Historic Newark Site Uses Pipe Piling for Foundation Support in New Facility Construction Project
L.B. Foster Company has recently completed delivery of approximately 40 truckloads of 10 ¾ and 12 ¾ inch diameter steel pipe to Kansas City-based Burns & McDonnell for use as foundation support in the excavation and conversion of a Newark, New Jersey gas-fired power generating station. The New Jersey construction site has a rich history dating back to the late 1800's as being one of Thomas Edison’s original manufacturing facilities. The construction material was contracted by L.B. Foster from pipe manufacturer, Paragon Industries’ Oklahoma mill, who staged, fabricated end plates and coordinated just-in-time deliveries to the jobsite. The contractor required pipe in lengths of 30 and 40 feet with a wall thickness of .375 inches to be driven as additional foundation reinforcement for new state-of-the-art equipment and ancillary buildings. Burns & McDonnell, the project’s construction management firm, were instrumental in the overall planning, coordination, and control of the project from beginning to completion. “They have worked with us in the past on similar power plant projects, however this is the first time they have taken on the additional role as construction manager,” noted Roman Gwiscz, assistant general manager, piling products.
According to Burns & McDonnell Assistant Purchaser, Steven Johnson, “This order required flexibility from both parties and a great deal of communication. Terms and Conditions negotiations, schedule changes, material quantities, delivery delays and site visits were all part of this development and L.B. Foster was willing to work with us in all areas to make the process as smooth as possible.”
The L.B. Foster team was well represented in the lead up and award of this important energy project. “Our relationship with Burns & McDonnell was fostered as a direct result of lunch and learns and multiple follow-up meetings over the years,” commented Dru Kocina, Senior Client Manager, Construction Products.
Working closely with the client to produce technical information, material recommendations and provide critical jobsite logistics support were Senior Client Manager, Dru Kocina, Assistant General Manager- Piling, Roman Gwiscz, and Product Coordinator, Brandon Reiff. “Dru Kocina was our main point of contact through this order with L.B. Foster and he was able to work around the various project hurdles and help Burns & McDonnell find solutions that would help both parties succeed in completing their respective tasks. Last minute schedule changes and delays from the end user did not make the process easy and Dru kept things on track and worked well with Burns & McDonnell to overcome these challenges. We look forward to working with L.B. Foster in the future,” continued Johnson.
For the first time in decades, hydroelectric power generation is now being considered as an environmentally-sound energy source. Many existing U.S. dams that were originally constructed for flood control or irrigation applications are now being re-evaluated as potential retrofits to add power generation to a standing structure’s current uses. Iowa’s Red Rock Hydro Electric Plant on the Des Moines River was a successful candidate for this type of minimal-impact project.
L.B. Foster Company’s piling business unit is playing an integral role in the retrofit of this existing Army Corps of Engineers dam. L.B. Foster was awarded a contract by Ames Construction to supply 1,154 tons of PZC™ 26 steel sheet piling and 849 tons of wide flange king pile beams with PilePro® Connectors.
The project’s construction involves highly advanced civil engineering techniques and structural designs. L.B. Foster is playing a key part in providing the fabricated steel required to construct these unique retention walls. One innovative structure includes an array of complex deep cofferdams and combination retention walls for the hydro dam’s penstocks. The Pittsburgh-based steel fabricator and distributor is also providing material for over 400 feet of sheet pile wall for critical access road platforms to the new intake structures.
L.B. Foster’s piling material is being utilized in the construction of the hydro plant’s temporary excavations adjacent to the steep Red Rock Dam works. Initially, PZC sheets were used to create a closure dike which protects the site’s excavation against water from the river. PZC sheets connected with wide flange beams were also used as a combi-wall structure to reinforce excavation work that is continuing in the area where the powerhouse will be located.
