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Design, Testing, and Use of an Innovative Prestress Concrete Pile Joint
Long Pile Handling  ,[object Object],[object Object],[object Object]
Driving Long Piles ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Up to 65 ft-long pile segments: (4 Fork-truck and spreader for unloading & staging Spliced-Pile Alternative
Spliced-Pile Alternative ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Emeca Pile Joint  Male Stud Female Socket Locking pin  hole Cover Plate Reinforcing
Emeca Pile Joint  Automated Robotic Fabrication
Tension  Limit States 3. & 7.:   Weld rupture at reinforcing/locking mechanism interface Note:  Welds are designed to develop reinforcing Butt-Joint at female socket Lap-Joint at Male Stud
Structural Analysis ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Compression  Compression is transferred  directly through bearing of faying  surfaces Assembly Diagram of Emeca Joint
Shear  ,[object Object],[object Object],Shear failure plane
Tension  Tensile Limit States 1.&9.  Transfer tensile force from  prestress to mild reinforcing  2.&8.  Tensile yield of mild reinforcing 3.  Weld rupture at female socket  4.  Tensile rupture of female socket 5.  Shear rupture of pin 6.  Tensile rupture male stud 7.  Weld rupture at male stud
Tension  Limit States 1 & 2: CASE 2:  L embed.  <   L d  for strand: * Bond Limit (Strand) OR Mild Reinforcing Steel Limit * Ref: ACI 12.9.1  CASE 1:  L embed.  ≥   L d  for strand: Rupture Limit (Strand) OR Mild Reinforcing Steel Limit
Tension  In General: ,[object Object],[object Object],[object Object],[object Object]
Auxiliary Reinforcing Auxiliary Reinforcing Auxiliary Reinforcing
Tension  Summary: ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Bending Analysis at Joint Critical Sections: S2-Prestress Section S1-Section at Joint
Bending Analysis at Joint S1- Reinforced Section (12-in. pile)
Bending Analysis at Joint S1- Reinforced Section (12-in. pile) M n  = 41.7 ft-k
Bending Analysis at Joint max. stress in strand = f ps  = 173 ksi  S2- Prestress Section (12-in. pile)
Bending Analysis at Joint S2- Prestress Section (12-in. pile) PCI  Figure 4.12.4 (p. 4-122) 30 in. 173 ksi
Bending Analysis at Joint f ps  = 173 ksi M n  = 33.5 ft-k S2- Prestress Section (12-in. pile)
Analysis at Joint  Summary: Unreduced Capacities of Pile at Joint 12-in.  Pile Splice 14-in.  Pile Splice Limit Tension - T n 95.6 kips 150 kips Yield of Mild Reinforcing Bending  - M n 33.5 ft-kips 55.2 ft-kips Strand Slip reinforcing added -  M n 41.5 ft-kips 73.7 ft-kips Yield of Mild Reinforcing Shear - V n 19.0 kips 26.4 kips Shear Capacity of Pile
Interaction of 12-inch Piles vs. Emeca Joint Cross Section
Interaction of 14-inch Piles vs. Emeca Joint Cross Section
Bending Tests – University of South Carolina Test Set-up: Recorded Data: - Load - Displacement at ¼ points - Rotation at Joint Loading Protocol: - Quasi-static loading
Bending Tests – University of South Carolina Test Specimens (12 Total): I. Splice only (6) 28-ft. long piles, spliced at midpoint  (3) 14-in. Specimens (6 strand) (3) 12-in. Specimens (4 strand) II. Splices with “Auxiliary Reinforcing” (6) 28-ft. long piles, spliced at midpoint  (3) 14-in. Specimens (6 strand) (3) 12-in. Specimens (4 strand) Auxiliary reinforcing – (4) #5’s x 60”
Bending Tests Results: ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Bending Tests  Moment Strength Results  (ft-kips): M n ′  –Calculated theoretical moment using tested material strength: F y  = 73 ksi  f c ′ = 7,000 psi Theoretical  Test Results Mean Low M n M n ′ Mean Low M n ′ M n ′ Splice Only 12 in. 37 47 53.6 52.7 114% 111% 14 in. 61 79 85.4 77 108% 97% Auxiliary Reinforcing Added 12 in. 37 53 63 59.7 119% 112% 14 in. 67 93 99.3 90.5 107% 97%
