U.S. patent application number 11/249949 was filed with the patent office on 2006-04-27 for piling and pole protective wrap system.
Invention is credited to William Ellis.
Application Number | 20060088386 11/249949 |
Document ID | / |
Family ID | 36242685 |
Filed Date | 2006-04-27 |
United States Patent
Application |
20060088386 |
Kind Code |
A1 |
Ellis; William |
April 27, 2006 |
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.
Inventors: |
Ellis; William; (Sequim,
WA) |
Correspondence
Address: |
Innovation Law Group Ltd.
237 North Sequim Avenue
Sequim
WA
98382-3456
US
|
Family ID: |
36242685 |
Appl. No.: |
11/249949 |
Filed: |
October 13, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60622164 |
Oct 26, 2004 |
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60643749 |
Jan 13, 2005 |
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Current U.S.
Class: |
405/211.1 ;
405/211 |
Current CPC
Class: |
E02D 5/60 20130101 |
Class at
Publication: |
405/211.1 ;
405/211 |
International
Class: |
E02D 5/60 20060101
E02D005/60; E02D 31/00 20060101 E02D031/00 |
Claims
1. A multi-layer wrap system for protection of pilings and poles
against infestation of organisms, and against weathering and
service damage, particularly in wet environments comprising: a) a
first, seal wrap layer comprising a sheet of flexible, strong,
impervious polymer material wrapped around said piling or pole in
at least areas of exposure of said piling or pole to attack by said
organisms, said wrap overlapping on itself by a sufficient amount
to insure a conforming seal without gaps against the surface of
said piling or pole and terminating in an outer marginal edge; b) a
second, compression layer wrap applied over said first seal layer,
said second wrap layer overlapping on itself by a sufficient amount
to insure said second wrap can be secured to itself without gaps
exposing said first layer and terminating in an outer marginal
edge; c) at least one retaining bar placed over the marginal edge
of said second compression layer wrap; d) securing members,
selected from spaced bands under compression and bolts secured in
said piling or pole, engaging said retaining bar and compressing
said compression layer wrap tightly around said piling or pole and
said first, seal wrap layer; and e) said wrap system functioning to
conformingly seal and starve oxygen from organisms in or on said
piling or pole and to provide an outer protective shell that
protects from service damage.
2. A multi-layer wrap system as in claim 1 which includes a third,
intermediate gasket wrap layer comprising a sheet of plastic foam
wrapped around said seal layer to overlap on itself, which gasket
layer assists in conforming said seal layer to irregularities in
said piling or pole and which is secured in place by said outer
compression layer.
3. A multi-layer wrap system as in claim 1 wherein the marginal
edge of said seal layer is overlain with a strip of plastic foam
secured in place by said outer compression layer.
4. A multi-layer wrap system as in claim 3 wherein said outer
compression layer extends vertically downwardly from a datum line
and terminates above a soil or mud line and said compression layer
rests on a plurality of short, vertical spaced retaining bars in
contact with said seal layer and that extend below said soil or mud
line, said short retaining bars being secured to said piling or
pole by bolts, and said compression layer being secured to said
piling or pole by vertically spaced bolts placed adjacent said
outer marginal edge of said compression layer.
5. A multi-layer wrap system as in claim 2 wherein at least one of
said seal layer overlap and said gasket layer overlap is secured to
itself by tape or glue before application of said outer compression
layer.
6. A multi-layer wrap system as in claim 2 wherein said gasket
layer is closed cell foam.
7. A multi-layer wrap system as in claim 2 wherein said retaining
bar is secured to said piling or pole by bolts secured into said
piling or pole through said bar and wrap layers.
8. A multi-layer wrap system as in claim 1 which includes in place
of or in addition to said retaining bar at least one pair of
opposed retaining channels connected to each other by bolts passing
through said piling or pole.
9. A multi-layer wrap system as in claim 2 which includes in place
of or in addition to said retaining bar at least one pair of
opposed reinforcing steel channel members connected to each other
by bolts passing through said piling or pole.
10. A multi-layer wrap system as in claim 1 which includes in place
of or in addition to said retaining bar at least two pairs of
opposed vertical rub bars secured to said piling or pole at a level
bridging high and low water levels, said rub bars protecting said
outer compression layer from damage by dock structures to which
said piling or pole is tethered.
11. A multi-layer wrap system as in claim 1 which includes at least
one of a top or a butt cap member for protection of and assisting
the encapsulation of the piling or pole top or butt.
12. A multi-layer wrap system as in claim 1 wherein said seal layer
extends to and around the butt of said piling or pole, excess seal
layer sheet material is folded up and around adjacent the butt end
of said piling or pole, and said compression layer engages and
retains said folded excess seal layer material folded around the
butt end of said piling or pole.