The L.B. Foster piling team was well-represented in the lead up and award of this innovative project contract. MWH Global, the project’s engineers, specified L.B. Fosters’ products as the result of Lunch and Learn programs conducted by L.B. Foster’s Business Development Manager, Phil Wright and Senior Client Manager, Dru Kocina. Rich Mpistolarides, L.B. Foster District Sales Manager, Great Lakes District and Tom Thompson, Sales Coordinator worked closely with Richard Morales, M.Sc., P.E., L.B. Foster Director of Engineering to produce technical information, material recommendations and provide critical jobsite logistics support.
The Red Rock Hydro Electric Plant project is scheduled for
completion in 2018. The Des Moines River facility will be the
second largest hydropower plant in Iowa, with a capacity to
produce enough energy to meet the needs of 18,000 homes.
PZC™ is a trademark of Gerdau. PilePro® is a registered trademark of The PilePro Group.
Richard Morales, M.Sc., P.E., F.ASCE, L.B. Foster Construction Product’s technical leader and director of engineering, has been named a fellow of the American Society of Civil Engineers (ASCE).
ASCE is an international organization that was founded in 1852, making it the oldest engineering society in the U.S. The Membership Application Review Committee elects ASCE members to fellow grade through a review of professional accomplishments and contributions. Out of the more than 150,000 ASCE members, fewer than 3.5 percent are fellows.
Morales, who works at the firm’s Atlanta office, joined the company in 2008. He oversees the company's technical design and engineering for deep foundation and piling markets domestically and internationally. He recently provided technical and engineering support on the Panama Canal Expansion Mega-Project for the Borinquen Dam utilizing 58 Cellular Cofferdams over one mile long. He also provides leadership for the marketing development and develops strategies and resources to enhance and sustain growth and profitability.
Morales is a member and the current president of the ASCE Georgia Section and a member of its Structural Engineering Institute (SEI) and Coasts, Oceans, Ports and Rivers Institute (COPRI) Groups; in 2015, the engineering community for the state of Georgia named him Engineer of the Year. He also is a member of the educational committee for the Pile Driving Contractors Association; the Deep Foundation Institute; and the Society of American Military Engineers of Georgia. He serves as Chairman of the Boy Scouts of America (BSA), Atlanta Area Council, for Exploring Engineer Academy at Georgia Tech which encourages metro Atlanta youth to explore the exciting world of engineering as a profession and was honored with the organization’s Distinguished Service Silver Beaver Award in 2013. He also serves as an industry board member for the non-profit SkillsUSA Board of Directors which promotes leadership and training for our nations future work force.
He has a bachelor’s degree in civil engineering from the University of New Mexico in Albuquerque, New Mexico and a master of science degree from the University of California at Berkeley. Morales is also is a licensed professional engineer in California, Texas, Georgia and New Mexico.
Pittsburgh, PA-based L.B. Foster Company (NASDAQ: FSTR) is supplying 11,000 tons of PZC™ steel sheet piling and piling connectors to Southern California’s Orange County Flood Control District for use in the rehabilitation of the East Garden Grove - Wintersburg channel levees. L.B. Foster has completed delivery of the material to the general contractor, Reyes Construction, Inc. of Pomona, CA, for widening and seismic retrofitting of levees at high risk areas of the channel.
The PZC sheet piling was manufactured by Gerdau at their Petersburg, VA plant to ASTM A690 marine grade standards. The Virginia facility is the only plant in North America that can roll this unique material. PZC sheets are designed by Gerdau to be wider, lighter and stronger than typical Z sheets.
L.B. Foster’s piling professionals arranged for shipment of the material by train from the mill to an L.B. Foster yard in Central California and an additional third party facility in Southern California. The sheet piling was paired at the yards and delivered to the jobsite in Huntington Beach, CA in the precise order of installation to minimize handling by the contractor.
