Estimating Material Requirements

Transcription

1 A CMI Technical White Paper Ben Brown January 2007 Physical properties are defined by ASTM testing standards, The Aluminum Association Design Manual, and/or standard engineering practice. The values shown are nominal and may vary. The information found in this document is believed to be true and accurate. No warranties of any kind are made as to the suitability of any CMI product for particular applications or the results obtained there from. ShoreGuard, C-Loc, TimberGuard, GeoGuard, Dura Dock, Shore-All, and Gator Gates are registered trademarks of Crane Materials International. ArmorWare, Ultra Composite, GatorDocks, and CMI Waterfront Solutions are trademarks of Crane Materials International. United States and International Patent numbers 5,145,287; 5,881,508; 6,000,883; 6,033,155; 6,053,666; D420,154; 4,674,921; 4,690,588; 5,292,208; 6,575,667; 7,059,807; 7,056,066; 7,025,539; 1,245,061; Other patents pending.. All Rights Reserved.

2 A seawall, like the foundation of a building, must be designed and constructed to handle very high loads and withstand numerous forces and environmental influences. A typical seawall is made up of sheet piling, and an anchor system (typically a wale beam, tie rods, and dead-man anchors). All components must be made of materials designed to withstand the forces and environmental conditions expected. If any one component is overlooked, the system will fail. High performance seawall components are available in a number of colors and styles, and are produced in a wide range of strength capabilities. Soil characteristics and other environmental conditions are the primary factors in determining sheet pile requirements. Using these properties and standard design methods (see engineering analysis of a sheet pile wall), the wall s designer will be able to specify sheet length and the required structural capacity of the sheet piling and anchor system components. For the budgetary and comparison purposes of this exercise, CMI has evaluated several wall construction styles in typical soil conditions. These evaluations, in no way, represent the loading, soil, and/or site conditions for any particular project or location. - WARNING - The following charts and tables list typical values for budgetary purposes only. Please rely on your engineer for specific design recommendations. Because of the complexity of geotechnical loading calculations and the susceptibility to extreme change of soil loads with minor changes in local site conditions such as soil parameters, water levels, and surcharge loads, etc., we strongly recommend the use of design professionals who are familiar with local wall construction to determine the required sheet piling and component capacity. 2

3 Before you begin: Have in mind the architectural style the owner would like to achieve. Long gone are the days when a seawall was built solely to retain earth. In the new sheet piling market, aesthetics often drive the structural decisions. A seawall is an investment. Much like a house, you have to live with this investment day in and day out. Choose the look that you want, and suitable components are available to fill that desire. A comprehensive sampling of color and architectural variations can be reviewed at Determine the effective height of the wall (H). Wall height (H) is defined as the distance from firm soil at the base of the wall to the top of the wall. This value will be used throughout the guide. Determine the Linear Footage of the wall (L). Linear Footage (L) is defined as the total length or distance along the shoreline the seawall is intended to protect. 3

4 Estimating Material Requirements Step 1. Choose the wall type. While there is no single right way to construct a sheet pile wall, there are different advantages and tradeoffs achieved by varying component configurations. Shown below are four common sheet pile wall configurations and conditions. This guide will evaluate component selection based on these scenarios. Typical Sheet Pile Wall Configurations and Conditions

5 Step 2. Select a Sheet Pile Product The sheet piling must meet or exceed the strength requirements of the job. For the conditions specified in step 1, the charts below show each product s estimated maximum wall height (H) based on moment capacity (the sheet s ability to resist bending). Depending on local conditions and the structure s configuration, different achievable wall heights may be determined. * limited by deflection * limited by deflection The charts above are based off typical values, shown in step 1, for budgetary purposes only. Please rely on your engineer for specific design recommendations. Because of the complexity of geotechnical loading calculations and the susceptibility to extreme change of soil loads with minor changes in local site conditions such as soil parameters, water levels, surcharge loads, etc., we strongly recommend the use of design professionals who are familiar with local wall construction to determine the required sheet piling and component capacity. 5

