Advanced Pile Encapsulation...Hazem Jadallah. LPG Trestle, Ju’Aymah, Saudi Arabia •Trestle...
Transcript of Advanced Pile Encapsulation...Hazem Jadallah. LPG Trestle, Ju’Aymah, Saudi Arabia •Trestle...
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Advanced Pile EncapsulationSolutions for the Repair and Protection of Underwater Structures
Hazem Jadallah
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LPG Trestle, Ju’Aymah, Saudi Arabia
•Trestle constructed in 1980•Precast concrete cylinder piles
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LPG Trestle, Ju’Aymah, Saudi Arabia
•Routine inspection in 1983 (3 years after construction) revealed severe marine borer attack•616 piles affected
1”
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LPG Trestle, Ju’Aymah, Saudi Arabia
•The owner required that the repair method…•Would eradicate the existing borers•Would repair the damage done by the borers•Would not be susceptible to future borer attack•Would stay in place and continue to provide protection for 20+ years without any maintenance
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LPG Trestle, Ju’Aymah, Saudi Arabia
•The 616 piles were encapsulated using the advanced pile encapsulation technique in 1984
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Repairing Marine Structures
•Marine Structures• Submerged Piles• Submerged Piers• Seawalls• Dams / raceways• Offshore Platform Supports
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The Need for Repair and Protection
•Marine Environment• Highly Corrosive Environment• Susceptible to Rot• Attack from Marine Organisms• Damage from Scour and Abrasion
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Repairs to Marine Structures
•Repair Zones• Atmospheric Zone• Splash Zone• Submerged Zone
Atmospheric Zone
Splash ZoneSubm
erged Zone
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Repairs to Marine Structures
•Splash Zone• Wetting & Drying
Cycles• Available Oxygen• Heavy Wear &
AbrasionSplash Zone
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Repairs to Marine Structures
•Repair Challenges• Durability of Materials for Repair / Protection• Adequate Performance of Materials for Repair / Protection• Proper Placement of Materials for Repair / Protection
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The Encapsulation Process
•Step 1• Surface preparation• Remove marine
growth• Clean rust and scale• Profile substrate
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The Encapsulation Process
•Step 1• Sandblasting• Pneumatic Rotary Grinder
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The Encapsulation Process
•Step 1• Sandblasting• Pneumatic Rotary Grinder
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The Encapsulation Process
•Step 2• Fiberglass Jackets
Placed Around Structure
• Leaving 3/8” to 1/2” Annulus between Jacket and Structure
• Seams are sealed with epoxy
Translucent Fiberglass Jackets
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Purpose Designed FRP Jackets
•Step 2• Appropriately sized FRP
Jackets Delivered to Site• Polymer Stand-offs• Seam adhesive applied
on deck
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Purpose Designed FRP Jackets
•Step 2• Jackets set in place
around pile
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The Encapsulation Process
•Step 3• Seams are riveted
in place• Temporary bracing
is installed• Bottom of Jacket is
sealed w/ epoxy coated backer rod
Temporary Bracing
Epoxy Seal
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Encapsulation Purpose Designed FRP Jackets
•Step 3• Temporary bracing
installed
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The Encapsulation Process
•Step 4•Each component of a two-component marine grade epoxy is mixed with sand
A B
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Epoxy Grout Infill Properly Placed
•Step 4• Plural component
grout plant• Part A & Part B
mixed with sand in each hopper
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The APE Process
•Step 5• Grout plant is
attached to injection port in fiberglass jacket
• Dual-umbilical hose w/ static mixer at injection site
A B
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Epoxy Grout Infill Properly Placed
•Step 5• Downstream mixer
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Epoxy Grout Infill Properly Placed
•Step 5• Fluid sand-filled epoxy
grout is dispensed out of the mixer
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The Encapsulation Process
•Step 6• Epoxy grout is
pumped into annulus
• Water in the annulus is displaced and expunged out of the top of the jacket
A B
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Epoxy Grout Infill Properly Placed
•Step 6•Grout is pumped into the annulus•Water is displaced above grout•Grout progress is monitored
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Epoxy Grout Infill Properly Placed
•Step 6•Water is expunged out of the top of the jacket
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The Encapsulation Process
•Step 7•Top of jacket is sealed with epoxy•Bracing is removed
Seal top of jacket
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The Encapsulation Process
•Encapsulation is complete!