13. Method of protecting pilings or poles from weathering, attack
from organisms, and against leaching of preservatives applied to
said pilings or poles into the environment comprising the steps of:
a) wrapping a first, seal layer comprising a sheet of flexible,
strong, impervious polymer material around said piling or pole in
at least areas of exposure of said piling or pole to attack by said
organisms, and overlapping said seal layer on itself by a
sufficient amount to insure a conforming seal without gaps against
the surface of said piling or pole and terminating in an outer
marginal edge; b) wrapping a second, compression layer over said
first seal layer, and overlapping said second compression layer on
itself by a sufficient amount to insure said second layer can be
secured to itself without gaps exposing said first layer and
terminating in an outer marginal edge; c) placing at least one
retaining bar to bridge over the marginal edge of said second
compression layer wrap; d) emplacing securing members, selected
from spaced bands under compression and bolts secured in said
piling or pole, to engage said retaining bar to compress said
compression layer tightly around said piling or pole and said
first, seal wrap layer; and e) said wrap system functioning to
conformingly seal and starve oxygen from organisms in or on said
piling or pole and to provide an outer protective shell that
protects from service damage and reduces leaching into said
environment.
14. Method as in claim 13 which includes the added step of wrapping
a third, intermediate gasket layer, comprising a sheet of plastic
foam, around said seal layer to overlap on itself, said gasket
layer assists in conforming said seal layer to irregularities in
said piling or pole and is secured in place by said outer
compression layer.
15. Method as in claim 13 which includes the added step of
overlaying the marginal edge of said seal layer with a strip of
plastic foam secured in place by said outer compression layer.
16. Method as in claim 14 which includes the steps of: extending
said outer compression layer vertically downwardly from a datum
line to terminate above a soil or mud line; emplacing a plurality
of short, vertical spaced retaining bars in contact with said seal
layer and extending said short retaining bars to below said soil or
mud line; securing said short retaining bars to said piling or pole
by bolts; resting a lower margin of said compression layer in
contact with upper ends of said short retaining bars, and securing
said compression layer to said piling or pole by vertically spaced
bolts placed adjacent said outer marginal edge of said compression
layer.
17. Method as in claim 14 which includes the added step of securing
at least one of said first seal sheet and said gasket wrap marginal
edges to itself with tape before wrapping said compression
layer.
18. Method as in claim 13 which includes the step in place of or in
addition placing said retaining bar, placing and securing at least
two pairs of vertical rub bars at substantially 90.degree. to each
other on sides of said piling or pole at a level bridging high and
low water levels, said rub bars protecting said outer compression
layer from damage by dock structures to which said piling or pole
is tethered.
19. Method as in claim 14 which includes the step in place of or in
addition placing said retaining bar, placing and securing at least
two pairs of vertical rub bars at substantially 90.degree. to each
other on sides of said piling or pole at a level bridging high and
low water levels, said rub bars protecting said outer compression
layer from damage by dock structures to which said piling or pole
is tethered.
20. Method as in claim 13 which includes the step of extending said
seal layer to and around the butt of said piling or pole; folding
excess seal layer sheet material up and around adjacent the butt
end of said piling or pole; and engaging and retaining said excess
folded seal layer material folded around the butt end of said
piling or pole beneath said compression layer.
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
.sctn..sctn. 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 wrap that is secured to the pilings or poles by a
banding-and-bar seal system useful both for new construction and
retrofit to existing pilings and poles, including pilings that are
already infested with marine organisms or poles that already show
infestation or leaching of preservatives. The inventive wrap system
reduces the oxygen availability to below the survival level, so
that the organisms die or cannot become established in or on the
pilings, and encapsulates the pilings or poles to reduce
environmental contamination.
BACKGROUND
[0003] 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. Uncoated wood pilings
may be destroyed by marine organisms in one year or less. Absent
invasion by marine boring organisms (worms), creosote-coated and
other chemically treated wood pilings may last on the order of from
10 to 40+years, depending upon the climactic, immersion and usage
conditions, before natural deterioration renders them unsafe to
carry the load for which they were intended.
[0004] The current industry standard is to impregnate the wood with
coal-tar creosote and/or copper arsenate to protect it by retarding
attack by marine boring organisms. The protective coating must be
thorough and deep, because marine boring organisms seek out any
unprotected area of the wood surface and spread inward to destroy
the untreated interior of the piling. 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.
[0005] 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. Iron is extensively used in
bulkheads, and metal bulkheads, pilings and poles may be coated
with paints, galvanized coatings or other oxidant and corrosion
resistive coatings to prolong service life.
[0006] In the case of poles, creosote and various copper and
copper/arsenic or other organic or metallo-organic compounds have
been extensively used for many years against boring insects, and
deterioration due to fungus and rot. 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.
[0007] There is an increasing need to address the issues of
leaching of corrosion by-products, and the anti-corrosion,
anti-fungal, anti-rot and anti-insect coatings into the
environments. Thus, there is a vital need to encapsulate at least
the base portion of poles emplaced on land (in soil) and wet
environments to prevent such leaching into the environment where
they pose or may cause harm to animal and plant life.
[0008] A number of approaches have been tried to address the
problems outlined above. Williams U.S. Pat. No. 5,516,236 describes
a single layer wrapped around a piling, with the top edge, bottom
edge and overlap of which employs a compressible seal. The top and
bottom are compressed with straps and the vertical overlap is
compressed with a reinforcing bar nailed to the piling. This single
layer system requires careful cleaning before installation, special
sealing material, and is relatively fragile in a marine
environment.
