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Building Resilient Foundations: The Power of Composite Sheet Piles

sheet piling design
esc general catalog

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Numerous unforeseen events frequently occur in aquatic and terrestrial environments, posing challenges to establishing a resilient foundation. However, with the advent of various man-made structures, anticipating disasters has become more feasible.


Among these structures, Sheet piling serves both practical and for safety purposes. It maintains stability by retaining soil and can prevent landslides or collapses. In flood and water management, it acts as a barrier against water infiltration, preventing inundation of populated areas and safeguarding lives and property.


For marine and coastal protection, it shields shorelines, harbors, and infrastructure from erosion and wave impact. On construction sites, it secures the working environment of construction workers and engineers during excavation and foundation work.


Sheet Piling comes in various types, each with its unique benefits. Steel Sheet Piles offer strength and durability, Concrete Sheet Piles provide stability, Vinyl Sheet Piles are lightweight and easy to install, and Composite Sheet Piles stand out for their exceptional resilience, making them a reliable and confident choice for challenging environments. These options were developed because traditional wood piling systems are unsuitable for harsh aquatic environments.


sheet piling interlock

Steel Sheet Piles, with their long structural sections and vertical interlocking system, form a continuous wall. They are ideal for retaining soil or water, thanks to their resistance to high driving stresses and good watertightness. However, their susceptibility to rust and deterioration, even with corrosion-resistant coatings, necessitates frequent maintenance or replacement.


They are also not recommended for highly saline or corrosive marine environments without additional protection. Furthermore, their installation and maintenance costs can be high due to their pure steel composition.


Concrete Sheet Piles, as structural foundation elements, support offshore structures such as bridges, oil rigs, and floating airports. While they may be costly, their infrequent maintenance requirements offset this, providing a sense of ease. They offer high stress, stiffness, convenient materials, and simple construction.


Unlike steel sheet piles, they do not require consideration for pile extraction. However, they are unsuitable for permanent structures, serving only temporary applications like excavation support or retaining walls during construction.


Their durability for long-term infrastructure projects may be questionable, and they can be challenging to install in soils with boulders and cobbles, which can affect their overall effectiveness.


Vinyl Sheet Piles are an effective alternative to Steel Sheet Piles for bulkheads, seawalls, and cutoff walls. They resist corrosion, chemicals, and UV exposure and are lightweight, making them preferred for various applications. Manufacturers claim they have a service life of up to 50 years. However, they lack strength compared to steel, limiting their use to marine applications that don't require deep foundations.


Composite Sheet Piling, also known as fiber-reinforced polymer, utilizes various materials to create separate piles stacked atop each other. It comes in two types: concrete and timber composite piles and concrete and steel composite piles. Timber is used when the water table is unavailable, while concrete is used when water contact is possible.


Composite sheet pile design

Combining steel with concrete extends pile length beyond what cast-in-situ piles can achieve. This method eliminates the challenge of joining different materials but requires superior quality supervision, such as the products offered by ESC. According to a civil engineer's article, it can handle a maximum load of up to 1471 KN, approximately 150,000 kg.


The U.S. military and civilian marine and waterfront communities incur significant costs due to the deterioration of wood, concrete, and steel piling systems, estimated at $1 billion annually. FRP composite sheet piling was developed to rival steel sheet piling, the strongest and most durable synthetic piling product globally.


It meets environmental requirements as it is non-biodegradable, doesn't require coating or extra thickness, maintains performance across temperatures, and is virtually maintenance-free. It's lighter than steel, resulting in potential cost savings in transportation. According to Gilbert Gedeon, P.E., concrete sheet piling is advantageous for marine environments, streambeds with high abrasion, and situations where the sheet pile can support significant axial loads.


ESC Composite sheet piling offers reasonable upfront material costs and requires lower maintenance, contributing to long-term cost savings. One key advantage of ESC composite sheet piling is its ability to provide a solid barrier against soil and water infiltration, enhancing its protective function. Manufactured from a combination of materials like steel and concrete, ESC composite sheet piles provide additional strength and durability.


composite sheet pile installation

ESC offers different specifications of Composite Sheet Piles:


The ESC-GC458-FR sheet pile offers a balance between material costs and long-term savings. With a width of 457 mm and a height of 203.2 mm, it provides a section area of 101.7 cm²/m. Its sectional modulus is 696 cm³/m, and the moment of inertia stands at 7,072 cm⁴/m. The flange width measures 140 mm, while the flange thickness is 6.35 mm. The E-modulus is 39,212 MPa. This composite sheet pile effectively guards against soil and water infiltration due to its solid barrier properties. Combining steel and concrete ensures robustness and durability, making it a reliable choice for various applications.


The ESC-GC510-FR sheet pile maintains cost-effectiveness while providing enhanced strength. It boasts a width of 508 mm and a height of 254 mm. The section area is 142.2 cm²/m, with a sectional modulus of 1,219 cm³/m and a moment of inertia of 15,481 cm⁴/m. Its flange width is 165 mm, and its thickness measures 8.65 mm. The E-modulus remains at 39,212 MPa. Like its counterpart, this sheet pile resists soil and water penetration due to its solid construction, making it suitable for various engineering projects.


The ESC-GC610-FR sheet pile combines cost efficiency with substantial strength. With a width of 610 mm and a height of 356 mm, it provides a section area of 173.5 cm²/m. Its sectional modulus is 1,994 cm³/m, and the moment of inertia reaches 35,494 cm⁴/m. The flange width measures 175 mm, and the flange thickness is 10.9 mm. The E-modulus remains consistent at 39,212 MPa. Its robust design ensures soil and water resistance, contributing to long-lasting performance in various applications.


The ESC-GC760-FR sheet pile excels in strength and durability. With a width of 762 mm and a height of 431.8 mm, it offers a section area of 218.7 cm²/m. Its sectional modulus is an impressive 3,130 cm³/m, and the moment of inertia stands at 67,580 cm⁴/m. The flange width measures 240 mm, and the flange thickness is 13.7 mm. The E-modulus is 30,419 MPa. Its solid composition effectively shields against soil and water, making it a reliable choice for various engineering projects.


Composite sheet pile retaining wall

ESC Composite sheet piling offers a cost-effective solution for foundation projects. These sheet piles, manufactured from a combination of steel and concrete, provide additional strength and durability. Their solid barrier properties guard against soil and water infiltration, making them reliable choices for various engineering applications.


ESC’s range of specifications, including the ESC-GC458-FR, ESC-GC510-FR, ESC-GC610-FR, and ESC-GC760-FR, caters to different project requirements.


Composite sheet piles are used in civil engineering and construction projects, particularly marine ecosystems and waterfront applications. They combine different materials to create a composite structure that offers specific advantages over traditional sheet piles.


Composite sheet pile materials

These sheet piles typically consist of a combination of materials such as steel, fiberglass, concrete, or polymers. The combination of materials allows for improved strength, durability, corrosion resistance, and other desirable properties that may not be achievable with a single material.


Composite sheet piles are often used where traditional materials like steel may corrode quickly due to exposure to water, chemicals, or other environmental factors.


They offer advantages such as lighter weight, easier handling, and longer service life than conventional sheet piles. In addition, composite sheet piles have unique design features that enhance their performance, such as interlocking mechanisms for better stability or special coatings to resist abrasion and corrosion.


For more information, visit our website to explore the diverse products and services that ESC provides. Contact us at 📞 +852 8198 2349 or visit our website: www.escpile.com


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