1. P3 (Preventive Pile Protection)
Scott Stotlemeyer
Asst. State Bridge Engineer
Missouri Department of Transportation
Missouri Bridge Conference
May 17, 2017

2. The Legacy Section 702.4.8 Protective Coatings
Apply heavy bituminous coating to
Steel piles in end bents from the bottom of the concrete cap to 3’ below it.
All exposed steel piles coating from 1‘ above the finished ground line to 3’ below it.
Apply 6-mil thick epoxy mastic coating to all other exposed steel pile surfaces, including bracing.
No requirements for protective coatings below the normal low water line.
Problems with this:
Estimation of proper depth
Effective cleaning and application
Appropriate products
Erosion/Scour
Ground disturbance
Corrosive environment (soil and water)
Salt exposure

3. The Legacy Leads to . . . Corrosion
Pics of corrosion and location (at abutments, at water line, at ground line, and under cap)

4. The Legacy Leads to . . . Advanced Section Loss
Pics of corrosion and location (at abutments, at water line, at ground line, and under cap)

5. The Legacy Leads to . . . Failure
Pics of corrosion and location (at abutments, at water line, at ground line, and under cap)

6. The Legacy Resulting Challenges
Corrosion may occur in as little as 20 years
Difficult to access for inspection and repair
700 bridges need some type of pile maintenance
300 have pile section loss (80 advanced enough to limit loads)
Pile maintenance activities need to be repeated throughout life of bridge
Traffic impacts due to weight restrictions and repairs

7. The Legacy Preservation, Repair, and Replacement Strategies
Preservation (e.g., Coatings, Zinc Tape, Spray Galvanizing (Metallizing))

8. The Legacy Preservation, Repair, and Replacement Strategies
Repair (e.g., Plating, Encasement, FRP)
5 Star Marine
Simpson Strongtie

9. The Legacy Preservation, Repair, and Replacement Strategies
New Plating and Encasement Standard Drawings
5 Star Marine
Simpson Strongtie

10. The Legacy Preservation, Repair, and Replacement Strategies
Replacement

11. The Legacy Preservation, Repair, and Replacement Cost
Example Maintenance Costs
Preservation
Paint - $75,000 (8 Bents w/ LBP) = $2000/pile
Zinc Tape - $150K (75 pile) = $2000/pile
Repair
Plating - $3200/lin. ft.
Encasement - $105,500 (bent) = $21,100/pile
FRP - $610/lin. ft. (40 pile)

12. The Legacy Preservation, Repair, and Replacement Cost
Estimated Maintenance Cost Over Life of Bridge
Paint
$2,000/pile x 4 piles/bent x 2 bents x 2 applications = $32,000/bridge
Repair
$25,000/bridge

13. The Legacy Preservation, Repair, and Replacement Cost
Estimated Total Maintenance Cost
$32,000/ bridge x 400 bridges
+ $25,000/bridge x 300 bridges
= $20.3M

14. The Future Preventive Strategy Issues to Mitigate
Corrosion may occur in as little 20 years
Difficult to access for inspection and repair
700 bridges need some type of pile maintenance
300 have pile section loss (80 advanced enough to limit loads)
Pile maintenance activities need to be repeated throughout life of bridge
Traffic impacts due to weight restrictions and repairs

15. The Future Preventive Strategy Objectives Reduce/Eliminate Corrosion
Maintenance Cost
Traffic and Economic Impacts

16. The Future Preventive Strategy Why Galvanize?
Why Galvanize?
Provides barrier and cathodic protection
Relatively maintenance-free
Provide a substructure that will
typically outlast superstructure
Maximizes traffic and worker
safety
Reduces inspection time and
frequency
Minimal increase in initial cost
($9000/bridge)

17. The Future Preventive Strategy Cost to galvanize
Cost to galvanize
Estimate lbs. x $0.25/lb.
≈ 27.5%(1%) increase in pile(bridge) cost
Actual ( )
Ungalvanized
Galvanized
Cost Increase
10” H-Pile
$49.07
$64.78
32%
12” H-Pile
$57.55
$75.36
31%
14” CIP
$52.05
$88.36
70%
16” CIP
$80.00
$93.69
17%
20” CIP
$137.00
71%
24” CIP
$131.00

18. Design Guidance EPG Article 702.1.2
Experience has shown that corrosion of this type of pile can be a serious maintenance problem in the future. Therefore, all piling is required to be galvanized.
EPG Article
Galvanized steel piles shall be required for all piles.