[0009] Imhof U.S. Pat. No. 4,713,129 is another single layer system
employing a plastic cover or sheet the overlapped ends of which are
sealed and secured by a heatable strip to form a fused plastic
seam. The sheet is temporarily secured with a strap and bar system
that holds it while the electrically heated fusing occurs. This is
a specialty system that depends on retention under severe use
conditions on the success of the fusing process.
[0010] Hellmers U.S. Pat. No. 4,697,957 describes use of preformed
thick walled split tube of extruded hexene-ethylene copolymer that
is used to sheath marine pilings. The sheath is then sealed with
polyurethane foam and aluminum nails secure the tube to the piling.
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.
[0011] Christenson U.S. Pat. No. 5,919,004 involves placing a
tubular jacket over a piling sized to have a gap, introducing a
marine grade foam in the gap with a propellant, and curing the foam
in place so it adheres to the jacket and the piling. 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.
[0012] Hsu U.S. Pat. No. 5,553,438 provides an elongated cap having
internal ribs that engage slots pre-cut in the butt end of wooden
utility poles prior to preservative pressure treatment of the
poles. Blair U.S. Pat. Nos. 6,019,549 and 6,347,911 use a flexible
elastomer wrap panel that is stretched and clamped around submerged
pilings. The wrap panel includes an interior felt layer impregnated
with a corrosion-inhibiting and biocidal gel. A particular feature
is the use of helical rib-strakes along the outside of the wrap
that reduces or eliminates Aeolian vibration induced by flowing
ocean currents. Pfaender U.S. Pat. No. 5,770,265 involves emplacing
a ring-like reservoir of a microbial treating solution such as
molasses or sodium dodecyl sulphate around wood pilings and poles
followed by covering the treated area with a substantially insect
impenetrable plastic sheet. These specialty approaches are costly
and relatively complex.
[0013] Accordingly, there is an unmet need in the art for a piling
and pole protective system that comprises a relatively inexpensive
and easy to install yet robust system that is simple to retrofit on
existing pilings and poles, and can equally be used for
encapsulating new pilings and poles before emplacement, both in
salt water and fresh water wet and marine environments, and on
land, to extend the useful life of the pilings and poles by
retarding decay, rot, corrosion and attack by marine and insect
organisms, and to prevent leaching of piling and pole preservative
coating chemicals into the water and soil.
THE INVENTION
Summary, Including Objects and Advantages
[0014] The invention is directed to a multi-layer wrap system that
meets the needs in the art and extends the useful life of pilings
and poles exposed to a wide range of service environments. More
particularly, the inventive multi-layer wrap system is equally
applicable to retrofit and new construction involving pilings and
poles that are exposed to or stand in water and soil, particularly
wet areas, including fresh and salt water locations such as salt
and fresh water marine locations, lakes, rivers and marshy areas,
and areas that are seasonally or frequently wet. In addition, the
inventive wrap system is used to encapsulate the bases of poles
used strictly in land-based, soil-emplaced service.
[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.
[0016] The invention comprises a multi-layer wrap that, in the
fresh or salt water marine environment essentially starves marine
organisms of sufficient oxygen to become established, propagate and
survive. In a presently-preferred 2-layer system of the best mode
embodiment, a first seal wrap of a flexible, strong, impervious
sheet of polymeric plastic or plastic-impregnated fabric is
extended from above the water surface, preferably the top of the
piling (generally at least 2' above the high-water line), to a
depth of from about 6'' to about 24'' or more below the mud-line,
e.g., the sea, river, pond or lake bed or the marsh bottom.
[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.
[0018] In a presently-preferred best mode embodiment, the seal wrap
layer of the inventive piling wrap system comprises a continuous
sheet of polyester, nylon or other suitable woven, polymer-fiber
fabric that is seal coated on both sides with polyvinyl chloride
(PVC) having thickness on the order of from about 15 mil to about
40 mil or more, depending on the service requirements, the
condition of the pilings and poles, the desired service life, and
the like, thicker (within reasonable cost effectiveness
requirements) generally being preferred. This impervious layer
seals the wood, creating a smooth surface to which the next layer
can conform and adhere, and cuts off the water and oxygen to the
piling surface. A second embodiment of the seal wrap comprises an
extruded plastic polymer, co-polymer, ter-polymer, or the like,
impervious sheet of similar gauge.
[0019] Where conditions warrant protecting the top or base (butt
end) of the piling or pole, caps made of galvanized or stainless
steel, copper, polyolefin or other plastic, or wood-plastic
composite material may be used to cover the end(s) of the piling or
pole and can be designed to overlap or otherwise shield the upper
edges of the inventive wrap system. As an example the same material
as used for the compression layer can be used for the caps.
[0020] A second preferred 3-layer embodiment of the inventive
piling and pole wrap system has additional features for pilings and
poles exposed to more severe weather or marine conditions. A third,
intermediate foam layer is positioned between the first, inner seal
wrap and the outer compression layer. This third foam layer
functions as a conformation or gasket wrap, and comprises a sheet
of plastic, closed-cell foam. This intermediate foam layer is
wrapped about the piling, extending the same length as described
for the seal wrap layer. Although the presently preferred
embodiment employs a closed-cell foam, an open or
partially-open-celled foam can be used, particularly where it is
desired to permit the foam to be a reservoir of leachate. Thus in
the case of poles emplaced on land, the intermediate layer of foam
can serve to absorb leachate run-off as it comes down from the
upper, exposed portions of the pole aboveground. The leachate is
trapped between the compressive wrap cover and the inner-seal
layer.