The flood control channel is located on an earthquake fault near sensitive wetlands. The project’s close proximity to the Newport- Inglewood Fault required a specially engineered configuration to accommodate seismic movement. The new levees consist of soil and cement columns placed between two rows of steel sheet piling. The construction presents additional concerns because the waterway winds through residential neighborhoods. The piling contractor, Blue Iron, Inc. of West Sacramento, CA, employed an exclusive silent piler system to minimize pile driving sounds.
PITTSBURGH, May 2, 2013 /PRNewswire/ -- Pittsburgh, PA-based L.B. Foster Company (NASDAQ: FSTR) has completed delivery of approximately 2,600 tons of 36 inch diameter steel pipe to Balfour Beatty Infrastructure, Inc. for use as lateral shoring struts in the excavation of San Francisco's new Transbay Transit Center. The contractor required pipe in lengths from 40 feet to 70 feet with a unique wall thickness of 1.125 inches to 1.5 inches to support the steel wide flange beams of the shoring walls inside the 60 foot deep excavation.
The material was contracted by L.B. Foster from the mill and delivered to the Port of San Francisco. L.B. Foster's piling professionals managed logistics from the port to a steel fabricator for additional finishing and transport back to the jobsite. "More than 160 truckloads of pipe as heavy as 17 tons each were required for the excavation of this signature transit project," said Dan Schrager, L.B. Foster Construction Products Senior Sales Representative.
The multi-billion dollar Transbay Transit Center replaces the old bus terminal near San Francisco's Embarcadero with a state-of-the-art regional hub that links the city to eight Bay Area counties and beyond with rail and bus transit systems. The new California High Speed Rail will also travel from the Transbay Transit Center to Southern California once that ambitious project is completed. Construction of the new transit hub began in 2011 with the final completion currently scheduled for 2018.
Balfour Beatty Infrastructure, Inc. delivers industry-leading
civil engineering and construction expertise for transportation
and water infrastructure projects throughout the United States.
Balfour Beatty Infrastructure is part of Balfour Beatty plc, a
global engineering, construction, services and investment business
organization specializing in large infrastructure and building
PITTSBURGH, July 13, 2010 /PRNewswire via COMTEX/ --
Pittsburgh, PA-based L.B. Foster Company (Nasdaq: FSTR) has been awarded a $4.7 million contract to provide PZC sheet piling to Balfour Beatty Infrastructure of Fairfield, CA for use in phase II of the construction of the Red Bluff Fish Passage Improvement Project. PZC 28 sections will form a permanent structure within the U.S. Bureau of Reclamation's Red Bluff Diversion Dam complex on the Sacramento River. Balfour Beatty is building a 1,118 foot-long fish screen and pumping station at the Northern California Central Valley project site with funds provided from the American Recovery and Reinvestment Act.
The PZC sheet piling is manufactured by Gerdau Ameristeel in
Petersburg, VA and shipped by rail to L.B. Foster's Chowchilla, CA
facility to be paired into sections for this
environmentally-sensitive project. "The innovative design of PZC
sheet pile provides a superior ball and socket interlock and is
domestically produced to assure short lead times," said Dan
Schrager, L.B. Foster Sales Representative. L.B. Foster is
installing interlock sealant to prevent permeation of water
through the interlocks and also attaching protective tips to
decrease damage during the installation process. "We are providing
important value-added services that will facilitate the delivery
of installation-ready sections as needed to expedite project
completion," noted Gary Wheeler, General Manager, L.B. Foster.
"This screen and pumping station will help allow fish to run
unobstructed in the Sacramento river and will deliver water to
more than 1,500 family farmers in the Sacramento valley via the
Tehama Colusa Canal," said Crandall Bates of Balfour Beatty. "It
should be a win-win project for everyone involved."
Construction of this unique project began in the early summer of 2010 with completion anticipated in 2012.
PZC(TM) is a trademark of Gerdau Ameristeel.