6 * limited by deflection * limited by deflection The charts above are based off typical values, shown in step 1, for budgetary purposes only. Please rely on your engineer for specific design recommendations. Because of the complexity of geotechnical loading calculations and the susceptibility to extreme change of soil loads with minor changes in local site conditions such as soil parameters, water levels, surcharge loads, etc., we strongly recommend the use of design professionals who are familiar with local wall construction to determine the required sheet piling and component capacity. 6

7 Step 3. Select the anchor system components and cap The anchor system is composed of anchors (buried in stable soil), tie rods (which connect the wall to the anchors), and a wale (which distributes the load from the wall to tie rods). Capping is used to finish the look of the seawall and in many circumstances can perform the function of a top wale as well. Wale Selection Appearance commonly dictates wale selection. The wale may lose its laser straight look long before actual failure. For this exercise, a deflection limit of L/360 was imposed, as well as the maximum allowable bending moment. The maximum allowable rod load was also evaluated for a minimum washer size of 4 x4. Several wale options are given for each typical scenario as defined in step 1. Tie Rod Spacing It is important to ensure that tie rods fall on the outer corrugations of the sheet for proper load transfer. This consideration, as well as budgetary concerns, should be evaluated when deciding on the tie rod spacing. Polymer coated steel as well as aluminum rod options are shown. Anchor Selection Anchor selection is heavily dependant on soil conditions. Your wall relies on the anchor and soil interaction to resist the forces placed on them by the wall. As with all components, proper design techniques should be executed to determine the suitability and placement of the anchor. Capping Capping is the finishing touch to a seawall, and is often used as a top wale as well. When performing the function of a wale, the suitability of a cap product is highly dependant on site conditions and each product should be evaluated on a case-by-case basis. Use the following charts to select the appropriate wale, anchor rods, and anchor, then choose your capping. 7

8 Wale at Top Wall Height (ft) Anchor Rod Spacing (ft) Wale Rod Anchor Wale Rod Anchor Wale Rod Anchor Wale Rod Anchor TG 4x6 STR STR STR STR GR 1 1/4 GR 1 1/4 STR STR STR STR WB-6 GR 1 1/4 Al 1 1/2 Al 1 1/2 STR STR STR WB-6 GR 1 1/4 Al 1 1/2 WB-8 Al 1 1/2 WB-8 Al 1 3/4 STR STR STR WB-6 GR 1 1/4 WB-8 Al 1 1/2 WB-8 Al 1 1/2 WB-8 Al 1 1/2 The chart above is based off typical values, shown in step 1, for budgetary purposes only. Please rely on your engineer for specific design recommendations. Because of the complexity of geotechnical loading calculations and the susceptibility to extreme change of soil loads with minor changes in local site conditions such as soil parameters, water levels, surcharge loads, etc., we strongly recommend the use of design professionals who are familiar with local wall construction to determine the required sheet piling and component capacity. 8

9 Single Dropped Wale Wall Height (ft) Anchor Rod Spacing (ft) Wale Rod Anchor Wale Rod Anchor Wale Rod Anchor Wale Rod Anchor STR STR STR STR Al-1 1/2 Al-1 1/2 WB-6 Al-1 3/4 STR STR STR STR Al-1 1/2 WB-6 Al-1 1/2 WB-6 Al-1 1/2 AW AW AW AW AW STR STR AW STR STR WB-6 Al-1 1/2 STR WB-6 WB-8 The chart above is based off typical values, shown in step 1, for budgetary purposes only. Please rely on your engineer for specific design recommendations. Because of the complexity of geotechnical loading calculations and the susceptibility to extreme change of soil loads with minor changes in local site conditions such as soil parameters, water levels, surcharge loads, etc., we strongly recommend the use of design professionals who are familiar with local wall construction to determine the required sheet piling and component capacity. 9

