maintenancecosts.Asafirststep,tobetterunderstandtheconditionstateofitsmaritimeinfrastructure,
theBBPCengagedCH2MHILL(CH2M,formerlyHalcrow)in2008toperformaboveandunderwater
inspectionofthewaterfrontstructuresalongtheBBP.Inspectionfindingsrevealedsignificant
deteriorationofthefoundationelementsand,accordingly,constructionrehabilitationdocumentswere
generated.
Tobetterunderstandthelongtermmaintenancecostsofitsmaritimeinfrastructure,theBBPCengaged
CH2Mtocreatealifecyclecostanalysis(LCCA)foratermof50years.TheLCCAwasapredictivestudy
thatusedknownunitconstructioncostsandratesofmaterialdeteriorationtoestablishanticipatedfuture
maintenancecosts.Thefirststudyscenario,theTraditional/ReactiveModel,assumedthatstructural
elementswouldberepairedonlyaftersignificantdeteriorationhadtakenplace.Forthepurposesofthis
document,significantdeteriorationisdefinedasthatwhichresultsinalossincrosssectionalareaofa
primaryfoundationelementthateitherreducestheloadcarryingabilityoftheelementormandatesa
reductionintheelementsallowableliveloadingcapacitywithinsixmonths.
Aftertheinstallationofrepairsrequiredasaresultofthe2008to2009inspections,BBPCrequestedthat
CH2MmodelanadditionalLCCAontheremaining,unrepairedwaterfrontstructuralelementsthroughout
thepark.Thepurposeofthelatterstudywastodetermineiftheparkshouldcontinueutilizingareactive
maintenanceapproachor,instead,movetoapreventativemodel.
Areactivesystemrepairsstructuralelementsaftertheyhavesignificantlydeteriorated.Apreventative
systeminstallsrepairsonstructuralelementspriortoanysignificantdeteriorationinordertomaintain
theelementsloadratingforboththeshortandlongterm.
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Thepurposeofthisreportistoprovideabriefoverviewofthehistory(2008topresent)andcurrent
conditionoftheBBPmaritimeinfrastructure,discusstheprosandconsofthelongtermreactiveand
preventativemaintenancesystemsandmakearecommendationtoBBPofwhichsystemshouldbe
selected.
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Section 3
Section 2
Bulkheads
Bulkheadsareusedattheupland/waterinterfacetodefinetheshorelineandretainfill.Themajorityof
thebulkheadsattheparkareofsteelsheetpileconstruction.Thesheetpilesweredrivenintothe
mudlineandthentiedbacktoasteelsheetpiledeadmananchoringsystem,locateduplandofthe
bulkhead.Asteelwalemember,typicallyachanneloranHsection,mountedhorizontallyalongthe
exteriorofthesteelsheeting,servesasananchorpointforaseriesoftierods.Thetierods,whichare
spacedatregularintervalsandconnectthebulkheadtothesteelsheetpiledeadmansystem,workin
tensiontoresistthebulkheadstendencytooverturn.Lastly,aCIPconcretecaptopsthesteelsheetpile
bulkhead.
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Section 4
Timber
Marineboreractivityistheprimarymechanismofdeteriorationforthetimberfoundationelements
(piles)atthisparticularlocation.TherearetwopredominantspeciesofmarineborerspresentintheEast
River:LimnoriaandTeredo.Limnoria,commonlyreferredtoasgribbles,aresmall(upto0.15in.long)
woodeatingcrustaceansthatattackthetimberpilesfromtheoutsidebyboringsmalltracks(onthe
orderof0.1in.wide),continuallyreducingthediameteruntil,inseverecircumstances,thepileembodies
theshapeofanhourglass.Teredo,commonlyreferredtoasshipworms,arelarger(upto8in.long),
woodeatingmollusksthatburrowverysmall(0.25in.diam)holesintothetimberandattackfromwithin,
eventuallyresultinginthehollowingoftimberpiles,leavingonlytheoutershells,suchthatthepilesmay
appearnormal.
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Inbothcases,themarineboreringeststhewoodcellulose,whichreducesthecrosssectionalareaofthe
structuralelement.Thereductionincrosssectionalarealeadstoareductiontheloadcarryingcapacityof
theelement.
Timberpilesthatareinserviceinamarineenvironmentaretypicallytreatedwithapreservativemeantto
preventtheingressofmarineborers.Thetwomostcommonpreservativesfoundontimberpilestoday
arepressureinjectedcreosoteandchromatedcopperarsenate(CCA).Timberpilesaretreatedwiththese
compoundspriortoinstallation;however,thesepreservativeswillgraduallyleachoutofthepileandinto
thewatercolumnovertime.Asthisleachingprocesscontinuesandretentionofthepreventative
diminishes,thetreatmentbecomeslesseffectiveinpreventingmarineborerattack.
AlloftheoriginalpilessupportingthepiersatBBPweretreatedwithcreosote.Theexactlevelof
concentrationanddepthofpenetrationofthistreatmentisunknown.In2010,diversextractedatotalof
40coresamples,eachhavinga0.2in.diameter,fromthetimberpiles.Thisquantityincludestencores
eachfromthepilesunderPiers2,3,5,and6.Thecoresamplesweresubjecttolaboratorytestingby
WoodAdvisoryServicesInc.(WAS)inordertoestablish:woodspecies;remainingdepthofwood
preservativepenetration(depthoftheremainingpreservativeintothecoreofthewood,measuredfrom
theoutside),andretentionconcentration.TheresultsofthistestingareshownbelowinTable41.
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BrooklynBridgeParkPreventativeMaintenancePlanReport
Table 4-1. Results of the Creosote Retention Analysis for Piers 2, 3, 5 & 6.
Sample
Pier2
Pier3
Pier5
Pier6
Species*
AverageCreosote
Penetration
Douglasfir(6cores)
1.25in.
Southernpine(4cores)
3.25in.
