2012 Geofoam Presentation - Wisconsin Society of ... GeoFoam.pdfInsulfoam Geofoam 7 Bridge Column...
Transcript of 2012 Geofoam Presentation - Wisconsin Society of ... GeoFoam.pdfInsulfoam Geofoam 7 Bridge Column...
Insulfoam Geofoam
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“Geofoam – A Light Weight Fill Alternative”
•A wholly owned subsidiary of
Carlisle Construction Materials
•Headquarters in Tacoma, WA
•Producer of expanded polystyrene
(EPS) for more than 40 years
•The largest manufacturer of block-
molded expanded polystyrene in
North America
Insulfoam is the only manufacturer of Expanded Polystyrene (EPS) with the ability to service national customers
Insulfoam
Family of Products
Agenda
• Manufacturing Process• History of Geofoam• Geofoam applications/projects• Recent Trends• Standards• Specifications• Placement/handling/installation
ProcessRaw Material - Resin
Cutting
Finished Goods
Recycling
Bead Storage
Pre-Expansion
Laminating
Customers
History of Geofoam
• EPS invented circa 1950• 1st use of EPS in a geotechnical application in 1965 was
done in Norway• Late 1960s – Germany - Frost Protection utilization • 1972 – Norway - First Road Embankment project• Early 1970s – The Netherlands - First EPS geofoam
projects • Mid to Late 70’s – Alaska - EPS used during the famed
oil-pipeline construction days • 1985 – Japan - First Abutment back-filling and road
construction on soft ground• 1990 – 14th Green at Coeur d' Alene Resort • 1992 – The word “GeoFoam” was being termed• Late 1990’s – United Kingdom – First Levee - Torne
Levee
Insulfoam Geofoam
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History of Geofoam
• 1997 - Geofoam Research Center was established• 2001 - First Geofoam Bridge Approach in the USA- Buffalo
Road Bridge, Warsaw, NY • 2001 - I-15 project• 2005 - ASTM D6817 released
• 2008 - FHWA New Technology →Functional Technology • 2010 –Geofoam had been used on State DOT projects in
most States• 2011 – 2nd Geofoam Conference in Oslo
FHWA National Deployment Goal
• EPS geofoam is to be routinely used as a lightweight fill alternative for State DOTs on embankment projects where the construction schedule is of concern.
• By October 2011, all States will have evaluated EPS geofoam as a lightweight fill alternative.
5 MAJOR APPLICATIONS
TO CONSIDER GEOFOAM
Lighten the Load
ELIMINATE OR REDUCE LATERAL LOADING ON
RETAINING STRUCTURES
ZERO NET LOADING FOR
SOFT SOIL REMEDIATION
ENGINEERED FOR
SLOPE STABILIZATION
PROTECT AND LIGHTEN THE LOAD ON
BURIED UTILITIES
KEEP IT SIMPLE AND FAST WITH
STRUCTURAL VOID FILL CONCRETE APPLICATIONS
RETAINING STRUCTURES
Eliminate or Reduce Lateral Loads for
• InsulFoam GF replaces thesliding soil wedge
• Native soils are self supportingwhen excavated back to the angle of repose
• InsulFoam GF is self supporting
• End result: ZERO lateral loadon the retaining structure
University Student Housing
Morgantown, WV
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I80 & 148th Street
Waverly, NE
Inn at the Mountain Gods
Mercalero, NM
InsulFoam® GF Benefits
• Significantly reduces structural steel, concrete and forming costs/time• Decreases or Eliminates the need for geo-grids or mechanical tie-backs • Allows walls to be designed taller and in more narrow rights-of-way
• Eliminates the need for secondary compaction which speeds construction
for Retaining Structures
Bayamun, Puerto Rico
SOFT SOIL REMEDIATION
Net Zero Load Designs for
• Soft soils only settle whenmore weight is added on top
• Calculate the weight of theGeofoam and all other loads
• Excavate an equivalent weightof native soil
• End Result: Net ZERO loadingI-680 Interchange – Martinez, CA
I-80/94 & I-65 - Gary, IN
I-405 Totem Lake Freeway
Kirkland, WA
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Louis Armstrong Int’l Airport
New Orleans, LA
• Increases -‒ Speed of installation
‒ Productivity
• Decreases -‒ Rights-of-way concerns
‒ Traffic closures
‒ Heavy equipment costs
‒ Soil removal costs
‒ Borrow-fill placement
•Eliminates -‒ Surcharging time/cost
‒ Soil Settlement
‒ Secondary compaction
InsulFoam® GF Benefitsfor Soft Soil Remediation
Port of Longview, WA
SLOPE STABILIZATION
Lighten the driving block for
• Heavy Soils + Gravity + H2O= High Landslide Potential
• Geofoam is up to 100 timeslighter than soil
• Using Geofoam reducesthe weight and the risk
US 101 - Willits, CA
US 50 Slide Remediation
Montrose, CO
• Increases -‒ Speed of installation
‒ Productivity
‒ Space for additional
traffic lanes
• Decreases -‒ Traffic closures
‒ Heavy equipment costs
‒ Borrow-fill placement
‒ Concerns about future
landslide/erosion issues
‒ Environmental impact on
sensitive hillside jobsites
‒ Long-term maintenance
and slope failure costs