10 Wall Height (ft) Double Wale Anchor Rod Spacing (ft) Wale Rod Anchor Wale Rod Anchor Wale Rod Anchor Wale Rod Anchor STR STR STR STR Al-1 1/2 Al-1 1/2 WB-6 Al-1 3/4 STR STR STR STR Al-1 1/2 WB-6 Al-1 1/2 WB-6 Al-1 1/2 STR STR STR STR WB-6 Al-1 1/2 STR STR WB-6 The chart above is based off typical values, shown in step 1, for budgetary purposes only. Please rely on your engineer for specific design recommendations. Because of the complexity of geotechnical loading calculations and the susceptibility to extreme change of soil loads with minor changes in local site conditions such as soil parameters, water levels, surcharge loads, etc., we strongly recommend the use of design professionals who are familiar with local wall construction to determine the required sheet piling and component capacity. 10

11 Navy Wall 5 Anchor Rod Spacing (ft) Wale Rod Anchor Wale Rod Anchor Wale Rod Anchor Wale Rod Anchor 6 7 STR 8 STR STR WB-6 9 STR STR STR STR WB-8 10 STR STR STR STR Wall Height (ft) STR STR STR STR WB-6 WB-6 Al-1 1/2 13 Al-1 1/2 14 Al-1 1/2 WB-6 Al-1 1/2 15 Al-1 1/2 16 Al-1 1/ WB-6 Al-1 3/4 DMA-20 The chart above is based off typical values, shown in step 1, for budgetary purposes only. Please rely on your engineer for specific design recommendations. Because of the complexity of geotechnical loading calculations and the susceptibility to extreme change of soil loads with minor changes in local site conditions such as soil parameters, water levels, surcharge loads, etc., we strongly recommend the use of design professionals who are familiar with local wall construction to determine the required sheet piling and component capacity. WB-6 Al-1 3/4 WB-8 Al- 2 11

12 Sheet Compatible Caps CL-4500 AW-575 AW-575 STR AWL-3 SC-7 SG-225 AW-575 AW-575 STR AWL-8 SC-7 SG-325 AW-850 AW-850 STR AW-855 AW-855 STR SG-300 AW-850 AW-850 STR AW-855 AW-855 STR AWM-3 SC-9 SG-425 AW-850 AW-850 STR AW-855 AW-855 STR CL-9000 AW-1075 AW-1075 STR SG-400 AW-850 AW-850 STR AW-855 AW-855 STR AWM-8 SC-9 SG-525 AW-1075 AW-1075 STR GG-20 AW-575 AW-575 STR SG-550 AW-850 AW-850 STR AW-855 AW-855 STR CL-9900 AW-1075 AW-1075 STR PZM-16 SC-9 SG-625 AW-1075 AW-1075 STR PZM-19 SC-9 SG-650 AW-1075 AW-1075 STR SG-750 AW-1075 AW-1075 STR PZH-1 SC-13 GG-30 AW-850 AW-850 STR AW-855 AW-855 STR PZH-3 SC-13 PZH-7 SC-13 SG-950 PZH-153 SC-15 PZH-159 SC-15 The time and expense of being short on materials can be crippling. Most contractors add around 3%-5% onto materials (rounded up) to account for the unknown and potential errors in the field. Step 4. Estimate the required sheet pile length. Although proper design techniques will yield the required sheet pile length, the sheet piling industry rule of thumb for an anchored wall is half-in, half out. The estimated sheet length is typically two times the wall height (H). If the soil at the base of the wall is soft or irregular in depth, longer sheets may be required. Estimated Sheet Length ~ 2 x H 12

13 Step 5. Estimate the number of sheets required Divide the anticipated linear footage (L) of your wall by the width of your sheeting choice and round up to the next whole number. Sheet quantity ~ L (linear footage) Sheet Width Step 6. Estimate the number of wale sections Sheet Widths (ft) 1 1¼ 1½ 2 2½ CL-4500 PZH-153 SG-650 SG-225 SG-625 AWL-3 PZH-159 GG-30 SG-325 AWL-8 SG-950 SG-300 AWM-3 SG-425 SG-400 CL-9000 AWM-8 SG-525 SG-550 GG-20 PZM-16 CL-9900 PZM-19 SG-750 PZH-1 PZH-3 PZH-7 Divide the anticipated linear footage (L) of your wall by the length of your wale choice and round up to the next whole number. Wale section quantity ~ L (linear footage) Beam Length Wale Beam Lengths (ft) TG 4X4 TG 4X4 WB-6 TG 4X6 TG 4X6 WB-8 TG 6X6 TG 6X6 TG 6X8 TG 6X8 TG 8X8 TG 8X8 TG 8X10 TG 8X10 TG 10X10 TG 10X10 TG 12X12 TG 12X12 STR STR 13