Douglasfir(1core)
1.25in
Southernpine(9cores)
3.44in
Douglasfir(9cores)
1.31in
Southernpine(1core)
4in
Douglasfir(10cores)
1.19in
Southernpine(0cores)
CompositeCreosote
Retention
4.60pcf
5.03pcf
6.40pcf
4.49pcf
*ThenumberofcoresineachsamplewhichwereidentifiedaseitherDouglasfirorSouthernpineareindicatedinparentheses.
Testingrevealedthatthetimberpilesconsistoftwospeciesofwood:DouglasFirandSouthernPine.The
averagecreosotepenetrationdepthfortheDouglasFirpileswas1.25in.,whilethatfortheSouthernPine
piles3.25in.ThecompositeretentionvaluesforPiers2,3,5,and6were4.60pcf,5.03pcf,6.40pcfand
4.49pcf,respectively.TheAmericanWoodProtectionAssociation(APWA)recommendsminimum
penetrationdepthsof1.0in.forDoulasFirand4.0in.forSouthernPine.Inaddition,aretention
concentrationof8.0pcfisgenerallysufficienttoeffectivelyprotectbothtypesoftimberpilesfrom
marineborerattack.Laboratorytestingrevealedthatcompositeretentionvaluesinallcoresampleswere
between20.0percentand43.9percentbelowthe8.0pcfthresholdthatisconsideredtobeaneffective
levelofprotection.TheaverageremainingpenetrationdepthofthepreservativeintheDouglasFirpiles
exceededtherecommendedthresholdby25percent;however,theaverageremainingpenetrationdepth
oftheSouthernPinewasdeterminedtobe81percentoftherecommendedthreshold.Thefulltextofthe
WASCoreReportisprovidedinAppendixA.
Marineborerdeteriorationratesaredependentonmanyvariablessuchastemperature,salinity,current,
pollutionlevels,andremainingconcentrationofpreventativetreatment.Intermsofremainingeffective
pilediameter,annualsectionlosscanbeashighas0.5in.foruntreatedpilesincomparisontozerofor
fullyprotectedpiles.Ourexperiencealsoshowsthatdeteriorationratesvarywithgeography,local
conditionsmaybevastlydifferentthaninotherareas.Basedonavailableinformation,therateoftimber
deteriorationinthelifecyclemodelinganalysiswassetat0.0625in.fortheinitial6years,0.125in.forthe
subsequent6years,and0.250in.fortheremaining38yearsofthestudy.Bycomparison,theinitialrate
ofdeteriorationissomewhatlow,whichislargelyattributabletotwofactors.Namely,allseverely
deterioratedtimberelementswererepairedpriortothestudyasaresultofthe20082009inspection
findingsandthedeteriorationratesassociatedwiththerepairedelementsarenotaccountedfor.Second,
therateatwhichtheeffectivetimberpilediameterisreducedgenerallyincreasesovertimebecause
conditionsareexacerbatedasincreasedmarineboreractivitycreatesnewpointsofingress,leavingthe
woodsusceptibletofurtherattack.ThelaboratoryanalysesperformedbyWASindicatedthatalthough
thepenetrationdepthandretentionconcentrationremainedrelativelyintact,compositeretentionvalues
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werelessthantherequiredthresholdforprotection.Overall,leachingofthepreservativeisalready
underway,stimulatingongoingdeterioration.
Photo 4-2. Underwater Photo of Severe Deterioration at Pier 5
Concrete
Severalconditionscanbedetrimentaltoinwaterconcretestructures,includingchemicalattack,
corrosion,anderosion.Theprevailingdeteriorationmechanismfortheconcreteelements,primarilythe
pileextensionsandbulkheads,iscorrosionofthereinforcingsteelthatisdrivenbytheinfusionof
chloridesintotheconcretematrix.Exposureconditions,aswellastheconcretetransportproperties(a
functionofthemixdesign),anddepthofconcretecoverage(fromthefaceoftheelementtothe
reinforcingsteel)ofeachstructuralelementaretheprimaryfactorsthatdeterminetherateofchloride
ionpenetration,ortherateatwhichthechloridesmovethroughtheconcretematrix.Aschlorideions
reachthedepthofthereinforcingsteel,thechloridesbreakdownthepassivelayeroffilmprotectingthe
steel.Oncethisfilmisdestabilizedandoxygenandwaterareavailable,corrosionofthereinforcingis
initiated.Asthesteelcorrodes,itexpandstomanytimesitsoriginalvolume,andtheassociatedexpansive
forcescancausecrackingand/orspallingintheadjacentconcrete.Althoughthesteelexpands,its
effectiveremainingcrosssectionalareaisactuallydecreased,asistheyieldstrength,resultingina
reducedloadcarryingcapacity.Corrosionofconcretestructuresinmarineenvironments(brackishor
seawater)occursmostfrequentlyinthetidalandsplashzones,wheremoistureandoxygencontentsare
optimalforthedevelopmentofacorrosioncell.
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ThesecondmostfrequentmechanismofconcretedeteriorationatBBPiserosionoftheconcretematrix
overtime.Thisconditionalsooccursprimarilyinthesplashandtidalzones.Concreteerosionis
characterizedbyagraduallossofsurfacemortarandaggregates,whichresultsinsectionlossandcan
initiateavenuesforotherformsofdeterioration.Therearemultiplecauseforthisconditionincluding
continuouswaveactionoverlongperiodsoftime,andcyclicalwettinganddryingoftheconcrete.These
wetdrycyclescarrybothwateranddissolvedsaltsintotheconcretematrix.Subsequentevaporation
causesthesaltstocrystalizeinthematrixpores,producingstressthatcancausemicrocracking.This
microcrackingmanifestsitselfintheformofthebreakdownandlossofthecementpaste.