[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 1/4''-1/2'' 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.
[0022] The presently preferred compression cover layer or "shell"
of the inventive piling and pole base wrap system comprises a
heavy-duty, tough, continuous sheet of somewhat pre-curled, rigid
high molecular weight polyethylene (HMWPE) having a thickness of
from about 0.040'' to about 0.150''. The thick shell of HMWPE takes
the abuse of contact with water, waves and marine vessels. Its
composition includes ultra-violet resistant fillers as additives.
Typically the shell HMWPE is black. In the alternative, other
polymers, particularly polyolefin shell materials can be used.
[0023] With respect to installation, the inner edge of the seal
layer of the inventive piling wrap system, it is stapled or
otherwise secured to the piling or pole (e.g., by nailing,
screwing, taping or gluing), wrapped tightly 360 degrees around the
cylindrical piling or pole and overlapped on itself by 5-24''
depending on the piling or pole diameter, then secured in place
with plastic coated or impregnated cloth, water resistant, highly
adhesive tape or glue. A good tape to use is "Duct" tape. Stated
another way, the seal layer is over-wrapped, that is, wrapped in
the range of about 370-420.degree. around, measuring from the inner
edge.
[0024] Next, in cases where the optional foam layer is used, it is
wrapped around the seal wrap, overlapped by 1-6'' (about
5-15.degree.), and affixed to itself with the same type of adhesive
tape.
[0025] The rigid plastic compression shell is wrapped around the
one or two inner layers, overlapped by 6'' (about 10-30.degree.) at
the vertical longitudinal seam. A banding-and-bar seal assembly or
galvanized nails or stainless steel lag bolts are installed to hold
the compression shell in place.
[0026] In a presently-preferred best mode embodiment of the
inventive wrap system, a rigid, vertically oriented, retainer bar
is placed directly over the seam (the exterior lip edge) of the
shell layer of the inventive wrap system. The retainer bar in this
embodiment is made of ultra-high molecular weight polyethylene
(UHMWPE), having dimensions in the range of from about 3/8'' to
about 1'' thick and from about 1'' to about 3'' inch wide, and as
long as the entire wrap system (which extends from 6-18'' below the
mud line to the top or near the top of the piling) The retainer bar
is transversely grooved, typically at 1'-3' intervals to receive
stainless steel compression bands that go around the piling or
pole. The compression bands are preferably corrosion-resistant
bands, made of 317L stainless steel or equivalent metal or
polymeric material, having typical dimensions of from about 0.015''
to about 0.150'' thick by from about 3/8'' to about 1'' wide. The
bands are positioned in each of the grooved section of the bar,
ratcheted tight to a maximum compression of in the range of from
about 1000 to 2000 pounds and held closed with clips. In an
alternate embodiment of the banding material, an Inconel alloy band
or a high-strength polymer strap material of suitable dimensions
can be used to replace the stainless steel banding.
[0027] When the inventive wrap system is installed prior to pile or
pole installation, several feet at the base of each piling is left
unwrapped, and will be driven into the sea or lakebed so that on
installation, 12-24'' of the inventive wrap system will be driven
into the earth. When the inventive wrap is installed onto already
embedded pilings (retrofit installation), the sea or lakebed is
excavated by 18-24'' to expose sufficient piling wood to wrap the
layers tightly. Then the earthen sea or lakebed is replaced to the
same level it reached before it was excavated, thus covering 6-18''
of the wrap below the mud line.
[0028] With regard to retrofitting already installed embedded
pilings with the inventive wrap, if the tide retreats far enough to
expose the piling, the wrapping is done at low tide. If the piling
remains underwater at low tide, the wrap is installed by SCUBA
divers working underwater.
[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.
[0030] The presently-preferred best mode embodiments of the
inventive wrap system assist in protecting pilings and poles from
harsh underwater or soil conditions. A first alternate embodiment
of the inventive wrap system may suffice for conditions where the
floor of the body of water is regular and unchanging, the action in
the body of water relatively calm, and/or the piling or pole
surface exceptionally smooth. Under these conditions, not all
layers need to extend below the mud line or soil line. For example,
the gasketing foam layer (where used) need only be a vertical strip
wide enough to cover the sealing wrap edge (rather than the entire
piling) and the outer shell is affixed to the piling with stainless
steel bolts instead of compression straps.