Recommendations for Use ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],General:
[object Object],[object Object],[object Object],[object Object],Emeca Pile Joint  PDCA  National Project of the Year, 2008
Casting Splices ,[object Object],[object Object],[object Object],[object Object],[object Object]
Casting Splices ,[object Object],[object Object],[object Object]
Casting Splices ,[object Object],[object Object],[object Object]
Casting Splices ,[object Object],[object Object],[object Object]
Installation  ,[object Object],[object Object],[object Object]
Installation  ,[object Object],[object Object],[object Object]
Projects  Owner:  Vitol Oil Company Contractor:  Sun Marine Project Status: Complete Emeca Product:  12-in. Pile Joints Notes:  6300, 100-ft-long piles installed Vitol Oil Tank Farm, Seaport Canaveral, FL
Projects  Owner:  Northrup Grumman Contractor:  Ford Pile Foundations Project Status: Active Emeca Product:  12-in. Pile Joints Notes:  Piles and splices designed to resist hydrostatic tension Northrup Grumman Naval Shipyard - Dry Dock Facility, Newport News, VA
Projects  Contractor:  Junttapojat Oy Emeca Product:  14-in. Pile Joints Notes:  -  8000 Emeca Pile Joints used on project -  656,000 total pile length  -  Up to 105 foot long piles driven in 3 sections -  Battered piles driven at 4V:1H Vousaari Harbor Project for the Port of Helsinki, Helsinki, Finland
Projects  Contractor:  Aarsleff Piling Status:  Complete Emeca Product:  16-in. Pile Joints Notes:  50 wind turbine foundations constructed  using 85-ft-long,16-in. spliced piles Wind Farm, Ransonmoor, Finland
Projects  Contractor:  Kiewit Construction Project Status:  Active Emeca Product:  14-in. Rock Points customized for 30-in.-square concrete piles  Notes:  Piles driven through concrete mooring anchors at approximately 30-ft. Brayton Point Cooling Tower, Summerset, MA
Projects  Anacostia Naval Station Drainage Phase IV, Washington, DC Owner: NAVFAC Project Status:  Completed August 2008 General Contractor:  Corinthian Contractors Pile Contractor:  Coastal Pile Driving, Inc. Property Manager:  Whiting-Turner Contracting Product:  12-in. Pile Joints Notes:  Up to 83-ft-long spliced piles

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Emeca SPE-USA Pile Joint Product

  • 1. Design, Testing, and Use of an Innovative Prestress Concrete Pile Joint
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  • 4. Up to 65 ft-long pile segments: (4 Fork-truck and spreader for unloading & staging Spliced-Pile Alternative
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  • 6. Emeca Pile Joint Male Stud Female Socket Locking pin hole Cover Plate Reinforcing
  • 7. Emeca Pile Joint Automated Robotic Fabrication
  • 8. Tension Limit States 3. & 7.: Weld rupture at reinforcing/locking mechanism interface Note: Welds are designed to develop reinforcing Butt-Joint at female socket Lap-Joint at Male Stud
  • 9.
  • 10. Compression Compression is transferred directly through bearing of faying surfaces Assembly Diagram of Emeca Joint
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  • 12. Tension Tensile Limit States 1.&9. Transfer tensile force from prestress to mild reinforcing 2.&8. Tensile yield of mild reinforcing 3. Weld rupture at female socket 4. Tensile rupture of female socket 5. Shear rupture of pin 6. Tensile rupture male stud 7. Weld rupture at male stud
  • 13. Tension Limit States 1 & 2: CASE 2: L embed. < L d for strand: * Bond Limit (Strand) OR Mild Reinforcing Steel Limit * Ref: ACI 12.9.1 CASE 1: L embed. ≥ L d for strand: Rupture Limit (Strand) OR Mild Reinforcing Steel Limit
  • 14.