Nondestructivetesting(concretecoring)wasperformedontheconcreteelementspriortothelifecycle
study.Inlieuofsubjectingconcreteelementstofurtherdestructivetesting/laboratoryanalysesof
concretecoresamples,pastinspectionreports(from2001,2004,2007,2009and2013asavailable)were
reviewedtoestablishafailurerateoftheconcretepileextensions.Forthepurposesofthelifecyclestudy,
failureoftheconcreteextensionelementsisdefinedbythefollowingcriteria:
Concreteerosionorspalldepthsof6in.ormoreatbottomofextension
Groutlossof6in.ormore,asmeasuredverticallyfromthebottomoftheextension
Concretecracksgreaterthanorequalto0.25in.
HistoricaldatarevealedthattheCIPextensionsatPier5aredeterioratingsignificantlyfasterthanthe
precastconcreteextensionsatPiers2,3and6.Thedifferenceindeteriorationratesislikelyduetothe
variablelevelofqualitycontrolthatispossiblebetweenthetwoinstallationoptions.Precastconcreteis
manufacturedinashopinacontrolledenvironment,whichgenerallycorrelatestoabetterquality
productwithalongerservicelife.
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TheamountofdeteriorationintheprecastconcreteextensionsatPier3currentlyexceedsthatatPiers2
and6.ReviewofpriorinspectionandrepairdataindicatesthatPier3waspreviouslysubjecttofewer
repairinstallationsincomparisontoPiers2and6,whichwouldaccountforagreaternumberof
extensionsthatcurrentlyrequirerepair.
Thishistoricalrepairdatawasutilizedtopredictthefuturefailurerateoftheremaining,unrepaired
concreteextensionsunderthepiers.Thisfailureratewasrepresentedasapercentageoftheremaining,
unrepairedconcreteextensions.
Steel
Theprimarydriverfordeteriorationofsteelinamarineenvironmentiscorrosion.Steeliscomprisedof
manydifferentelementsandis,therefore,notahomogeneousmaterial.Slightinconsistenciesand
anomaliesinthemakeupofthematerialcaninitiatecorrosion.Ingeneral,corrosionisanelectrochemical
processwheredifferencesinelectricalpotentialcausedistinctareasofasteelsurfacetobecomeanodic,
whileotherstobecomecathodic.Asoxidationoccurs,theanodicareaswillloseelectronsandcorrode.
Theaggressive,brackishenvironmentatBBPsignificantlyincreasesboththefrequencyandseverityof
corrosiononsteelelements.Thisenvironmentcontainsthethreekeyelementsrequiredtoinitiate
corrosion:anefficientelectrolyte(seawater),oxygen,andmoisture.Whensteelisimmersedinseawater,
theavailableoxygencontentdropsandtheprocessslows.However,thesplashzoneandtidalzoneare
continuallysubjecttowetdrycycles,whichsupplyabundantquantitiesofbothmoistureandoxygen.
Accordingly,steelsurfaceswithintheseregionstypicallyexhibitthehighestlevelsofcorrosion.
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ThemajorityofstructuralsteelelementsatBBParesheetpilebulkheads.Theexposedheightsofthese
structuresgenerallyrangefrom5ftto35ft.Asthesteelsheetingcorrodes,thecrosssectionalareais
reduced,asistheabilityofthebulkheadtoresistlateralforcesandsupportappliedloadsfromthe
surfaceabove.Severecorrosionresultsinthroughholes,whichallowlossofthefillfrombehindthe
bulkhead.Voidsleftbythefilllossoftenresultinsinkholesasthepavement/loadingsurfaceabove
collapseswithin.
Photo 4-5. Corrosion on Steel Sheet Pile at Wharf 2-3
Ultrasonicthicknessmeasurements(UTMs)wererecordedatrepresentativelocationsthroughoutthe
steelstructuresatBBPtodetermineremainingthicknessesofsteelelements,suchthatexistingstructural
capacitiescouldbeestablished.IntheReactiveModel,itisassumedthatthestructuralintegrityofthe
bulkheadswillbemaintainedthroughacombinationofinstallingcathodicprotectionandconcretefascia
installation.Bulkheadelementsthatarecurrentlyratedinfairconditionareslatedtoreceiveconcrete
fasciaprotection.Thistypeofrepairisoutlinedinthefollowingsection.Bulkheadelementswherethe
crosssectionalareahasnotbeencompromisedbycorrosion,andarethusratedinfairconditionwill
receivegalvanicanodes.Galvanicanodesystemsconsistofsacrificialanodesthatareaelectrically
connectedtothestructureandimmersedinanelectrolyte(water).Theanodecontainsmetalofahigher
potentialthanthesteelitisprotecting.Becauseofthepotentialdifferencebetweentheanodeandthe
structurecathode,theanodeisconsideredtoproducetherequiredcurrenttomaintainthestructurein
cathodiccondition.Theseanodesarescheduledtobereplacedona15yearcycle.Bymaintainingthe
anodes,thesteelbelowwatercanbecontinuouslyprotectedfromfuturecorrosionandessentially
freezesthecurrentconditionofthebulkheads.
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Section 5
SummaryofRequiredRepairs
Pier
LFRepaired
PilesRepaired
Pier2SteelPipe
3021
182
Pier2Timber
4330
381
Pier3Phase1&2
7429
1314
Pier3Phase3
3461
625
Pier5
9249
1072
Pier5Bulkhead
776
146
SubwayPilePier5
361
27
Pier45Bulkhead
152
28
Wharf56
262
32
Pier6Inshore
1806
279
Pier6Outshore
7517.5
821
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Laborandinstallationofthisrepairtypeissignificantduetothemultiplecomponentsinvolved.Each
elementisbroughtfromthetopsidepiertothepileandisinstalledmanuallybydivers.Photo51shows
thedifferentcomponentsoftherepairpriortoinstallingtheconcreteforms.Oncetheseelementsarein
place,andtherebarhasbeeninspected,diversinstalltheformworkandpumpconcretethroughthe
concreteports.Photo52showsthefinalrepairafterconcreteisinplace.