[0031] In this first alternate embodiment, the seal layer extends
to 6-18'' below the mud line, and overlaps itself by 6-18''. Over
the resulting seam may be placed a 6'' wide strip of 1/4'' to 1/2''
thick closed or open cell plastic foam (as described above) as a
gasket, sealing the exposed edge of the seal layer into the surface
irregularities of the piling or pole surface. A compression shell
layer extending from the top of the piling down to 6-8'' above the
mud line is installed around the wrapped piling (the seal layer and
compression strip), overlapping on itself by 6''. It is held in
place with 4'' stainless steel lag bolts and washers located every
2' along the vertical length of the shell layer. Holding the seal
layer at the base of the shell is a series of four UHMWPE bars,
located at 90.degree. increments around the circumference of the
piling. These bars are made of the same UHMWPE material outlined in
the presently preferred embodiment but are only 6-8'' long, and
extend from 6-8 inches above to about 3'' below the mud line. They
are affixed to the piling with two-4'' stainless steel lag bolts
and washers, both located above the mud line. The bottom edge of
the compression shell rests on the four bars.
[0032] A second alternate embodiment of the inventive wrap system
differs from the presently-preferred best mode version only in the
method used to fasten the seal bar to the piling or pole and wrap
layers. In this embodiment, the seal bar, made of 1/2'' thick by
11/2'' wide UHMWPE is not grooved. Instead, 4'' stainless steel lag
bolts and washers are located every 2' along the length of a single
seal bar in place of the preferred stainless steel banding to
attach the bar to the piling or pole and seal the seam overlap of
the compression shell of the inventive wrap system. The two or
three wrapped layers and the seal bar extend to 6-18'' below the
mud or soil line. After the inventive wrap system has been
installed, the earth or seabed is replaced to the same level it
reached before it was excavated for installation, thus covering
6-18'' of the wrap.
[0033] A third alternate embodiment of the inventive wrap system is
designed specifically for "guide" pilings or poles used on
platforms which float up as the tide rises, and sink back down when
it recedes. The guide piling is typically tethered to the dock
inside a U-shaped loop and roller system (or other conventional
tether or box containment system), which allows the dock platform
to float up and down as the water level changes. In this case, the
two or three layer system is comprised of the same materials as the
presently-preferred best modes, including the full length seal bar.
In addition, three additional reinforcing bars made of UHMWPE are
installed at 90.degree. and 180.degree. to the seal bar. These
reinforcing bars extend vertically the length of the piling where
the loop and roller (containment) system engages the piling.
Preferably the reinforcing bars and the UHMWPE seal bar are placed
at the tangential intersection of the dock edge and the three edges
of the U-shaped loop tether (or other containment) assembly.
Together the four UHMWPE bars protect the wrapping in the area
where the loop and roller tubing system permits the dock platform
to float up and down as the water level changes. In this
embodiment, all four bars (one seal bar and three reinforcing bars)
are grooved to accept the stainless steel banding and clip system
described in the presently preferred embodiment.
[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.
[0035] Flat galvanized steel bars may also be utilized with the
presently-preferred bar-and-banding system, to act as a splint for
pilings which has slight deterioration or damage. In this
embodiment, the steel is installed behind the UHMWPE bar and
attached with stainless steel lag bolts prior to the
presently-preferred banding process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The invention is described in more detail with reference to
the drawings, in which:
[0037] FIG. 1 is a vertical elevation of an exemplary piling having
the inventive wrap system installed and in which the successive
layers are peeled back to reveal them, and in relation to the mud
line and the water level;
[0038] FIG. 2 is a series of schematic elevation views, FIG. 2a-2d,
showing the successive wrapping steps, in which: FIG. 2a is a
piling wrapped with the first, seal layer; FIG. 2b is a piling
showing the second, conformation layer (used only in the second
preferred embodiment); FIG. 2c is a piling with the third
compression layer; and FIG. 2d is a piling with the banding-and-bar
securing assembly in place.
[0039] FIG. 3 is a horizontal cross section of the piling of FIG. 1
taken along line 3-3 in FIG. 1 showing the completed wrapped
system;
[0040] FIG. 4 is an isometric view of a portion of the seal bar and
compression bands assembly;
[0041] FIG. 5a is a vertical elevation showing a piling having the
first alternate embodiment of the inventive wrap system installed
and in which the successive layers are peeled back to reveal
them;
[0042] FIG. 5b is a cross section of the first alternate embodiment
showing location 5b-5b in FIG. 5a;
[0043] FIG. 5c is a cross section of the first alternate embodiment
below the orthogonally-oriented bars around the compression shell
at location 5c-5c in FIG. 5a;
[0044] FIG. 6a is a vertical elevation of a piling having the
second alternate embodiment of the inventive wrap system installed
and in which the successive layers are peeled back to reveal
them;
[0045] FIG. 6b is a cross section at location 6b-6b of FIG. 6a;
[0046] FIG. 7a is an isometric of the upper end of a guide piling
having the third alternate embodiment installed, showing the
orthogonally-oriented reinforcing bars;
[0047] FIG. 7b is a cross section of a guide piling, showing the
orthogonally-oriented reinforcing bars held in place with steel
banding and clip;
[0048] FIG. 8a is an vertical elevation of a deteriorated,
"splinted" piling with the fourth alternate embodiment of the
inventive wrap system installed;
[0049] FIG. 8b is a cross-section of a splinted piling showing the
C-channel steel bars held together with carriage through-bolts;
and
[0050] FIG. 9 is vertical elevation view of a pole having a
wrapping from just above ground level to the butt.