PITTSBURGH, Feb 12, 2010 /PRNewswire via COMTEX/ -- L.B. Foster Company (Nasdaq: FSTR), headquartered in Pittsburgh, PA, is providing steel sheet piling for improvements to the Ports of Indiana-Burns Harbor. The Port has awarded a $3.7 million contract to L.B. Foster for PZC 26, PZC 18, PZ 40 and PS 31 sheet piling for use in new dock wall construction in the West Harbor area. The Harbor is located 30 miles east of Chicago, enabling shippers to transport products by truck, rail, barge, ship or container to and from manufacturing and agricultural markets of Indiana, Illinois, Michigan and Ohio.
Innovative PZC(TM) sheet piling is manufactured by Gerdau Ameristeel to be wider, lighter and stronger than traditional Z piling. "PZC sections incorporate less overall sheets and less driving time than PZ sections, providing significant benefits to the Port and contractor," said Matt O'Kray, L.B. Foster's Construction Products Sales Representative. The unique design of this material maximizes production, minimizes the amount of required steel and increases strength per pound.
The Ports of Indiana-Burns Harbor handles more ocean-going cargo than any other U.S. port on the Great Lakes. L.B. Foster will begin shipping the domestically-produced piling for this high priority project in February 2010 with the final shipment expected by early April 2010. PZC(TM) is a trademark of Gerdau Ameristeel. About L.B. Foster Company L.B. Foster Company is a leading manufacturer, fabricator and distributor of products and services for the rail, construction, energy, utility and recreation markets with approximately 30 locations throughout the United States. The Construction Products group of L.B. Foster Company markets steel sheet piling, pipe pile, H beams, piling accessories, fabricated bridge products and structural steel nationwide.
PITTSBURGH, July 13, 2010 - Pittsburgh, PA-based L.B. Foster Company (NASDAQ: FSTR) has been awarded a $4.7 million contract to provide PZC sheet piling to Balfour Beatty Infrastructure of Fairfield, CA for use in phase II of the construction of the Red Bluff Fish Passage Improvement Project. PZC 28 sections will form a permanent structure within the U.S. Bureau of Reclamation’s Red Bluff Diversion Dam complex on the Sacramento River. Balfour Beatty is building a 1,118 foot-long fish screen and pumping station at the Northern California Central Valley project site with funds provided from the American Recovery and Reinvestment Act.
The PZC sheet piling is manufactured by Gerdau Ameristeel in Petersburg, VA and shipped by rail to L.B. Foster’s Chowchilla, CA facility to be paired into sections for this environmentally-sensitive project. “The innovative design of PZC sheet pile provides a superior ball and socket interlock and is domestically produced to assure short lead times”, said Dan Schrager, L.B. Foster Sales Representative. L.B. Foster is installing interlock sealant to prevent permeation of water through the interlocks and also attaching protective tips to decrease damage during the installation process. “We are providing important value-added services that will facilitate the delivery of installation-ready sections as needed to expedite project completion,” noted Gary Wheeler, General Manager, L.B. Foster.
“This screen and pumping station will help allow fish to run unobstructed in the Sacramento river and will deliver water to more than 1,500 family farmers in the Sacramento valley via the Tehama Col us a Canal,” said Crandall Bates of Balfour Beatty. “It should be a win–win project for everyone involved.”
Construction of this unique project began in the early summer of 2010 with completion anticipated in 2012.
PZC™ is a trademark of Gerdau Ameristeel.
PITTSBURGH, Sept. 18, 2009 - L.B. Foster Company (Nasdaq: FSTR) of Pittsburgh, PA has been awarded a $20.5 million contract to supply Gerdau Ameristeel sheet piling to the Panama Canal Authority (ACP) for use in the construction of the Panama Canal Expansion. The successful bidder for the PAC-4 contract opening later this year will install the piling for the excavation of the Pacific Access Channel and the construction of the Borinquen Dam. Gerdau Ameristeel's PS 31 flat steel sheets will be delivered in lengths of 56 ft. to 69 ft. Also, their PZC(TM) 26 Z-type sheet piling will be delivered in 49 ft. lengths.