InsulFoam® GF Benefitsfor Slope Stabilization
Hillside Restoration in Japan
Insulfoam Geofoam
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BURIED UTILITY PROTECTION
Protect and lighten the load on top of
• Reduces dead and lateral loads on underground pipes, culverts and tunnels
• Protects utility during seismic activity by reducing axial strain
•Provides high thermal insulation values that protect against severe temperature fluctuations
Woodrow Wilson Bridge
Alexandria, VA
Route 1 & 9 Interchange
Jersey City, NJ
• Allows construction directly on top of buried utilities
• Eliminates right-of-way or eminent domain claims to move the utility
• Allows designers to specify less expensive structural utilities such as box culverts and pipes
• Reduced dead loads prolongs the life of structure
InsulFoam® GF Benefitsfor Buried Utility Protection
STRUCTURAL VOID FILL
CONCRETE APPLICATIONS
Keep it Simple and Fast with
• Eliminates separate concrete pours for vertical wall sections
• Reduces overall amount of concrete or other heavy fills
•Reduces dead loads on underlying structures
•Any shape or slope can be easily fabricated on site
Union Pacific Depot
Salt Lake City, UT
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High School Theater
Sun Prairie, WI
Green Roof Application
Rooftop Pool Decks
Water Treatment Plants
Box Beam Bridge Girders
Bridge Column Voids
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Bridge Column Custom Forms
InsulFoam® GF Benefitsas a Structural Lightweight Void Fill
• Eliminates the need to pour the walls separately from the topping slab
• Decreases labor costs versus heavy soil backfill
• Decreases forming time and material costs
• Easily supports the weight of concrete slabs
Community College, Scottsdale, AZ
Full Scale Test
Løkkeberg Bridge, Norway
• Built on two EPS embankments
• Monitoring deformation, creep and stress distribution
Full Scale Test
Løkkeberg Bridge, Norway
• An impressive ‘creep’ deformation of less than 1.3%
• Most of which occurred during construction
• Bridge is still in operation today
• No signs of cracks or uneven deformation have been observed
Excavated after 24 years
@ Flom Bridge, Norway
• Excavation of a 24 year old EPS block from the first EPS Embankment at Flom Bridge (1972)
• No signs of material deterioration after 24 years
• Above groundwater level <1% water content by volume
• Below groundwater level <4% water content by volume
• Water pickup over the years in the ground will not affect material strength
• If a tendency towards change is to be noted –it would suggest a slight increase in material strength.
Recent Trends
UTA TRAX, Salt lake City, UT
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Load Distribution Slab within Assemblage
Shotcrete over Geofoam
Topaz Bridge, McCammon, ID
Bridge Abutments
Grimsøyveien, Norway
Sloped vs. Vertical
Rte 1 & 9, Jersey City, NJ
Port of Longview, Longview, WA
Levee Applications
North Creek Levee – Bothell, WA
Utilization of Geomembrane
“There is no FHWA “position” on the topic of using geo-membranes with load distribution slabs. I will say that I
recommend that states go with one or the other. “Silas Nichols, P.E., FHWA Senior Bridge Engineer
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Case StudyState Rt. 19, Noble County, IN
• Reconstructed 3,100 ft of highway, very soft soil extending 38 ft in some areas, continuous maintenance from horizontal movement, causing sheer cracking
ASTM D6817
Understanding ASTM D6817 (different than ASTM C578)
ASTM
D6817 vs. C578
Density lb/ft³, min.
Compressive Resistance, min. psi @
10% deformation
Flexural Strength, Min.,
psi
ASTM D6817 EPS 15 .90 10.2 25
ASTM C578 Type I .90 10.0 25
ASTM D6817 EPS 19 1.15 16.0 30
ASTM C578 Type VIII 1.15 13.0 30
ASTM D6817 EPS 22 1.35 19.6 40
ASTM C578 Type II 1.35 15.0 35
ASTM D6817 EPS 29 1.80 29.0 50
ASTM C578 Type IX 1.80 25.0 50
Geotechnical Insulation
InsulFoam GF Specifications
QC & Compression Testing
ASTM D1621 on 2”cube
Insulfoam: Service Sets Us Apart
• Specification assistance• 3rd party certification testing• Staffed Technical Center• Two Geofoam Specialists• Dedicated CAD drafters• Layout & Installation shop
drawings• Jobsite visits/startups• Hot wire cutting tools• Presentations/Box Lunches• Value engineering support
Insulfoam Geofoam
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Reduce Your Carbon Footprint
1 truckload of Geofoam = 12 dump trucks of fill
Handling
Geofoam Installation
InsulGrip / INSTA-STIK™
• 4” x 4” 20 ga. galvanized steel plate• 60 lbs designed lateral load per plate• Minimum of two plates per 4' x 8' area
• moisture cured polyurethane adhesive
• works well in a wide range of temperatures
Hot Wire Cutters