  • 15. Auxiliary Reinforcing Auxiliary Reinforcing Auxiliary Reinforcing
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  • 17. Bending Analysis at Joint Critical Sections: S2-Prestress Section S1-Section at Joint
  • 18. Bending Analysis at Joint S1- Reinforced Section (12-in. pile)
  • 19. Bending Analysis at Joint S1- Reinforced Section (12-in. pile) M n = 41.7 ft-k
  • 20. Bending Analysis at Joint max. stress in strand = f ps = 173 ksi S2- Prestress Section (12-in. pile)
  • 21. Bending Analysis at Joint S2- Prestress Section (12-in. pile) PCI Figure 4.12.4 (p. 4-122) 30 in. 173 ksi
  • 22. Bending Analysis at Joint f ps = 173 ksi M n = 33.5 ft-k S2- Prestress Section (12-in. pile)
  • 23. Analysis at Joint Summary: Unreduced Capacities of Pile at Joint 12-in. Pile Splice 14-in. Pile Splice Limit Tension - T n 95.6 kips 150 kips Yield of Mild Reinforcing Bending - M n 33.5 ft-kips 55.2 ft-kips Strand Slip reinforcing added - M n 41.5 ft-kips 73.7 ft-kips Yield of Mild Reinforcing Shear - V n 19.0 kips 26.4 kips Shear Capacity of Pile
  • 24. Interaction of 12-inch Piles vs. Emeca Joint Cross Section
  • 25. Interaction of 14-inch Piles vs. Emeca Joint Cross Section
  • 26. Bending Tests – University of South Carolina Test Set-up: Recorded Data: - Load - Displacement at ¼ points - Rotation at Joint Loading Protocol: - Quasi-static loading
  • 27. Bending Tests – University of South Carolina Test Specimens (12 Total): I. Splice only (6) 28-ft. long piles, spliced at midpoint (3) 14-in. Specimens (6 strand) (3) 12-in. Specimens (4 strand) II. Splices with “Auxiliary Reinforcing” (6) 28-ft. long piles, spliced at midpoint (3) 14-in. Specimens (6 strand) (3) 12-in. Specimens (4 strand) Auxiliary reinforcing – (4) #5’s x 60”
  • 28.
  • 29. Bending Tests Moment Strength Results (ft-kips): M n ′ –Calculated theoretical moment using tested material strength: F y = 73 ksi f c ′ = 7,000 psi Theoretical Test Results Mean Low M n M n ′ Mean Low M n ′ M n ′ Splice Only 12 in. 37 47 53.6 52.7 114% 111% 14 in. 61 79 85.4 77 108% 97% Auxiliary Reinforcing Added 12 in. 37 53 63 59.7 119% 112% 14 in. 67 93 99.3 90.5 107% 97%
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  • 38. Projects Owner: Vitol Oil Company Contractor: Sun Marine Project Status: Complete Emeca Product: 12-in. Pile Joints Notes: 6300, 100-ft-long piles installed Vitol Oil Tank Farm, Seaport Canaveral, FL
  • 39. Projects Owner: Northrup Grumman Contractor: Ford Pile Foundations Project Status: Active Emeca Product: 12-in. Pile Joints Notes: Piles and splices designed to resist hydrostatic tension Northrup Grumman Naval Shipyard - Dry Dock Facility, Newport News, VA
  • 40. Projects Contractor: Junttapojat Oy Emeca Product: 14-in. Pile Joints Notes: - 8000 Emeca Pile Joints used on project - 656,000 total pile length - Up to 105 foot long piles driven in 3 sections - Battered piles driven at 4V:1H Vousaari Harbor Project for the Port of Helsinki, Helsinki, Finland
  • 41. Projects Contractor: Aarsleff Piling Status: Complete Emeca Product: 16-in. Pile Joints Notes: 50 wind turbine foundations constructed using 85-ft-long,16-in. spliced piles Wind Farm, Ransonmoor, Finland
  • 42. Projects Contractor: Kiewit Construction Project Status: Active Emeca Product: 14-in. Rock Points customized for 30-in.-square concrete piles Notes: Piles driven through concrete mooring anchors at approximately 30-ft. Brayton Point Cooling Tower, Summerset, MA
  • 43. Projects Anacostia Naval Station Drainage Phase IV, Washington, DC Owner: NAVFAC Project Status: Completed August 2008 General Contractor: Corinthian Contractors Pile Contractor: Coastal Pile Driving, Inc. Property Manager: Whiting-Turner Contracting Product: 12-in. Pile Joints Notes: Up to 83-ft-long spliced piles

Editor's Notes

  1. Photo of piles segments being joined in Finland The splice component is identical: -simplifies casting and storage of piles Discuss anatomy of splice
  2. Photo of piles segments being joined in Finland The splice component is identical: -simplifies casting and storage of piles Discuss anatomy of splice
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