19. Design Guidance EPG Article 751.1.2.20 (cont.)
All surfaces of piles shall be galvanized to a minimum galvanized penetration (elevation) or its full length based on the following guidance.
The minimum galvanized penetration (elevation) shall be estimated in preliminary design and finalized in final design. The minimum galvanized penetration (elevation) or full length will be shown on the design layout and in the plans.

20. Design Guidance
Bridge Memo and Design Layout example

21. Construction Guidance
Galvanized Structural Steel/Cast-In-Place Concrete Pile and Bracing BSP (rev. 1/03/17)
DESCRIPTION
Sets forth requirements in addition to Sec 702.
MATERIALS
Galvanize per ASTM A123 and Sec 1080.
Field Galvanizing and repairs per ASTM A780. Zinc-rich paints not allowed.
No requirement for protective coatings.
DESCRIPTION
- Furnishing, coating and placing galvanized steel piles and bracing as shown on the plans and shall be in addition to the requirements of Sec 702 (Load-Bearing Piles).
- Revised Sec 702 forthcoming.
MATERIALS
- ASTM A123 = Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
- Sec 1080 (Structural Steel Fabrication)
- ASTM A780 = Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
- Acceptable repair methods include Zinc-Based Solders (Stick) and Zinc Spray (Metallizing)
- Repairs not needed where pile encased or below specified elevation.

22. Construction Guidance
Galvanized Structural Steel/Cast-In-Place Concrete Pile and Bracing BSP (rev. 1/03/17) – Cont.
CONSTRUCTION
Galvanizing limits.
Omit/remove 1” galvanizing at weld locations.
If weld area falls within the galvanizing limits,
Clean the weld area and remove all welding slag.
Field galvanize as noted previously.
MEASUREMENT/PAYMENT
Standard requirements
CONSTRUCTION
- All pile below the pile concrete encasement shall be galvanized down to an elevation as shown on the plans.
- At the contractor’s option, the entire pile length may be galvanized.
- Omission or removal accomplished by masking, grinding or other methods as approved by the engineer.
MEASUREMENT
- Actual length to the nearest linear foot for that portion of the pile that remains permanently in the structure. See Sec 702 Basis of Payment for any additional length authorized by the engineer resulting from pile splices. No separate measurement will be made for pile that is not galvanized. Measurement of bracing as Galvanized Fabricated Structural Carbon Steel (Misc.) will be based on the plan quantities.
PAYMENT
- Accepted quantity of galvanized and non galvanized pile in place will be paid for at the contract unit price. No direct payment will be made for incidental items necessary to complete the work unless specifically provided as a pay item in the contract. Galvanized pile bracing in place will be paid for at the contract unit price for Galvanized Fabricated Structural Carbon Steel (Misc.).

23. Construction Guidance

24. Construction Guidance
EPG Article – Standard Detailing Notes
E2. Foundation Data Table (old)
Old version of JSP specified a minimum of 20’ of galvanized pile below the finished ground line at end bents.

25. Construction Guidance
EPG Article – Standard Detailing Notes
E2. Foundation Data Table (recently revised)

26. Construction Guidance

27. Construction Guidance
- All pile below the pile concrete encasement shall be galvanized down to an elevation as shown on the plans.
- At the contractor’s option, the entire pile length may be galvanized.
- Omission or removal accomplished by masking, grinding or other methods as approved by the engineer.
MEASUREMENT
- Actual length to the nearest linear foot for that portion of the pile that remains permanently in the structure. See Sec 702 Basis of Payment for any additional length authorized by the engineer resulting from pile splices. No separate measurement will be made for pile that is not galvanized. Measurement of bracing as Galvanized Fabricated Structural Carbon Steel (Misc.) will be based on the plan quantities.
PAYMENT
- Accepted quantity of galvanized and non galvanized pile in place will be paid for at the contract unit price. No direct payment will be made for incidental items necessary to complete the work unless specifically provided as a pay item in the contract. Galvanized pile bracing in place will be paid for at the contract unit price for Galvanized Fabricated Structural Carbon Steel (Misc.).

28. Galvanizers AZZ Galvanizing Kansas City - 30’L × 5’W × 6’D
St. Louis - 51’L × 7’W × 10’D
Hubbell Power Systems
Centralia - 16’L × 3’W × 7’D
Monnig Industries, Inc.
Glasgow - 32’L × 7’W × 5’D
Monnig Industries, Inc. - Universal Galvanizing
Saint Peters - 25’L × 5’W × 7’D 
Many more within 500 miles of Columbia
Avg. kettle length – 40’

29. Future Applications New and Existing Girders
R0568 – MO 179/Splice Creek, Moniteau Co.
Duplex Coatings

30. Questions? Scott Stotlemeyer, Asst. State Bridge Engr.
(573)