"ACP is acting independently of the contractor in this purchase to minimize costs and pre-stage the material for a 1Q 2010 start of the PAC-4 construction contract," said Jim Wiehage, Houston/International Sales Manager for the Construction Products Group within L.B. Foster Company. "As with other Gerdau deliveries to international locations, the sophisticated logistics required for the shipment of $20 million of piling from mid-state Virginia and Texas to the middle of Panama are considerable," noted David Maedgen, Gerdau Ameristeel Piling Sales Manager. Gerdau Ameristeel and L.B. Foster teamed to assure the client that the piling will move expeditiously by rail and truck to US ports, by ship to an Atlantic terminal near Colon, Panama and then by trucks to the jobsite. The first delivery is scheduled for October 2009 with 3 additional shipments of equal size completing transit by the end of January 2010.
"L.B. Foster is proud to join with Gerdau Ameristeel to supply construction materials for such a monumental effort and to participate together in this historic project," said Don Foster, Senior Vice President of L.B. Foster's Construction Products Group. The Pacific Access Channel and the Borinquen Dam will be integral parts of the Panama Canal Expansion and provide navigation access to the Gaillard Cut via the new Pacific Post-Panama Locks. The completed canal project will allow ultra-large intermodal ships traveling from Asia to continue by sea to the US East Coast, rather than unloading containers on the West Coast and continuing freight by rail or truck across the United States.
PITTSBURGH, Aug. 27, 2009 -L.B. Foster Company (Nasdaq: FSTR) of Pittsburgh, PA has been awarded a $1.9 million contract by the City of Ashland, KY to supply Gerdau Ameristeel PS 27.5 flat sheet piling and PilePro connectors for the construction of an OPEN CELL structure at Veteran's Riverfront Park on the Ohio River. Project engineer KZF Design of Cincinnati, OH, recommended L.B. Foster and OPEN CELL technology over traditional tie-back walls to reduce material and installation costs. Gerdau Ameristeel flat sheets and PilePro connectors are best suited for the construction of OPEN CELL systems.
The OPEN CELL SHEET PILE((R)) system is a patented technology developed by PND Engineers, Inc. and marketed worldwide by L.B. Foster Company. "We became familiar with the benefits of this unique design and recommended this innovative and cost-saving technology to the City of Ashland," said David Tomley, P.E., Project Manager, KZF Design. "The OPEN CELL design provides superior load carrying capabilities at a reduced cost and offers future opportunities to construct recreational buildings at the Ohio River's edge," noted Rich Fifield, Sales Manager within the Construction Products Group of L.B. Foster Company. Smith Contractors, Inc. of Lawrenceburg, KY began work on the project in June 2009 and expects pile driving to be completed by the end of September 2009.
PITTSBURGH, July 23, 2009 - L.B. Foster Company (Nasdaq: FSTR) of Pittsburgh, PA has been awarded a contract to provide 480 tons of cost-efficient TRU 12" pipe piling and end plates for the reconstruction of 8 Minnesota Department of Transportation bridges in Steele County. The piling will be delivered to the subcontractor, Lunda Construction Company, in 30 to 50 foot lengths for use in the rehabilitation of 4 bridges in the city of Owatonna and 4 additional spans in the community of Waseca. TRU 12" pipe piling met or exceeded the Minnesota DOT's budget constraints and performance requirements for this series of bridge projects. "TRU 12 is becoming widely accepted and we anticipate it will soon become a staple in the piling market," said Don Foster, L.B. Foster Construction Products Senior Vice President.
L.B. Foster's innovative piling solution is ideal for demanding project budgets and tough construction requirements. "Cost-efficient TRU 12" pipe piling reduced the material costs and met all DOT project specifications," said Rich Mpistolarides, L.B. Foster Piling Sales Representative. Domestically-produced TRU 12 ERW pipe piling has an actual 12" OD diameter width, unlike typical 12.75" pile. This 3/4" difference lessens the amount of steel and construction fill needed per foot and allows up to 6% more pipe to be delivered in each truckload.