DETAILED DESCRIPTION, INCLUDING THE BEST MODES OF CARRYING OUT THE
INVENTION
[0051] The following detailed description illustrates the invention
by way of example, not by way of limitation of the scope,
equivalents or principles of the invention. This description will
clearly enable one skilled in the art to make and use the
invention, and describes several embodiments, adaptations,
variations, alternatives and uses of the invention, including what
is presently believed to be the best modes of carrying out the
invention.
[0052] In this regard, the invention is illustrated in the several
figures, and is of sufficient complexity that the many parts,
interrelationships, and sub-combinations thereof simply cannot be
fully illustrated in a single patent-type drawing. For clarity and
conciseness, several of the drawings show in schematic, or omit,
parts that are not essential in that drawing to a description of a
particular feature, aspect or principle of the invention being
disclosed. Thus, the best mode embodiment of one feature may be
shown in one drawing, and the best mode of another feature will be
called out in another drawing.
[0053] All publications, patents and applications cited in this
specification are herein incorporated by reference as if each
individual publication, patent or application had been expressly
stated to be incorporated by reference.
[0054] FIG. 1 shows in vertical elevation an exemplary embodiment
of the inventive wrap system 10, in this case a wrap applied to a
wood piling as exemplary of pilings of various materials in
general, and for poles emplaced in wet environments. Thus, where
there is reference to piling, one skilled in the art upon
consideration of the teachings herein will readily perceive how the
inventive wrap system can be applied to a wide range of piling and
pole types and their service use and environments.
[0055] The inventive wrap is shown mounted on wood piling 12 in use
in a marine environment, driven into the seabed 14 with a suitable
length 16 below the mud line 18. The three-layer inventive wrap
system 10 comprises the seal layer 20, the conformation or gasket
layer 22 and the compression layer 24. In this case the butt end 17
and a medial portion extending upwardly thereof of the piling is
not wrapped as the mechanical driving action would shred or tear
the sealing layer. Where piling or post holes are drilled, the
piling or pole emplaced in the hole and the hole back-filled or
filled with sealing compound (e.g., bentonite, montmorillionite or
similar swelling fill) or concrete, the piling or pole may be
wrapped to, and optionally around, the butt end 17, un which case a
cap, like top cap 36, may be used to seal off the butt end 17.
[0056] A vertically oriented HMWPE (polyethylene) retainer bar 28,
is transversely (horizontally) grooved 30 at 2' intervals, that is
secured with stainless steel compression bands 32 that are
overlapped, ratcheted tightly and secured to themselves by clips
34. A plastic or steel cap 36 covers the top of the piling and the
upper edges of the inventive wrap system. Where needed, such as the
case of poles placed in-ground, a similar cap can be employed at
the butt 17 to seal that end of the pole when emplaced. It should
be understood that while it is shown in this and other
illustrations, the conformation or gasket layer 22 is included only
in the second preferred embodiment, and is selected for use or not
by one skilled in the art on the basis of piling, pole and
surrounding water conditions.
[0057] Note that the raw edges of each of the three layers (seal
edge 40, gasket edge 42, compression edge, 44) are offset around
the circumference of the piling.
[0058] FIG. 2 shows the progression of the inventive wrap system as
it would be installed.
[0059] FIG. 2a shows the seal layer 20 wrapped around the piling
12, from an upper datum line 13 to a depth of 6-18'' below the mud
line 18. In the case of a piling the upper datum line 13 is at or
near the top of the piling, or at least sufficiently high above the
high water mark to provide a reasonable zone of protection. In the
case of a pole, the pole continues upward above the datum line 13 a
considerable amount (many feet). Conversely, in the case of a pole,
the mud line 18 is the soil line and may be only 6-24'' below the
datum line 13, and the wrap may extend from as little as 6-18''
below the soil line to all the way to, and optionally around, the
butt end 17.
[0060] The seal layer is stapled 11 to the piling 12, wrapped
around it and overlapped on itself by 10-24'', resulting in an
exposed edge 40 which held in place with adhesive tape 26 attached
in spiral fashion around the piling 12.
[0061] FIG. 2b shows the conformation or gasket layer 22 of foam,
closed cell foam being preferred in marine and wet environments,
used in the second preferred embodiment of the inventive wrap
system, wrapped around the initial (first) seal layer 20 and
overlapping by 1-6'' The resulting raw edge 42 is sealed with
adhesive tape 26. In one suitable method the tape may be wrapped in
spiral fashion around the circumference of the piling 12, as
shown.
[0062] FIG. 2c shows the compression or shell layer 24 wrapped
around the prior layer, either the first, seal layer 20 where no
gasket layer 22 is used, or around the second, gasket layer 22
where that layer is used. The compression shell layer 24 overlaps
on itself by 6'' (creating layer edge 44).
[0063] FIG. 2d shows a rigid, polyethylene retainer bar 28 placed
vertically over the edge 44. The bar has 1/2'' wide, approximately
1/16'' deep grooves 30 every 2' to accept stainless steel bands 32
which are ratcheted tight, overlapped and secured to itself by
clips 34.