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Photo 5-1. Different Components of Repair Prior Installing Concrete Forms at Pier 3 Rehabilitation Project
Stagingforthesestructuralrepairprojectsisalsosignificant.Settingupdivestations,storingconstruction
materials,testingconcreteanddeliveryofconcretetrucksarepartofeverydayoperationsduring
rehabilitationprojects.
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Reactive Model
Asstatedintheintroduction,theReactiveModelsimulatesthegradualdeteriorationofindividual
elementsandusestheinformationtoestimateofthelongtermrepaircostsassociatedwithmaintaining
BBPCswaterfrontassets.ThisLCCAutilizedaninspectionandrehabilitationcyclewithanassumed3yr
intervalbetweeninspections.Theinspectionswouldidentifyelementswithsignificantdeteriorationand
quantifythedeteriorationsuchthatstructuralrepairdocumentswouldbegeneratedandrepairsinstalled
ontheminimumnumberofelementsrequiredtomaintainadesiredlevelofservice.
IntheReactiveModel,eachstructuralelementisassignedaninitialdiameterbasedonafield
measurement.Aforementionedannualdeteriorationratesareapplied,andsimulateddeteriorationof
eachelementisexpressedbytabulatedvaluesofremainingsectionpropertiesthatcorrelatetoeach3
yearinspectionmilestone.Themodelprovidesanunderstandingoftherelationshipbetweenstructural
capacityandsectiondiameter,asitprovidescapacitycalculationsthatcorrelatetoremainingsection
diametersatvariouspointsintime.Inthesimulation,designatedserviceloadsareappliedtothe
elementsinordertoidentifydeficientelements,orelementswithcapacitiesthatdonotmeetorexceed
thedesiredserviceloads.Eachyear,deficientelementsarerepairedbasedongenerationofrepaircosts
andquantities,andsubsequentlyremovedfromtheoverallset.Theremaining,unrepairedelements
undergocontinued,iterativeevaluationusingthisprocessuntiltheyqualifyasdeficient.Forthepurposes
ofthisstudy,allstructuralrepairswereassumedtohaveaneffectiveservicelifeof50years.Usingthis
method,themodelprovidesagraphoftherepaircostseachyearforthemaintenanceofeachfacility.A
representativeyearvs.costcurveisshownbelowinFigure53.
TR0909151011NYC
18
BrooklynBridgeParkPreventativeMaintenancePlanReport
$100,000,000
$90,000,000
$80,000,000
$Amount
$70,000,000
$60,000,000
$50,000,000
$40,000,000
$30,000,000
$20,000,000
$10,000,000
$0
Period
TheoveralltotalcostoftheReactiveprogramforthetimberpiles,includingbothcapitalandoperational
costs,isapproximately$334Min2015dollars.
TR0909151011NYC
19
Section 6
TR0909151011NYC
20
BrooklynBridgeParkPreventativeMaintenancePlanReport
Manyvariousepoxybasedpreventativerepairsystemsarecommerciallyavailable.Inaddition,no
specialtyequipmentorlaborisrequiredfortheinstallationofthistypeofrepair.Fourofthemost
commonlyusedepoxygroutrepairencapsulationsarelistedbelow:
BASF:WaboAPE(AdvancedPileEncapsulation)
Denso:SeaShieldSeries500System
FiveStar:PileJacketGroutHPandFRPJacket
SimpsonStrongTie:FX706MPMultipurposeMarineEpoxyGroutandfiberreinforcedpolymer
(FRP)Jacket
ManufacturercutsheetsforeachofthefourproductsareprovidedinAppendixB.
Thistypeofrepairdoesnotcarryloadandthereforerequiressignificantlylessmaterialandlaborduring
installation.Thesystemeliminatestheneedforstructuralcomponentsseeninthereactiverepairssuchas
galvanizedspikesandreinforcingsteelandconsequentlythereareonlytwomaterialcomponentstothe
system.
Additionally,agreatbenefittothepreventativemaintenanceprogramisthatstagingcanbedone
completelyonabargealongsidethepier.Epoxygroutisabaggedproductthatismixedonsite,thereby
eliminatingtheneedforconcretetruckdeliveries.Eachpierisabletostayopenandoperational
throughoutthecourseoftheproject.
TR0909151011NYC
21
BrooklynBridgeParkPreventativeMaintenancePlanReport
Case Studies
Epoxygroutencasementshavebeeninuseforapproximately30years.TheChesapeakeBayBridgeisone
ofthelongestinserviceinstallations.Encasementswereinstalledon30030in.diameterconcretepiles.
Thesepilesexhibitedcrackingthatallowedmoistureandsalttopenetratethepile.Theinstalledrepair
frozetheconditionoftheconcretebeforeanyfurtherdeteriorationcouldhappenandpreventedfurther
ingressofmoisturesaltintothepile.
Photo 6-1. Workboat and Divers Preparing Piling for Installation of FX-70 System
LakePontchartrainCausewayinLouisianaholdsthedistinctionoftheworldslongestbridgeandisalso
oneoftheearlierinstallationsofepoxygroutencasements.Thisbridge,builtin1956,has9,00054in.
diameterconcretepiles.In1988,21testpileswereselectedtoberepairedwithanepoxygroutpile
encapsulationsystem.In1996,thesepileswerecoredandtested.Theepoxygroutencapsulationsystem
wasworkingasdesignedandsowasselectedtobeinstalledonanadditional414pilesforthefirstphase
ofthepileprotectionprogram.Theserepairsarestillperformingwellnearly30yearslater.Additional
phasesofepoxygroutencapsulationswereundertakenin2002(174piles),2004(174piles),and2010
(586piles).
PreventativemaintenanceisalsoapopularstrategyusedinNewYorkHarbor.TheNYEDCisaproponent
ofpreventativemaintenanceandhasinstalledepoxygroutpileencasementsatthefollowingfacilities:
1.
