Piling and pole protective wrap system

Abstract

A multi-layer protective wrap system for wood or metal pilings and poles comprising multiple organic polymer layers (an inner seal wrap, an optional foam conformation layer, and an outer compression shell) secured to the pilings by a bar-and-band system provides resistance to decay, thereby extending the life of pilings / poles in both new and retrofit installations. The 2- or 3-layer wrap system not only extends the life of pilings / poles by protecting them from new infestation by organisms, but also starves existing organisms of the oxygen they require to survive. In addition, because the inventive wrap system seals the piling / poles, it prevents leaching of creosote or other protective coating materials into the environment, reducing the threat of toxicity. This permits industry current standard practice of impregnating pilings with creosote to act as a third or fourth layer inside the 2-3 layers of the inventive wrap system.

Description

CROSS REFERENCE TO RELATED APPLICATION [0001] This application is related to Provisional Application Ser. No. 60 / 622,164 filed Oct. 26, 2004 under the title Wood Piling Wrap System and Provisional Application Ser. No. 60 / 643,749 under the title Wood Piling Wrap System II filed Jan. 13, 2005, both by the same inventor, the priorities of which are claimed under 35 US Code §§ 119 and 120, and the entire subject matter of which is hereby incorporated by reference.FIELD [0002] The invention relates to marine construction and more particularly to a multi-layer wrapping system for pilings and poles that lengthens their useful life against corrosion, against decay and attack by marine and land based organisms. The inventive multi-layer wrap system also reduces leaching of preservative coatings into the environment, thereby reducing contamination of the water and soil into which the pilings and poles are emplaced in service. The inventive wrap system comprises a multi-layer organic polymer w...

AI Technical Summary

Benefits of technology

[0015] Although the preferred embodiment described herein is described in terms of the harshest conditions, namely the application of the inventive multi-layer wrap system to pilings used in a marine environment, and more particularly to salt-water marine construction such as docks and navigation structures, it should be understood that the various embodiments of the inventive wrap system apply equally to wrapping the bases of power and other pole structures (e.g., pole and beam building structures; deck and building support structures; telephone, utility and light poles; fencing, barrier and support structures; grandstands; automotive and railroad trestles and ties; and the like) emplaced in soil on land in a wide variety of environments, ranging, for example, from persistently dry to persistently or occasionally wet, including marshes, flood plains, low spots, water run off areas, streams, rivers, ponds and lakes. In the case of the marine environments, the inventive multi-layer wrap system functions to prevent attack primarily from marine organisms, and in the case of the land emplaced environments, the inventive wrap system functions to prevent attack primarily from insects, fungus and rot. In both types of uses, the inventive wrap system also functions to encapsulate and reduce leaching into the environment of preservatives used in and on the pilings and poles, whether creosote or other organic or organo-metallic compounds, paints, anti-corrosion coatings and the like.

[0017] A second, wrap layer comprising a compression shell-like cover layer (called the compression layer) of relatively rigid but flexible, tough, high molecular weight polyolefin polymer (HMWP) of thickness in the range of from about 0.040″ to about 0.150″ thickness is installed over and around the seal layer and secured in place with a vertical seal bar and corrosion resistant strapping system, which tightly seals the layered wrap and prevents water and oxygen from seeping in. This compression cover wrap is preferably selected from polyethylene, polypropylene or co-polymers of polyolefins, and preferably also includes UV stabilizer compounds to confer resistance to polymer breakdown due to sunlight, and carbon black or other colorants for weathering resistance and to confer opacity to assist in protecting the seal wrap or the optional intermediate gasket layer. Other additives may be used in the plastic compression layer to confer abrasion resistance, the desired degree of flexibility and toughness, color, and the like.