[0064] FIG. 3 shows a horizontal cross section of the layers of the
inventive wrap system 10; the pole or piling 12 at the center,
surrounded by the seal layer 20 overlapping by 6-18'', the
conformation or gasket layer 22 overlapping by 1-6'', the
compression layer 24 overlapping by 6'', and the rigid retainer bar
28 (the steel banding 32 is shown in FIG. 4).
[0065] FIG. 4 shows an isometric view of one end of a piling or
pole with the rigid polyethylene retainer bar 28 in place. It is
made of 1/2'' thick, 11/2'' wide material, with 1/2'' wide, 1/16''
deep transverse grooves 30 cut every 2' along its length. The bar
is placed directly over the outer edge 44 of the compression
(shell) layer 24. Fitting into each groove 30 is a tensioned band
32 made of 317L stainless steel, ratcheted tight (to a maximum of
1,200 pounds) and secured tightly in place with a clip 34.
[0066] FIG. 5a shows a second (first alternate) embodiment of the
inventive wrap system 10 on a wood piling 12 in place in a marine
environment, driven into the seabed 14 with a suitable length 16
below the mud line 18. In this embodiment the inventive wrap system
10 comprises two layers: First, the seal layer 20, which extends
from the datum line 13 down to below the mud line 18 by about 1',
and overlaps and is stapled and/or taped as in the above
presently-preferred best mode embodiment. In this first alternate
embodiment, the seal layer edge 40 is secured with only a vertical,
longitudinal strip of conformation or gasket layer material 56 of
closed cell foam on the order of 6'' wide. This strip overlaps the
seal edge 40 from top to bottom of the first layer wrap. A second,
compression layer 24 is placed around the seal layer 20 and gasket
strip 56. This compression layer 24 extends from the datum line 13
down to 6-8'' above the mud line 18. The first wrap layer 20 and
compression layer 24 are attached to the piling 12 with 4''
stainless steel lag bolts and washers 54 located every 2' along the
length of the compression shell. The bolts are emplaced adjacent
the edge 44 of the compression layer as shown.
[0067] Four un-grooved bars 52 made of 1/2'' thick by 11/2'' wide
ultra-high molecular weight polyethylene are placed 90 degrees
apart around the circumference of the piling 12 to secure the wrap
layer 20 below the bottom edge of the compression layer 24. These
short retainer bars extend from below the mud line 18, typically
about 3'' to 12'' below, to far enough above the mud line to meet
the bottom of the second compression layer 24, so that the bottom
edge 46 of the compression shell 24 rests on the top of the four
bars. Each of the bars is attached to the piling, through the seal
layer, with two-4'' stainless steel lag bolts and washers 54,
located above the mud line 18. This second embodiment is
particularly useful in retrofit situations.
[0068] FIG. 5b shows this second (first alternate) embodiment of
the inventive wrap system 10 in cross-section (at location 5b-5b in
FIG. 5a), with the piling 12 at the center, the seal layer 20
wrapped around it and overlapping by 10-20'', the gasket strip 56
placed over the seal edge 40, the compression shell 24 wrapped
around the seal and gasket layers, overlapping by about 6'' with a
lag bolt and washer 54 at the compression layer edge 44.
[0069] FIG. 5c shows the second (first alternate) embodiment of the
inventive wrap system 10 in cross section below the compression
shell (at location 5c-5c in FIG. 5a), showing the seal layer 20
held in place by four un-grooved retainer bars 52 which anchor the
seal layer to the base of the piling 12 at 90 degree intervals
around its circumference.
[0070] FIG. 6a shows a third (second alternate) embodiment of the
inventive wrap system mounted on piling 12 in place in a marine
environment, driven into the seabed 14 with a suitable length 16
below the mud line 18. The two or three-layer inventive wrap system
10 comprises the seal layer 20, the conformation or gasket layer 22
(where used) and the compression layer 24 extending from the datum
line 13 down to below the mud line 18. In this version, an
un-grooved 1/2'' thick by 11/2'' wide polyethylene bar 52, is
placed over the compression layer edge 44 and affixed through all
layers to the wood piling 12 with 4'' stainless steel lag bolts and
washers 54 at 2' intervals longitudinally along the piling 12.
[0071] FIG. 6b shows all of the components identified in FIG. 6a of
the second alternate embodiment of the inventive wrap system 10 in
cross section (at location 6b-6b in FIG. 6a) The piling or pole 12
is at center, followed in order by overlapped seal layer 20,
conformation/gasket layer 22 with overlap, compression layer 24
with overlap, and the un-grooved poyethylene retainer bar 52
affixed with bolts and washers 54.
[0072] FIG. 7a shows a fourth (third alternate) embodiment of the
inventive wrap system, which is designed for floating guide
pilings, a portion above the waterline 19 being shown. The two or
three-layer inventive wrap system 10 comprises the seal layer 20,
the conformation or gasket layer 22 (where used) and the
compression layer 24, as in the presently-preferred best mode
embodiment. In this embodiment, the system used to affix the
inventive wrap system comprises four grooved UHMWPE bars 28 running
the full length of the portion of the piling or pole 12 that must
withstand the banging and rubbing friction of the floating dock as
the water level (and therefore the dock) rises and falls due to
tides or waves. The inventive wrap system 10 is affixed to the
piling by the use of the same band 32 and clip 34 system used in
the presently-preferred embodiment.