2.
3.
4.
Pier92(+/$4millionconstructioncost)(ManhattanCruiseTerminal)
Piers13/14(EastRiver)
Pier16(EastRiver)
Piers88and90(ManhattanCruiseTerminal)
Inaddition,theBatteryParkCityAuthorityiscurrentlyinstallingPhaseIVofepoxygroutpreventative
maintenanceencasementswithatotalconstructioncostofapproximately$2million.
Epoxygroutencasementshavebeeninservicefornearly30yearsandarestillconsideredtobeoneofthe
mostreliableandeffectiveprotectivesystemsforalltypesofpilesundertheappropriateconditions.The
epoxygroutencasementisparticularlyeffectivefortimberpileswherethemaindeteriorationmechanism
ismarineborerattack.Byfullyencapsulatingthepileinepoxyandcuttingofftheoxygensupplythe
marineborersareunabletosurviveandpiledeteriorationisarrested.Aswithanyrepairsystem,the
TR0909151011NYC
22
BrooklynBridgeParkPreventativeMaintenancePlanReport
epoxygroutencapsulationwillstillneedtobeperiodicallyinspectedthroughoutitsservicelife;however,
basedontheperformanceofexistinginstallations,theepoxygroutencasementsareareliableand
proventechnologyforthepreventionoffurtherdeteriorationonthetimberpilesatthePark.Thereisno
otherprovencomparablealternativeonthemarketandepoxygroutencasementsarerecognizedbythe
NavyandAmericanSocietyofCivilEngineers(ASCE)asastateoftheartpilerepairmethod.
Preventative Model
Inordertoensurethatallelementsrequiringstructuralrepairsareaddressedpriortothe
commencementofapreventativemaintenanceprogram,thePreventativeModeladvancedone3year
cycleofreactivebasedmaintenancemethodology.Thiscycleidentifieddeficientelements,whichwere
thenremovedfromtheoverallset.Themodelthengeneratestherequiredrepairlengthandcalculates
thecostoftherequiredrepair.Lastly,thenondeficientelements,ortheremainderofelementsthatare
freeofsignificantdeteriorationareconsideredascandidatesforpreventativemaintenancerepairs.
BBPprovidedthreedifferentfundingscenariostoCH2Mforthepreventativemaintenanceprogram.In
thescenarioselected,thebudgetissufficienttofundrequiredstructuralrepairstobothpilesand
extensionsin2016forallfacilitiesandpreventativemaintenanceinstallationsonalltimberpileswiththe
exceptionofPier3.OnPier3thepilesinthebestcondition(notrequiringstructuralrepairsuntilpost
2034)receivedpreventativemaintenanceinstallations.Theremainingtimberpilesreceivestructural
repairsuptotheyear2034in3yearcycles.Thebudgetwasalsosufficienttofundtherequiredrepairsto
preventativemaintenanceinstallationsonthetimberpilesofallremainingfacilities.Thebudgetwasnot
sufficienttofundanyconcreteextensionpreventativemaintenanceinstallations.Alloftheconcrete
extensionsonallfacilitieswillthereforereceivestructuralrepairsover50yearsona3yearcycle.The
modelprovidesagraphoftherepaircostseachyearforthemaintenanceofeachfacility.A
representativeyearvs.costcurveisshownbelowinFigure62.
TR0909151011NYC
23
BrooklynBridgeParkPreventativeMaintenancePlanReport
$100,000,000
$90,000,000
$80,000,000
$Amount
$70,000,000
$60,000,000
$50,000,000
$40,000,000
$30,000,000
$20,000,000
$10,000,000
$0
Period
TheoveralltotalcostofthePreventativeprogramforthetimberpiles,includingcapitalandoperational
costs,isjustunder$250Min2015dollars.
TR0909151011NYC
24
Section 7
Comparison between Reactive and
Preventative Maintenance
Multiplefactorsshouldbecarefullyexaminedpriortoselectionofareactiveorpreventativemaintenance
system:
Unitcostofinstallation
Riskoffuturecostescalation
ServiceLife(durability)
StagingofConstructionOperations
Availablewarrantyofwork
Permittingandenvironmentalconcerns
Additionalsuperimposeddeadloadsonexistingstructure
TR0909151011NYC
25
BrooklynBridgeParkPreventativeMaintenancePlanReport
Inthefirstphaseofthework,themarinegrowthisremovedfromtherepairsurface,whichis
mostefficientlyaccomplishedbyhighpressurewaterblasting,orjetcleaning.
Atopsidecrewpreparestheweldedwiremeshsteelreinforcingcageandlowersittoafloat,
whichisbroughttotherepairlocation.
Diverssecurethereinforcingcagetothepileoverthelengthcalledoutintherepairschedule.For
encasementsthatextendasdeepasthemudline,repairstypicallycallforaminimumexcavation
of24in.intothemudlineatthebottomofthepile,suchthattherepairextendsintotheseafloor.
Tosealthebottomoftherepair,asoffitform,orothermeansofsupportingthebottomofthe
repairisinstalled.
Afterthesoffithasbeensecured,adiverinstallstherigidformworkovertheinstallationsite.Concreteis
thenpumpedintothevoidbetweenthepileandtheformwork.Concretemustbepumpedfrombottom
totop,whichrequiresdiverassistanceasconcreteispumpedthroughahosefromthepierdeckorfroma
barge.