[0021] In this second preferred embodiment employing a third, intermediate foam conformation / gasket layer of the inventive piling and pole wrap system, a continuous sheet of ¼″-½″ thick, closed or open-cell, water-resistant plastic foam is wrapped tightly against the first seal wrap, acting as a gasket which compresses the first layer to the piling or pole surface, to assist the first layer to conform to the grain and / or other surface irregularities, to better seal the piling surface. The flexibility and compressibility of the closed / open cell foam acts to fill and seal any irregularities in the surface of the piling or pole, particularly wood ones, sealing both layers flush against the piling or pole surface. One skilled in the art can easily determine whether or not the foam gasket layer may be employed based on weather, water and use conditions, such as: the degree of typical water, mud or earth movement surrounding the piling or pole; the amount of wood preservative in the piling or pole; the nature and texture of the piling or pole surface (smooth vs. pitted or rough); or the age or / and deterioration already sustained by the piling or pole, particularly in the case of retrofit wrapping.

[0029] In the case of poles, it is preferred to wrap the entire base of the pole that is installed in-ground, to some 6-18″ above ground level. That is, in the case of pilings the preferred wrap is top down to some 12-24″ below the sea, river, lake or marsh mud line, the remaining being un-wrapped, whereas in the case of poles, the wrapping is from bottom up to some 6-18″ above ground line. However, it should be understood that in the case of sensitive marine environments, whether fresh or salt water, it may be preferred or necessary to wrap the entire section of the piling or pole emplaced in the sea, lake, river, pond or marsh bed. To wrap the bottom of the piling or pole, that is the butt end, the inner seal layer is extended beyond the butt end of the piling or pole, and upon wrapping, the extension is folded over the butt and around the lower portion of the side-wall wrap. Then the outer compression layer shell can secure the folded material. In this case, the foam inner layer may be omitted in the area of the folded material. In addition, the folded material may be cut off square, that is, transverse to the longitudinal axis of the piling or pole to eliminate any undesirable bunching of material. As an alternative, a plastic end cap can be secured to and over the butt, wrapped or not, and the shell layer abuts the edges of the cap to provide an integral shell that covers the butt as well as the piling or pole sides.

[0034] A fourth alternate embodiment for attaching the inventive wrap is employed for pilings or poles which have already sustained some deterioration or use damage. In this embodiment, the two or three-layer inventive wrap system is held in place with opposed, hot-dipped galvanized steel C-channels running beyond (above and below) the length of the damaged area to act as a splint to reinforce the piling. These channels can run the full length of the piling, if needed. The C-channel is affixed to the piling with carriage through-bolts located vertically, generally every 2′ along the length of the reinforcing channels. The bolts are oriented on a diameter of the piling and, upon tightening, place the channels in compression to reinforce the piling. In addition they assist in retaining and sealing the compression shell. If deterioration has rendered any area too soft to hold a bolt, they may be installed at irregular intervals to insure that the bolts are anchored into healthy wood or other piling or pole surface material.

Problems solved by technology

In standard wood, metal and concrete piling systems, marine boring organisms and exposure to water promotes deterioration of the wood and concrete and corrosion of metal.

While these chemicals slow the processes of infestation and decay, they leach into the water, which is a growing, serious, and significant environmental concern, particularly around docks used for fishing and human recreation, or in areas where the leachate affects fish and aquatic plants and animals.

While both metal and wood are used for pilings and poles, the use of metal is far more common for poles than pilings, as the metal is far harder to protect from corrosion, particularly in salt water environments.

In addition, metal is subject to galvanic corrosion in wet environments.

Metal poles emplaced in the ground typically have longer service life than those emplaced in marine or wet environments (fresh water streams, lakes, ponds and marshes, or frequently wet ground), but the nature and composition of the soil, particularly the natural soil salts content, can significantly shorten the expected service life.

In addition, acid or alkaline soils, and those exhibiting natural electrical potentials or micro / milli currents can accelerate corrosion and failure.

This single layer system requires careful cleaning before installation, special sealing material, and is relatively fragile in a marine environment.

This system depends on the integrity of the foam and that the nailing does not permit or produce bulges or gaps that permit entry of marine organisms over time.

This system is very expensive and requires careful sealing top and bottom, and apparently can only be retrofit on pilings with unrestricted access from the top.

These specialty approaches are costly and relatively complex.

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