Abstract:
A collar for repairing a marine support has a tubular upper segment, a tubular lower segment, and a middle segment providing a transition region between the upper and lower segments. The collar can be opened and closed along a slit extending from the upper end of the collar to the lower end of the collar. To repair a marine support, the collar is opened and positioned so as to surround the marine pile and the extension. The collar is then closed and secured along the slit. The upper end of the collar is secured to the extension, and the lower end of the collar is secured closely along the perimeter of the pile. A flowable fill material is then injected into spaces between the collar and the marine support, filling or encasing voids or damaged areas on the marine support.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims the benefit of U.S. Provisional Patent Application No. 61/898,289, filed on Oct. 31, 2013, the disclosure of which is incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to the repair and protection of marine piles, and, more specifically, to forms and methods for in situ repair of such piles through the use of injectable materials. 
     BACKGROUND OF INVENTION 
     Piles, also known as “pilings”, have been used in marine environments for many years as structural supports for piers, wharves, bridges, roadways, and other constructions. Usually, such marine piles are made of concrete, steel, or wood, or combinations of such materials. All of these materials are subject to corrosion or deterioration through exposure to the marine environment, which can weaken the piles to the point of failure. Wooden piles, in particular, are subject to attack by marine organisms (e.g., plants, gribbles, shipworms, etc.), which, along with corrosion of bolts and other fixtures attached to the wood, accelerate the deterioration of the piles. 
     For many types of structures, the piles are capped with a concrete extension that may rest on, or surround, the upper portion of the pile. Typically, any gaps between the pile and the extension are filled with concrete, a grout, an epoxy, or other material that prevents movement or dislocation of the pile, and provides a seal against the infiltration of water. In cases where the gaps are not completely filled, or in cases where the fill material deteriorates and falls away, water can flow into the gap, providing entry for marine organisms, or allowing deterioration through contact with the water. 
     As the pile, extension, and/or connection become damaged or deteriorated, they lose structural strength. In severe cases, the pile may become sprung from the extension, rendering the marine support incapable of bearing any load. 
     SUMMARY OF INVENTION 
     In an embodiment, the present invention comprises a collar that surrounds a portion of a pile and a portion of an extension where the pile and extension are joined, and allows the injection of a grout, epoxy, or similar filling material between the collar and the pile and extension. The collar has an upper segment formed of a continuous sheet and arranged to surround the extension with a gap between the upper segment and the extension, and a lower segment formed of a continuous sheet joined to the upper segment and arranged to surround the pile with a gap between the lower segment and the pile. In some embodiments, the upper and lower segments may be joined to each other by a middle segment formed of a continuous sheet which provides a transition between the upper and lower segments. In some embodiments, the continuous sheets of the upper, lower, and/or middle segments are made from a flexible fabric. 
     In some embodiments, the entire collar opens along a slit extending from the upper end of the collar to the lower end of the collar. In some embodiments, the slit is opened and closed by means of a closing mechanism extending at least the entire length of the slit. In some embodiments, the closing mechanism is a zipper. In some embodiments, the collar is provided with a support strap at the upper end of the collar. In some embodiments, the collar is provided with funnels through which the grout, epoxy, or similar repair material may be injected into the gaps between the collar and the extension and pile. 
     In a method according to an embodiment of the invention, deteriorated and/or damaged material are removed from a pile and/or extension using tools, water jets, or other means. An opened collar is then positioned on the pile and adjacent extension such that the upper segment of the collar surrounds the extension and the lower segment of the collar surrounds the pile. The upper end of the collar is closed securely along the perimeter of the extension, and the lower end of the collar is closed securely along the perimeter of the pile such that cleaned areas of the extension and pile are within the collar. In some embodiments, the upper end of the collar is secured by devices such as ratchet straps. In some embodiments, the upper end of the collar is secured by the support strap in combination with anchoring devices such as concrete anchors. In some embodiments, the lower end of the collar is secured by devices such as clamps or straps that surround the collar and pile, and secure the lower end of the collar to the pile without gaps between the lower end of the collar and the pile. 
     With the collar secured around the extension and pile, a flowable repair material, such as an epoxy or grout, is injected through one or more of the funnels in the collar, and manipulated such that it fills the gaps between the collar and the pile and extension. The repair material has a composition such that it hardens in place. In some embodiments, the repair material has a composition such that it flows into any gaps, spaces, or holes in the pile and extension, or gaps and spaces between the pile and extension, so as to fill such gaps, spaces, and holes. In some embodiments, the filler material has a composition such that it bonds to the material of the pile and/or extension. In some embodiments, the filler material has a composition such that it bonds to the material of the collar. 
     A combination according to the present invention includes: a marine pile, an extension supported by the pile, and a connection including materials used to connect the pile to the extension; a collar including a flexible fabric that surrounds a portion of the pile and a portion of the extension; and a repair material between the collar and one or more of the pile, the extension, and the connection. In some embodiments, the repair material penetrates and/or is bonded to one or more of the pile, the extension, the connection, and the fabric of the collar, thereby binding the pile, extension, connection, collar, and repair material into a composite structure. 
    