The first of 22 truckloads of pipe piling and end plates will begin delivery in September and complete during the Fall of 2010. "L.B. Foster's ability to stockpile product and ship it on an 'as needed' basis is critical to the construction schedule and another example of their value proposition," noted Steve Hoeschele, Lunda Construction Company Material Coordinator.
PITTSBURGH, July 17, 2009 - L.B. Foster Company (Nasdaq: FSTR) of Pittsburgh, PA has been awarded a $23.1 million contract to provide steel sheet piling to the U.S. Army Corps of Engineers (USACE) for the construction of T-wall type flood walls in the New Orleans area. The PZC(TM) piling will be manufactured in lengths of 20 to 75 feet at the Gerdau Ameristeel Petersburg, VA facility and stored for convenient availability at L.B. Foster's New Orleans storage facility. "Our local distribution facility will allow quick contractor access to the material required for T-wall installation in the USACE New Orleans District," said Ernie Koehler, L.B. Foster Construction Products Sales Manager.
T-wall construction is a field-proven design for effective flood wall structures that must withstand the surge elevation of a 100 year type hurricane. PZC-13 sheet piling will form an efficient below ground cutoff wall to prevent or minimize lateral water migration from undermining the T-wall. A protective coating of 16 mils of coal tar epoxy will be applied to the top 15 feet of each PZC steel sheet to assure long term corrosion resistance. "Our domestically produced PZC sheet piling is manufactured to be wider, lighter and stronger than traditional Z piling. The Army Corps has deemed this product to be an efficient solution for this type of critical application," noted David Maedgen, Gerdau Ameristeel Piling Sales Manager.
L.B. Foster/Gerdau Ameristeel sheet piling will form a protective barrier within T-wall structures in Orleans, Jefferson, St. Bernard, St. Charles and Plaquemine parishes. The USACE determined it would be beneficial to source material while mill capacity is readily available. "Gerdau Ameristeel and L.B. Foster worked closely as a strategic team to manage manufacturing costs and rolling capacity to win this important material supply contract," said Gary Wheeler, L.B. Foster Piling General Manager. Material shipments for the Corps of Engineers T-wall projects are scheduled to be completed by June 2011.
A failure of 450 ft. of floodwall lining the east side of the 17th Street Canal in New Orleans caused extensive damage when Hurricane Katrina made landfall on August 29, 2005. The immediate need was to provide an interim flood protection system that would prevent any reoccurrence of the storm surge from moving into the canal.
Contractor Boh Bros Construction Co., L.L.C.. along with numerous local construction / engineering related companies, and government agencies were awarded the project to construct the temporary pump station.
The foundation had to be designed to transmit very high lateral loads into extremely poor soil. Construction consisted of 2,530 tons of PZCTM-18, PZ-35 and PZ-40 steel sheet piles manufactured by strategic supply partner Gerdau Ameristeel.
L.B. Foster recently provided steel piling to the Freeport Regional Water Authority (a joint venture of the Sacramento County Water Agency and the East Bay Municipal Utility District) for a project on the Sacramento River in California. When completed, a new water intake and pumping station will supply water from the Sacramento River to customers in Sacramento County and the East Bay. A Combi-Wall structure was built to provide support for this new station. Various types of piles were utilized on this project from several strategic supply partners of L.B. Foster – 3,200 tons of various types of steel sheet piles (PZC™-13, PZC™-18 and PZC™-26) produced by supplier Gerdau Ameristeel and PSp 1017 Beams from supplier Peiner. PilePro Connectors were also used on the project, from PilePro. L.B. Foster also worked closely with local contractor Balfour Beatty during this project.
The Lake Hodges Project will connect the City of San Diego’s Hodges Reservoir with the Water Authority’s Olivenhain Reservoir. The connection will provide the ability to store 20,000 acre-feet of water at Hodges Reservoir for emergency use.