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Complete Encapsulation
•FRP Jacket •Epoxy Grout Infill•Complete Coverage of Grout•Well Bonded to the Pile
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Complete Encapsulation
•Epoxy Grout is pumped under pressure•Grout penetrates into cracks and voids in the substrate
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Lake Pontchartrain Causeway, New Orleans, Louisiana
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Lake Pontchartrain Causeway, New Orleans, Louisiana
•Pile Encapsulation• Started in 1988 – still ongoing• 26 mile long bridge• 54” diameter concrete cylinder
piles
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Lake Pontchartrain Causeway, New Orleans, Louisiana
•Pile Encapsulation• Encapsulations soon after
completion in 1989
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Lake Pontchartrain Causeway, New Orleans, Louisiana
Pile Encapsulation• Encapsulations in 2002
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Lake Pontchartrain Causeway, New Orleans, Louisiana
• Core sample
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Lake Pontchartrain Causeway, New Orleans, Louisiana
•Bond testing 13-year old encapsulations
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Rappahannock River Bridge, Tappahannock, Virginia
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Rappahannock River Bridge, Tappahannock, Virginia
•1993•RC Piers Showing Corrosion and Spalling•Encapsulations all Above Water
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Rappahannock River Bridge, Tappahannock, Virginia
•1993•RC Piers Showing Corrosion and Spalling•Encapsulations all Above Water
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Rappahannock River Bridge, Tappahannock, Virginia
•Jackets placed over spalled areas•No patching was done
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Rappahannock River Bridge, Tappahannock, Virginia
•Completed Encapsulation
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BG&E Facility, Baltimore, Maryland
•Badly deteriorated H-Piles
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BG&E Facility, Baltimore, Maryland
•Encapsulate 44 “H” Piles•Completed in 1993
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BG&E Facility, Baltimore, Maryland
•Corroded steel section replaced with new structural steel•Steel channels bolted and spliced onto existing piles
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BG&E Facility, Baltimore, Maryland
•Jackets sized to H-Pile Profile
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BG&E Facility, Baltimore, Maryland
•Encapsulations in place
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Warren Road Bridge, Baltimore, Maryland
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Warren Road Bridge, Baltimore, Maryland
Deteriorated piers Large concrete pier
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Warren Road Bridge, Baltimore, Maryland
Pier Encapsulation: Large concrete pier
Jacket Fabrication
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Warren Road Bridge, Baltimore, Maryland
Pier Encapsulation: Large concrete pier
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Des Joachims Hydroelectric DamDeep River, Ontario, Canada
•Tailrace Structure• Sits on the Ottawa River between
Ontario and Quebec• 200-km Upstream from Ottawa,
ON• 8 power generation units
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Challenges
•Tailrace Structure• Structure built in 1940’s• Damage to tailrace from scour
and abrasion
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Challenges
•Damage to Piers• Loss of section• 12” to 18” of section loss in
some instances• Reinforcing steel exposed
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Challenges
•Repair Procedure• Restore loss of section• Protect against future abrasion
damage• Protect the downstream
ecosystem• Minimize dam shutdown time to
less than 10-days
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Concept
Epoxy Grout Pumped In
Contaminated Water Vacuumed Out
Fiberglass Jacket
Encapsulation Complete
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Implementation
•FRP Panels • Face of peirs encapsulated using
FRP panels• Thicker than usual panels (1/4”)
were used due to severity of scour and abrasion
• Panels hoisted into place
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Implementation
•Panels Installed• Panels are anchored into the
face of the wall at appx 12”o.c. EW
• Stiffeners are placed to resist grouting pressure
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Implementation
•Grouting Operation• Grout pumped into annular space• Expunged water and excess grout
reclaimed by vacuum pumps installed on upper ports
• Contaminated water disposed of separately to minimize environmental impact
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Des Joachims Hydroelectic DamDeep River, Ontario, Canada
•Encapsulation in Place• Completed without dewatering• Only 7-days of shutdown time for
the generators
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Testing
•Core Samples• Excellent bond to backwall• Good grout consolidation• No cracking in grout from
exotherm
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Conclusion
•Before…
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Conclusion
•…and After
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Des Joachims Hydroelectric DamDeep River, Ontario, Canada
•…and In Service
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Gandy BridgeTampa Bay, FL USA
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Gandy BridgeTampa Bay, FL USA
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Gandy BridgeTampa Bay, FL USA
2010 • Condition Survey• First Encapsulated in 1987
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LPG Trestle, Ju’Aymah, Saudi Arabia
32 years later…
The repair and protection via Advanced Pile Encapsulation remains in place and continues to provided protection without any maintenance
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