[0073] FIG. 7b shows the fourth (third alternate) embodiment in
cross section along the line 7b-7b of FIG. 7a, the four
orthogonally-oriented bars 28 being held in place with the steel
band 32 and clip 34 system.
[0074] FIG. 8a shows a fifth (fourth alternate) embodiment, in
which channel members are used to "splint" pilings which have
sustained some deterioration, this application of the inventive
wrap system 10 shown mounted on piling 12 in place in a marine
environment. The two or three-layer inventive wrap system 10
comprises the seal layer 20, the conformation or gasket layer 22
(where used) and the compression layer 24. Galvanized steel
C-channel 60 runs the length of the piling on two opposite sides of
the piling, and is held in place with stainless steel carriage
through-bolts and washers 58. The dotted line 62 indicates where
the piling 12 has suffered some deterioration; the carriage bolts
58 have been placed above and below the damage to anchor them
securely in healthy wood.
[0075] FIG. 8b shows in cross section along line 8b-8b of FIG. 8a a
C-channel 60 and carriage through-bolt 58 system used to splint
deteriorated pilings. In this embodiment, the channel can be
reversed, with the legs against the compression layer 24, where
there is no concern for the bolt head and opposed nut to be
exposed. As an alternative, angle brackets can be used in the place
of C-channel, although the latter is preferred.
[0076] FIG. 9 shows in elevation a fifth embodiment comprising the
inventive multi-layer wrap system applied to a utility pole 12, in
this case one in an area where there is permanent water 48, such as
a stream, lake, pond or marsh, or the water is transient or
seasonal, or the ground 14 is typically moist. The wrap system
extends from a suitable datum line 13 above the ground level 18 or
above the high water line 50 down to below the ground level, and
optionally to the butt 17 of the pole 12. As shown the pole extends
well above the datum line 13. In this example the wrap system,
comprising an inner, first seal layer material 20 and an outer
compression layer shell material 24 extends to the butt end of the
pole 17. Further, the inner seal layer 20 is extended beyond the
bottom end of the pole, then upturned and folded back up the side
64. The compression layer 24 engages and securely retains the
folded material 64, and the retaining bar 52 retains the entire
assembly in place by means of the bolts 54, preferably of stainless
steel or other corrosion resistance-treated steel (such as
galvanized bolts). The outer compression layer can extend down to
the lower end of the pole 17. Optionally, a cap 36 can be emplaced
over the end, either over just the seal layer 20 or both the seal
layer and the compression layer 24.
INDUSTRIAL APPLICABILITY
[0077] It is clear that the inventive two or three-layer wrap
system of this application has wide applicability to the marine
industry, namely to dock, bridge and marine structure builders and
the like, and to land-based utilities and construction industries,
namely to power, lighting, telephone and structural support poles.
The system extends the useful life of wood or metal pilings and
poles by encasing them in a multi-layer protective sheath that
slows the natural process of deterioration by marine boring
organisms, insects and effectively encapsulates them against escape
into the environment of leachate from preservative coatings.
[0078] By way of example, the inventive system of multi-layer
wrapping of poles and pilings reduces the cost and frequency of
replacing them to only as frequently as once per decade or more
(several to many decades for land-based service use), and has the
clear potential of becoming adopted as the new standard for sealing
pilings and poles. From an industrial perspective, each year of
life extension for a piling represents a 10 percent increase in the
life of the piling and thus a 10 percent cost benefit.
[0079] It should be understood that various modifications within
the scope of this invention can be made by one of ordinary skill in
the art without departing from the spirit thereof and without undue
experimentation. For example, the wood piling system cap can have a
wide range of designs to provide the functionalities disclosed
herein. Likewise the sealing bar may be made of metal rather than
polyethylene. The invention is therefore to be defined by the scope
of the appended claims as broadly as the prior art will permit, and
in view of the specification if need be, including a full range of
current and future equivalents thereof.
Parts List
[0080] This parts list is provided as an assist to examination; it
may be canceled upon allowance TABLE-US-00001 10 Inventive wrap
system 11 Stainless steel staples 12 Piling or Pole 13 Upper Datum
Point 14 Sea or lakebed 16 Depth of piling into sea or lakebed 17
Butt end of piling or pole 18 Mud line 20 Seal layer of wrap system
22, Conformation or gasket layer of wrap system 24 Compression
shell layer of wrap system 26 Adhesive tape 28. Grooved
polyethylene retainer bar 32 Stainless steel banding 34 Stainless
steel clips 36 Galvanized, stainless steel or plastic cap 40 Seal
layer outer edge 42 Conformation/gasket layer outer edge 44
Compression shell outer edge 46 Bottom edge of compression shell 48
Body of water 50 Waterline 52 Ungrooved UHMWPE bar 54 4'' stainless
steel lag bolt and washer 56 Conformation/gasket strip 58 Stainless
steel through bolt and washer 60 Hot dipped galvanized steel
C-channel bars 62 Area of deterioration of piling or pole 64
Up-turned seal layer material
* * * * *