Port Authority of New York and New Jersey
| Operator | PORT AUTHORITY OF NEW YORK AND NEW JERSEY |
| Location | NEW YORK/NEW JERSEY - RUNWAY EXTENSIONS AT LGA AIRPORT |
| Product |
RETROWRAP HD |
| Operation | PILE SUPPORTED UNDERDECK REHAB |
| Date | MARCH/OCTOBER 2002 |
INTRODUCTION
In September 1988, the Port Authority of New York/New Jersey, under the direction of the then staff corrosion engineer, Victor Chaker, embarked upon an extended evaluation of splash zone corrosion protection systems for the protection of 3,200, 16" and 18" pipe piles originally installed in 1964 to support the runway extensions at LGA Airport .
CCI, then known as NICC Inc. along with others, was invited to participate in the trials and provided the Retrowrap Mark 1 design for long term testing which after 18 months of evaluation was subsequently approved for the protection of 1,800 deepwater piles. The test results were published by the PA of NY/NJ in a paper presented at Corrosion 90 which quoted corrosion rates of 0.19 mils per year when measured by weight loss coupon method at 9 separate locations on each of the test piles.
Contract 495. Commencing in the summer of 1991 and completed in 1992 when approximately 1,800 18" and 16" diameter Retrowrap Mark 1 wraps were installed by J. Picone along with 1,400 multi component wraps of the Denso SeaShield design. During the ensuing years, under deck inspection of the piles revealed that certain wraps and anode assemblies were suffering from impact and abrasion damage primarily caused by contractor's work barges in areas under the runway where extra piles were being driven during strengthening modifications which commenced in 1999.
In 2000, CCI was invited by the PA NYNJ to participate in discussions regarding the feasibility of providing both impact and abrasion resistant wraps to replace those that have failed and repair those wraps exhibiting localized impact damage. CCI propsed that our Retrowrap HD (.246") developed for offshore oil and gas riser protection be modified to accept the new anode bracket attachment design and also designed a shorter localized repair wrap for installation over both the original Retrowrap Mark 1 and Denso SeaShield systems. All replacement wraps were fitted with special Grade B8 Class 2 SS316L as specified by the client.
Contract LGA 669. In September 2002, CCI was specified on a no substitution basis to supply Retrowrap HD with impact resistance of 175 ft lbs and abrasion resistance of 90,000 cycles when tested to tabor A H-18.
PQT trials commenced in March followed by a presentation of production drawings and approval
to commence production in late April. Installation and on site training of divers commenced in
June together with a number of technical audit visits to site during the installation period primarily
to insure that all CCI approved installation procedures were being followed. Completion on schedule
in October proved that by utilizing offshore methods to control all aspects of design, supply
and installation produced results that in spite of a higher than normally paid wrap supplied price,
the overall project was completed ahead of schedule and under budget and provided a 25 year design
life.
After damaged wrap removed, close up of blisters in the existing epoxy located near connection of anode cable. Note entrapped water running out of disbonded area.
Complete area covered by wrap showing limit of existing splash zone epoxy
and extent of active corrosion. Note areas of disbondment clearly visible in epoxy mastic.
Disbonded area packed with Retrogel P before replacement wrap installed.
Top seal installed on 16" vertical pile. Note the position of collar against under surface of pile cap .
Top
seal installed on 16" batter pile. Note existing epoxy clearly visible.
Good surface preparation.
16" diameter Retrowrap HD being secured into position. Once 3 rd draw bolt is engaged in opposing flange, the wrap is lifted tightly under pile cap over seal and draw bolt sequentially tightened.
Tension operation commencing. Note double sealing flaps at anode bracket
locations
Temporary draw bolts fully tightened. Awaiting installation of permanent bolts. Outline of top seal clearly visible. Note double seal closed at anode bracket location.
Retrowrap HD fully installed with special Class 2 SS316L bolts fitted with nylon thread protectives. Note corrosion inhibited gel exuding from between flanges during tensioning insuring complete seal both at joint and circumferential locations.
16" diameter
batter pile showing outline of top seal in contact with underside of deck. Note closure flange
always positioned on inside of batter angle.
16" diameter
completed Retrowrap HD installation. Note top seal forced against underside of pile cap by
hoop tension induced into fabric during installation.
LP water jet removal of marine growth from damaged Denso wrap prior to fitting 18" x 28" repair wrap. Note all cavities in the damaged wrap are pre packed with Retrogel P before installing the Retrowrap repair jacket .
Double repair over damaged Denso SeaShield. Note outline of closure bands clearly visible under lower installed wrap.
Impact and Abrasion Resistant Retrowrap HD retrofitted over piles where earlier installed wraps have been damaged or failed.
Full length retro fitted wrap in foreground. Note pile on far left fitted with 2, 28" repair wrap installed over original wrap.
UAL 757 landing on runway extension 4-22 retro fitted piles with Retrowrap HD in foreground.
PQT of rubber lined mild steel pre production anode bracket installed at two pre determined factory provided positions within wrap flanges. Production bracket produced from SS 316L material.
Note outline of surface irregularities of earlier hand applied splash zone epoxy clearly visible.