14 Step 7. Estimate the number of Anchor rods and Anchors For straight wall runs, divide the anticipated linear footage (L) of your wall by the rod spacing (A), round up to the next whole number, then add 1. Additional rods may be needed for corners. Anchor rod and Anchor Quantity ~ L (linear footage) A (rod spacing) +1 Step 8. Estimate the number of cap sections Divide the anticipated linear footage (L) of your wall by the length of your cap choice and round up to the next whole number. Wale section quantity ~ L (linear footage) Cap Length Cap Lengths (ft) AW-575 SC-7 AW-575 STR SC-9 AW-850 SC-13 AW-850 STR SC-15 AW-855 AW-855 STR AW-1075 AW-1075 STR Step 9. Estimate the number of component corners and accessories Estimate the number of sheet, cap, and wale corners that will be required as well as any accessories desired. Most sheets have around of play in each lock. If a larger angle needs to be made, corner pieces may be required. Cap and wale corner inserts are available in 45 and 90 for most products. A wide array of special washers and other accessories are available as well. 14

15 Gather Preliminary Information What is the wall height (H)? Anticipated Linear footage (L)? Choose your Components From Step 1. What type of wall will you be building? From Step 2. What sheet did you choose? From Step 3. What rod spacing did you choose? What Wale option did you choose? What anchor rod did you choose? What anchor did you choose? What capping option did you choose? Determining Lengths and Quantities 2 x H (wall height) From Step 4. Estimated sheet length L (linear footage) From Step 5. Sheet quantity Sheet Width L (linear footage) From Step 6. Wale Quantity Beam Length L (linear footage) +1 From Step 7. Tie Rod/ Anchor Quantities A (rod spacing) L (linear footage) From Step 8. Cap Quantity Cap Length From Step 9. Corners and other accessories The time and expense of being short on materials can be crippling. Most contractors add around 3%-5% onto materials (rounded up) to account for the unknown and potential errors in the field. Contact your CMI Waterfront Solutions representative for pricing, technical resources or experienced engineers serving your area.

16 Material Estimating Worksheet Example Gather Preliminary Information What is the wall height (H)? Anticipated Linear footage (L)? 7 ft 635 ft Choose your Components From Step 1. What type of wall will you be building? From Step 2. What sheet did you choose? From Step 3. What rod spacing did you choose? CL 9900 is a 2 wide sheet, so it needs to be divisible by 2. I will use a TimberGuard wale so I would like it to divide 4 ft into 16 or 20 What Wale option did you choose? I want to keep the look and color similar to the sheet Wale at the I like the look of vinyl, and the box profile CL 9900 TG 8X8 What anchor rod did you choose? What anchor did you choose? What capping option did you choose? ¾ DMA 8 AW Determining Lengths and Quantities From Step 4. Estimated sheet length 2 x H 2x7 = 14 (wall height) 14 From Step 5. Sheet quantity L 635/2=317.5 (linear footage) (3% buffer)= 328 Sheet Width From Step 6. Wale Quantity L 635/20=31.75 (linear footage) (3% buffer)= 33 Beam Length From Step 7. Tie Rod/ Anchor Quantities L 635/4= (linear footage) (3% buffer)= 165 A (rod spacing) 165 From Step 8. Cap Quantity L 635/20=317.5 (linear footage) (3% buffer)= 33 Cap Length 33 From Step 9. Corners and other accessories SG Corner (2), Corner Insert (2), Beveled PVC Washers (165) The time and expense of being short on materials can be crippling. Most contractors add around 3%-5% onto materials (rounded up) to account for the unknown and potential errors in the field. Contact your CMI Waterfront Solutions representative for pricing, technical resources or experienced engineers serving your area.