TR0909151011NYC
26
BrooklynBridgeParkPreventativeMaintenancePlanReport
Thepreventativemaintenancemodelintendstoremovethisriskbyawardingasinglecontractforthe
installationofpreventativerepairsatasinglepointintime,onaparkwidebasis.Thismethodwillsecure
anupfront,allinclusivepricefortheentiretyofthework,aswellasafixedunitpriceforanyadditional
workthatisrequiredduringthecontractterm.Thisworkwouldspanseveralyearsandcontractorswould
beallowedtoincludefixed,annualmaterialandlaborcostescalationsintheirbids.However,these
escalationsmustbeestimatedbythebidderduringthebiddingprocessandwill,therefore,besubjectto
thecompetitiveprocess.Bidderswillbemotivatedtokeepnotonlytheirinitialpricelow,butalsothe
rateatwhichthepriceincreasesduringtheallottedworkschedule.
TR0909151011NYC
27
BrooklynBridgeParkPreventativeMaintenancePlanReport
Agreatbenefittothepreventativemaintenanceprogramisthatstagingcanbedonecompletelyona
bargealongsidethepier.Epoxygroutisabaggedproductthatismixedonsite,therebyeliminatingthe
needforconcretetruckdeliveries.Eachpierisabletostayfullyopenandoperationalthroughoutthe
courseoftheproject.
28
BrooklynBridgeParkPreventativeMaintenancePlanReport
additionallevelsofwarranty,sothewarrantycanbeusedaspartofthecontractorselectioncriteriaand
willincentivizeprovisionofacomprehensivewarrantypackage.
TR0909151011NYC
29
SECTION 8 Conclusion
Section 8
Conclusion
Inbothreactiveandpreventativescenarios,onefactorremainsconstant:thatdeteriorationandcorrosion
areunescapableinthemarineenvironmentoftheEastRiver.Protectingtheparkinfrastructurewitha
proactivemaintenanceprogramisaninvestmentrequiredtoensurepublicsafetyandcontinual
operation.Whilebothapproachesachievethisgoal,thereareseveraladvantagestothepreventative
repairsthatmakeitadesirablesolutionforBBP.
Typically,thedriverforchoosingthetypeofrepairsformarinestructuresisdrivenbyavailablefunding.
Oftenpublicagencieshavelimitedfundingandcanrepaironlywhatisabsolutelynecessarytokeepthe
structurestanding(reactiveapproach).Iftheentitycontrollingthemaritimeassetswillbeinplaceona
longtermbasis(publicentity)andfundingisavailable,preventativemaintenancebecomesthepreferred
option.BrooklynBridgeParkisinasomewhatuniquelyadvantageoussituationwherepreventative
maintenanceisfinanciallyviableforamajorityoftheparkassets.Thepreventativeapproachhasbeen
usedwidelyinNewYorkHarborbymultiplecityagencies,howeverthescaleofthisproposedprogramis
somewhatunprecedentedduetofinanciallimitationsatotheragencies.
Thepreventativemaintenancemodelprojectsthatthisproactiveapproachwouldreducelifecyclecosts
byover$84millionovera50yearperiod.Theepoxymortarrepairischeaperperlinearfootofrepair
installedandadditionallyremovestheriskofconstructionpriceescalationlater.Inaddition,the
preventativeprogramminimizestheinterruptiontoparkoperationsasthelessintrusiveofthetwo
constructionstagingoperations(canbecompletelywaterbased).
Thereactivemethodrequirescyclicalinspectionsandrepairinstallations.Iftherepairsarenotinstalled
veryquicklyaftertheinspectionisperformedtheelementswillcontinuetodeterioratewhichinturncan
causereductioninallowableliveloadratingsandpotentiallocalizedstructuralfailure.Thepreventative
programeliminatesthisriskbyfreezingthecurrentconditionofeachselectedpileandprotectingitfrom
futuredeterioration.
Forallthesereasons,CH2Mrecommendsthepreventativemodelforthemaintenanceofmarine
structuresatBrooklynBridgePark.Welookforwardtotheopportunitytoworkwithyouonthislandmark
project.ThisinvestmentwillensureopenvenuesandexperiencesforthepeopleofNewYorkforyearsto
come.
TR0909151011NYC
30
Limnoria
Toredo
Gr Wt.1
OD Wt. 2
ODvol 3
MC4
SG5
SG6
D7 (lb/ft3)
D8 (lb/ft3)
Rating
Rating
(g)
(g)
(g)
(%)
OD
Basic
Basic
at MC
2+0
A-3
76.44
46.33
62.55
65.0
0.74
0.62
38.6
63.7
7+3
A-2
75.54
44.31
66.87
70.5
0.66
0.56
35.2
60.0
11
F+3
71.23
41.18
62.08
73.0
0.66
0.56
35.2
60.9
15+1 F+3
Light
94.27
58.27
72.76
61.8
0.80
0.66
41.2
66.7
Light
70.07
31.96
53.26
119.2
0.60
0.52
32.3
70.8
14+4 A+3
69.39
40.52
65.30
71.2
0.62
0.53
33.3
56.9
8+0 F+2
Light
98.06
48.30
73.27
103.0
0.66
0.56
35.0
71.1
1+4 F+0
86.22
48.87
63.87
76.4
0.77
0.64
39.7
70.0
13+4 C+8
0.66
41.0
68.8
2+3 D+0
64.73
68.25
0.80
51.56
46.37
67.7
10
86.47
79.72
71.9
0.68
0.58
35.9
61.8
11
4+3 A+5
75.88
48.74
70.04
55.7
0.70
0.59
36.7
57.1
12
11+0 A+2
33.3
61.9
54.51
69.18
0.53
2+1
33.83
49.06
0.62
62.96
82.01
86.1
13
67.2
0.71
0.60
37.3
62.3
14
90.64
44.34
70.15
104.4
0.63
0.54
33.8
69.1
15
16
6
6
Trace
-
81.90
36.38
58.72
75.45
42.19
64.03
125.1
78.8
0.62
0.66
0.53
0.56
33.2
35.0
74.8
62.6
81.1
20.8
0.68
0.06
0.58
0.05
36.0
2.8
64.9
5.4
11+3 35
16
36
MEAN
(SD)
1
WaboA-P-E
Advanced Pile Encapsulation
THE PROCESS OF
CORROSION
INTERVENTION &
STRUCTURAL REPAIR
The WaboA-P-E
Difference
Components
WaboA-P-E GROUT
A specially blended, three-component, 100% solids epoxy system, specically
designed for encapsulation, in both on-land and subsea applications.