L.B. Foster and strategic supply partner Gerdau Ameristeel provided approximately 1,100 tons of PS 27.5 flat web sheets as well as the PilePro Connectors and steel fabrication required to construct the cofferdam for the pump house inlet-outlet structure.
L.B. Foster also worked closely with contractor Traylor Pacific during this project.
L.B. Foster recently supplied over 700 tons of HP 12 X 53 H-Beam piles for a project to build an ethanol tank farm. The foundations for several multimillion gallon ethanol storage tanks consisted of driven H-Beams and concrete caps. Local Peoria-based Otto Baum, a subsidiary of Core Construction, acted as the contractor on this project.
The H-beams were supplied by strategic supply partner Gerdau Ameristeel. During the construction, 70 ft. H-Beam sections were initially driven into the ground using a vibro hammer. A 50 ft. section was then bolted and welded to the 70 ft. section using a splicer. This lengthened H-Beam section was then further driven into the ground using a diesel hammer.
L.B. Foster was selected to supply PS 31 flat web sheet pile used to construct 43 OPEN CELL structures for this project. The OPEN CELL design was determined to be the most cost-effective solution to construct a bulkhead for the LNG docking facility. The initial rolling began in July 2006 at the then Chaparral Steel (now Gerdau Ameristeel) plant in Midlothian, TX. Gerdau Ameristeel is L.B. Foster’s strategic supply partner for steel sheet piling. The 69-foot face sheets used in the construction were transported to Houston, transloaded and sent to a Houston-based coater. They were then transported via truck to the Sabine Pass jobsite. The tail wall sheets — in 77- to 80-foot lengths — had to be shipped via rail to a public port near the jobsite, transloaded and then barged down the Sabine River to the jobsite. Construction began in the spring of 2007 and was completed by the end of the year. In all, the 43 individual OPEN CELL structures required over 4,300 tons of PS 31 flat web steel sheet pile.
To read more click here for PDF.
L.B. Foster recently completed a key project with the Texas Department of Transportation. A ferry shuttles cars between Galveston Island and the Bolivar Peninsula across the Houston Ship Channel. The ferry landing on the Bolivar Peninsula side needed to be completely rebuilt. As a part of that rebuilding, a breakwater was constructed using a Combi-Wall structure.
The length of the breakwater is approximately 450 ft. It was built using 320 tons of PZ 27 steel sheet piles in 60 ft. lengths, produced by L.B. Foster’s strategic partner Gerdau Ameristeel. The top 30 ft. of the pile was coated with a thermal sprayed aluminum coating. The bottom 30 ft. utilized an epoxy coating. In addition, 1,572 tons of pipe piling – 54 inch OD x .625 wall X 105 ft. lengths – were used in the project and supplied by another strategic partner, Northwest Pipe. The top 30 ft. of the pipe pile was coated with a thermal sprayed aluminum coating and the bottom 75 ft. utilized an epoxy coating.
The Argosy Casino boat slip expansion is the largest OPEN CELL structure built on the Ohio River to date. It is the first structure built with back-to-back facewalls and interlaced tailwalls. It is also the first structure constructed at ground level, excavated and then flooded. 4,100 tons of PS 27.5 flat web steel sheet pile were used during the construction. Original bids to build the slip using other techniques were rejected in favor of using the more cost-effective OPEN CELL technology. L.B. Foster's strategic supply partner, the then Chaparral Steel (now Gerdau Ameristeel), rolled the flat web steel sheet pile in early 2006. The sheet pile was transported via rail to a transloading and storage facility near Cincinnati, OH. Due to permitting delays, actual construction did not begin until the spring of 2007 and was completed in seven months, which allowed the hulls for the new gaming vessel to be floated into place in November 2007. This accelerated schedule required close coordination between L.B. Foster and local contractor Richard Goettle, Inc. to ensure timely and consistent delivery of the steel sheet piles to the construction site.