253 DRUM POINT RD. • BRICK, NJ 08723
APF Jet Filter
Weep Hole
Filtration System
Model JF-50000
NEW
Sheet Pile
Connector
Timber Uplift
Connector Galvanized
Model TC-7612
Provides tension
capacity of 12 tons
Box 1264 Clifton, NJ 07012-1264
NEW
Tel. 973-773-8400/800-526-9047 / Fax. 973-773-8442
Email: apf@associatedpile.com Website: www.associatedpile.com
technical instrumentation devices were installed throughout the
project limits to continually monitor ground movement throughout
the project duration.
Another project that Corman is especially proud of is the
Reconstruction of Berths 1-6 Phase 2, Berth 4, at Dundalk Marine
Terminal in Baltimore, which was completed in October 2016.
This Maryland Port Administration project is at the Port of
Baltimore, considered one the nation’s busiest ports. After 80 years
of being subjected to the harsh marine environment, Berth 4 (a general
cargo receiver where goods are unloaded and stored onsite until
transport) was failing and needed to be replaced. Railroad access to
the wharf was no longer available due to weakening conditions, and
the docking area needed to be deepened to accommodate the deeper
draft ships transporting general cargo and paper pulp products.
“The new Berth 4 was constructed near an active storage facility,”
said Cox. “To keep it in service throughout construction and
secure it from ground movements, a new 700-LF king pile retaining
wall was driven in front of it. It was installed using 106 HZ10-80M
beams placed seven feet apart and interconnected with 105 AZ14 x
770 sheet pile pairs. Ten-inch PVC pipe sleeves were built into the
king pile concrete cap to house the 145 soil anchor tendons augered
125 feet deep and grouted into place prior to tensioning to secure
the wall. After securing the king pile wall, the old Berth 4 was
safely demolished.”
The new wharf is 70 by 700 feet long and consists of 306
24-inch, pre-stressed concrete piles. Piles were driven in bents of
six piles each to support 51 concrete pile caps and 350 precast deck
slabs were set on top of caps and locked in place with a 10-inch
concrete topping slab. The wharf fascia wall was constructed with
cast-in-place concrete and incorporates 12 200-ton ship mooring
foundations, new water and electric service and a fender system to
protect it from ship traffic. The new wharf includes two new rail
spurs and is topped with over 40,000 sq. ft. of 120mm interlocking
concrete paving blocks.
Before constructing the berth, there were test pile procedures
using seven 24-inch concrete piles, which were handled and driven
with a 275-ton Terex crane on a barge. Corman dynamically tested
seven piles to verify load capacity followed by a Statnamic test to
determine the axial compressive load. An explosive charge was
detonated in the Statnamic apparatus equal to 880-kips. They then
measured the pile displacement and analyzed the deflection versus
static load curve to determine failure load.
“Pile caps were originally cast-in-place,” said Cox. “We proposed
precast and worked through the design with the precast supplier
and Maryland Port Administration engineers. The concrete
pier caps were prefabricated offsite and then transported by barge
and installed by Corman’s 4100 Ringer Crane. By prefabricating
the caps, we drastically reduced the amount of concrete placed in
tidal areas and minimized the amount of concrete needing to be
barged to placement sites.”
What’s next?
As for the what the future holds for Corman, Cox says that in the
next two to five years, the company will increase its attention and
strength on marine and water/sewer projects, expanding in the
types of work within its markets and geographical reach.
“We will also continue to focus as a ‘Best in Class’ general
contractor in our core mid-Atlantic territory as we have for nearly
a century.” t
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