Benets
of deterioration to continue
Extremely durable
Lightweight
High strength
UV and chloride resistant
Custom molded to most shapes
Aesthetically pleasing
Longitudinal seam
Injection
port
Adjustable
standoffs
duplicated
at 18 intervals
Detail A
Minimum jacket
thickness 1/8
Detail B
Polymer standoff
HydroCote 3061-I
seam adhesive
Adjustable
standoff
HydroCote 1063
epoxy paste
Patterns of polymer
stand-offs maintain
proper clearance
Progression of grout is
monitored through the
translucent jacket
WaboA-P-E grout
is pumped into FRP
jacket, providing a
secure bond
Injection
port
Standoffs
duplicated
at 18 intervals
Radius
varies
with pile
HydroCote size
3061-I
seam
adhesive
Bottom seal
gasket
WaboA-P-E
encapsulations
on 14 diameter
Monotube piles. These
encapsulations were 15
feet tall.
Two WaboA-P-E column encapsulations flank a single column that has not
been encapsulated. As only some of the columns required repair, the owner
stressed that the repairs be similar in appearance to the existing columns.
This was accomplished by pigmenting the WaboA-P-E Grout that can be
seen through the translucent FRP jackets.
Bridge
At the splash zone or along the
entire length of the support structure,
WaboA-P-E is a proven solution for
controlling cracks, filling spalls,
providing corrosion protection and
protection from floating debris. Pile
caps, piles and pier caps all benefit
from Advanced Pile Encapsulation.
Custom shaped FRP jackets provide
lightweight structural rehabilitation
Port
A
A: Project: Pier
Location: Cape Canaveral,
Florida, U.S.A.
Owner: U.S. Navy
Industrial
Nuclear power generation,
hydroelectronic dams, industrial
A
WaboA-P-E encapsulations
provide splash-zone corrosion
protection on these gas risers,
98 miles offshore. WaboA-P-E
was selected to replace an earlier
system that had failed. Wabo
A-P-E has been providing maintenance-free protection since 1994.
Offshore
Owners of offshore structures are
engaged in a constant battle to protect
B
C: Project: Conductor
Encapsulation
Location: U.S. Gulf of Mexico
Owner: Anadarko Petroleum
Company
1. Planning
Briefing installation
crew
Field
Support
2. Gather
components at
site: Shaped jacket,
grout and adhesive
3. Standoff,
injection port and
rivet placement
4. Jacket
installation:
adhesive is applied
at seams and
fastened with
stainless steel rivets
5. Apply bottom
watertight seal and
longitudinal seam.
Install injection port
for grout.
Specialty Applications
Timber pile restoration
Marine borer remediation
Beam and column cap encapsulation
Bulkheads and walls
Sheet piles
Precision grouting machine bases and clamps
Relining pipe
WaboA-P-E
U.S. Patent No. 4.993.876+4.892.410
6. Inject grout.
Features
Outstanding abrasion resistance
Easy to install
Non-corrosive
Series 500
Heavy-duty pile protection system with a fiberglass jacket and SeaShield 550 Epoxy Grout
Materials
Application
The SeaShield Series 500 System is comprised of a FiberForm Jacket which is a high quality formulation Fiberglass
Reinforced Plastic (FRP) and SeaShield 550 Epoxy Grout.
The product is designed specifically for protection of
concrete, timber, and steel piles and provides an attractive, durable, and permanent system. Standard jackets
are fabricated in thicknesses of 1/8" and 3/16".
1-888-821-2300
TORONTO:
90 Ironside Crescent,
Unit 12, Toronto,
Ontario, Canada M1X1M3
Tel: 416-291-3435
Fax: 416-291-0898
e-mail: [email protected]
www.densona.com
A Member of Winn & Coales International
FX-70
(800) 999-5099
www.strongtie.com
Steel Piles
Concrete Piles
Wood Piles
New Structures
FX-70 Jacket
To protect the structure from external attack, the FX-70 Structural
Repair and Protection System starts with a high-strength fiberglass
interlocking jacket. The tongue-and-groove seamed jacket provides a
corrosion-resistant shell to the repair site, ranges from 18 in. to 14 in.
thickness, and is UV-resistant.
Advantages
Repair damage in-place, no need to
dewater or take structure out of service
High-strength materials bond well
to various substrate materials
Corrosion-free system prevents
deterioration, weathering and erosion
Accommodates piles of
various shape and size
System is low-maintenance
following repair
Safe for use in marine-life habitats
UV-resistant
H-Pile
Octagonal
Technical Specifications
ROUND
Property
Test Method
Result
Water Absorption
ASTM D570
1% Max
ASTM D638
Flexural Strength
ASTM D790
ASTM D790
Barcol Hardness
ASTM D2583
45 +/- 7
SQUARE
CUSTOM SIZES
H-SHAPED
OCTAGON
Where to Use:
Marine structure restoration, where forming is required
As a high-strength, non-metallic grout to
encapsulate wood, concrete or steel
Limitations:
Do not use at ambient or water temperatures below 35F (2C)
Do not exceed 134 fl. oz. (3.9 L) of water per 55 lb. (24.9 kg) bag
Minimum thickness of 2 in. (5.1 cm) when used as part
of the FX-70 structural repair and protection system
Package Size:
55 lb. (24.9 kg) bag
1,000 lb. (454 kg) bulk bag
2,500 lb. (1134 kg) bulk bag
Shelf Life:
1 year in unopened, original packaging
Performance Features:
Suitable for marine environments at 35F (2C) and above
Ready-to-use with the addition of water
May be extended by up to 50% by weight
with clean, coarse aggregate
Can be pumped or tremied through water
Will not stain or rust
No dewatering required
Performance Features:
May be applied underwater
Bonds to wet surface and resists wave action
Convenient 1:1 mixing ratio and long pot-life
Hand-applied
Where to Use:
Underwater repairs to concrete, wood and steel
Package Size:
10 US gallon (37.9 L) kit
4 US gallon (15.1 L) kit
2 US gallon (7.6 L) kit
US gallon (1.9 L) kit
Shelf Life:
2 years in original unopened packaging
Site Preparation
Areas of application must be free of marine growth, laitance, grease,
oil, and debris that could inhibit bond. For best results, prepare
surface to be treated with water or sand blasting. Blow or brush clean
to remove remaining debris.
FX-70 Jacket Spacers
Spacers to ensure a consistent annular void surrounding the area to be
repaired may be installed during jacket fabrication, or in the field. Field
installation is advisable for large jobs to maximize shipping efficiency.
See pg. 9 for recommended annular void recommendations.
1
Install a bead of FX-763 Low-Modulus Trowel
Grade Epoxy into the locking groove of the
jacket and place FX-70 jacket around the pile
to be repaired.
6"
=6"
7
For piles with 25% section loss, fill
remaining void in jacket with FX-70 -6MP.
For piles with > 25% section loss fill void
with FX-225 Non-Metallic Underwater Grout,
leaving 4" (102 mm) open at head of jacket.
Allow repairgrout to cure overnight. For FX-225
repairs, fill remaining 4" (102 mm) void with
FX-70 -6MP, and allow grout to cure overnight.
8
5
Install a stainless steel, self-tapping
machine screw every 6" (152 mm) o.c. to
secure the tongue-and-groove joint.
8
Install FX-763 Low-Modulus Trowel Grade
Epoxy at the head of the jacket and finish
to a 45 tapered bevel, creating a water- and
chemical-resistant barrier to the repair
system.
6
Install 6" (152 mm) of properly mixed FX-70-6MP
Multi-Purpose Marine Epoxy Grout to create
bottom seal; allow grout to cure overnight.
9
Remove ratchet straps. Repair complete.
CROSS-SECTION OF
TONGUE-AND-GROOVE JOINT
FX-70 -6MP
Multi-Purpose
Marine Epoxy
Grout
FX-70
Fiberglass Jacket
Spacer
1
2" (13 mm)
Annular Void
Pile diameter
FX-70-9 Coating
(optional)
1824 (457-610 mm)
Spacer
FX-225 Non-Metallic
Underwater Grout
Spacer
Reinforcing steel
(optional)
Bottom seal
2" (51 mm)
Annular Void
Pile diameter
Jacket diameter =
Pile column diameter
+ 2x annular void
Jacket diameter =
Pile column diameter
+ 2x annular void
Annular
Void
Annular
Void
Spacer
Pile column
size
Spacer
MODEL ONE
Jacket diameter
Bottom seal
Pile column
diameter
Pile columns
FX-70
Fiberglass Jacket
Length
Spacer
FX-70-9 Coating
(optional)
Pile columns
Damaged region
Length
Jacket diameter
Damaged region
Spacer
MODEL TWO
MODEL THREE
MODEL FOUR
9
10
Pile
FX-70 -6MP
Tidal zone
FX-70 jacket
FX-225
Reinforcing
specified by
Engineer of
Record
Repair extends
beyond the
damaged area
11
2
Workboat and divers preparing piling
for installation of FX-70 System
4
FX-70 -6MP grout mixed in work boat
30 Years Later
12
13
After
Before
14
In order to better assist you in making a solution recommendation, complete knowledge of all factors involved in the potential
use is necessary. Recommendations can only be based on information at hand today. Our recommendation will be as good
as the information you provide. In order to provide the most accurate recommendation possible, send project specifications
and drawings along with the completed form. Please be assured that all information will be held in strict confidence.
Pile
Beams
Bulkhead
Pier
Pile Composition:
Timber/Wood
Concrete
Steel
Other _____________________________________
Pile Shape:
Round
Square
H Pile
Octagonal
Condition of Pile:
Cracked
Spalled
Rusting
Other _____________________________________
Quantity Required:______________
Jacket Shape:
Other _____________________
Section Loss:
Other _____________________
Repair Type:
Round
Diameter:
Jacket Length:
Square
Square:
H Pile
H-type piles:
Octagonal
Octagonal:
Other ________________________
Other ___________________________
Various Lengths:
(If various lengths, list each separately)
Jacket Thickness:
4" (6 mm)
Other _______________________________________
Number Of Vertical
Joints:
None
Jacket Color:
Translucent
Gray
Brown
Other ________________________________________
Spacers / Standoffs:
2" Spacers
1" Spacers
2" Standoffs
Other ________________________________________
Filler Material:
FX-70 -6MP
8" (3 mm)
16" (5 mm)
FX-225
Other
Other_________
Other ________________________
Please return completed form(s) to [email protected] along with copies of project specifications and drawings.
15
This flier is effective until December 31, 2015, and reflects information available as of September 1, 2014.
This information is updated periodically and should not be relied upon after December 31, 2015; contact
Simpson Strong-Tie for current information and limited warranty or see www.strongtie.com.
2014 Simpson Strong-Tie Company Inc. P.O. Box 10789, Pleasanton, CA 94588
800-999-5099
www.strongtie.com
Five Star
Pile Jacket Epoxy Grout HP
Advantages:
Excellent flowability and
versatility
Can be pumped or poured
into place
High bond and
compressive strength
Moisture insensitive
before, during and after
cure
Excellent adhesion to
masonry, concrete, wood,
steel and most structural
materials
Adjustable aggregate
Applications:
Encapsulation material
Corrosion protection for
steel, concrete and wood
piles
TR0909151011NYC
CONTACT:
Maki Onodera, PE