    
     
       BRIEF DESCRIPTION OF FIGURES 
       For a more complete understanding of the present invention, reference is made to the following detailed description of various exemplary embodiments considered in conjunction with the accompanying drawings. These drawings are not necessarily drawn to scale, and are provided to denote various features of the invention. In these drawings: 
         FIG. 1  is a perspective view of a collar for repair of marine supports according to an embodiment of the present invention, the collar being shown in a closed configuration and a portion of the collar being broken away to facilitate consideration and discussion; 
         FIG. 2  is a perspective view of the collar of  FIG. 1 , the collar being shown in a partially opened condition; 
         FIG. 3  is another perspective view of the collar of  FIG. 1 ; 
         FIG. 4  is a front elevational view of the collar of  FIG. 1 ; 
         FIG. 5  is a rear elevational view of the collar of  FIG. 1 ; 
         FIG. 6  is a right-side elevational view of the collar of  FIG. 1 ; 
         FIG. 7  is a left-side elevational view of the collar of  FIG. 1 ; 
         FIG. 8  is a top view of the collar of  FIG. 1 ; 
         FIG. 9  is a bottom view of the collar of  FIG. 1 ; 
         FIG. 10  is a vertical cross-sectional view of a marine support comprising a pile and a concrete extension; 
         FIG. 11  is an elevational view of the marine support of  FIG. 10  with a collar of the present invention after completion of a repair operation, the collar and the repaired marine support being embodiments of the present invention; 
         FIG. 12  is a cross-sectional view taken through sectional line A-A of the marine support of  FIG. 11 ; and 
         FIG. 13  is a cross-sectional view taken through sectional line B-B of the marine support of  FIG. 11 . 
     
    
    
     DETAILED DESCRIPTION OF INVENTION 
     In an embodiment, the present invention comprises a collar that surrounds a portion of a marine support, which, for the purpose of the present disclosure, includes a pile, an extension supported by the pile, and the materials connecting the pile and extension (i.e., “the connection”). The collar allows the injection of a grout, epoxy, or similar filling material between the collar and the pile and extension to fill gaps, holes, and spaces within and/or between the pile, extension, and connection. 
     With reference to  FIGS. 1-9 , there is shown a collar  10  for repair of a marine pile, an associated extension, and a connection therebetween according to a first embodiment of the present invention. The collar of  FIG. 1  has an upper segment  12  arranged to surround the extension (not shown in  FIGS. 1-9 , but see reference number  104  in, for instance,  FIG. 11 ) with a gap between the upper segment  12  and the extension. The collar  10  also has a lower segment  14  arranged to surround the pile (not shown in  FIGS. 1-9 , but see reference number  102  in, for instance,  FIG. 11 ) with a gap between the lower segment  14  and the pile. In some embodiments of the present invention, the upper segment  12  may have a first diameter in the range of about 18 inches to about 36 inches, corresponding to a typical range of diameters for a corresponding extension, and the lower segment  14  may have a second diameter in the range of about 10 inches to about 20 inches, corresponding to a typical range of diameters for a corresponding pile. These ranges are not meant to be limiting, as the diameters of the collar  10  may be adapted (i.e., varied) so that they are usable with extensions and piles of other sizes. Further, the lengths of the upper segment  12  and lower segment  14  (in directions parallel to the longitudinal axes of the pile and extension) may be of any length that will serve to cover the sections of the pile and extension needing repair, limited only by the practicality of making and handling the collar  10  in such lengths. 
     With particular reference to  FIGS. 1, 2 and 4-9  the upper segment  12  and the lower segment  14  are joined to each other by a middle segment  16 . In the collar of  FIG. 1 , the middle segment  16  is arranged such that it tapers abruptly from the upper segment  12  to the lower segment  14 . The upper segment  12 , lower segment  14 , and middle segment  16  may be made of continuous sheets of flexible fabric. The collar  10  may be manufactured such that each of the upper segment  12 , lower segment  14 , and middle section  16  are adapted to cover the areas of the pile and extension that are to be repaired. In alternate embodiments of the invention, the middle section  16  may be arranged such that it is substantially flat in a plane between the upper segment  12  and the lower segment  14 , or tapers gradually from the upper segment  12  to the lower segment  14 . 
     Generally, the flexible fabric used to make the collar  10  is waterproof or resistant to the penetration of water, and resistant to damage or deterioration in the marine environment. The fabric may be woven, such as a sheet of woven nylon thread or threads comprising other polymeric materials, or it may be a non-woven sheet, such as a vinyl sheet. In embodiments where a woven sheet is used, it may be coated or impregnated with a material that strengthens the fabric and/or renders it resistant to penetration by water, such as a rubberized compound. Suitable woven fabrics may also incorporate materials that provide the fabric with high tensile strength or the ability to diffuse forces from impacts to the fabric. 
     Referring to  FIGS. 1-7 , the upper segment  12  defines an upper end  18  of the collar  10 , which is open. The lower segment  14  defines a lower end  20  of the collar  10 , which is also open. The middle section  16  is arranged such that the interior  22  of the lower segment  14  opens into the interior  24  of the upper segment  12  and is in hydraulic communication therewith. In the embodiment of  FIG. 1 , the middle segment  16  is joined to the upper segment  12  and the lower segment  14  by sewn seams  26  and  28 , respectively. Other methods of joining the middle segment  16  to the upper segment  12  and lower segment  14  may be used, such as heat welding or sonic welding overlapping sheets of material, or the upper segment  12 , middle segment  14 , and lower segment  16  may be formed as a single piece, by shaping methods known in the art. 
     Referring now to  FIGS. 1-4 and 6-9 , the collar  10  is arranged to open and close at a slit  30  that extends in a continuous fashion from the upper end  18  to the lower end  20 , such that the entire collar  10  may be opened. The collar  10  may be closed securely along the slit  30  by one of more water-tight and corrosion-resistant fasteners. In the embodiment of  FIG. 1 , the fastener is a water-tight zipper  32  that extends the entire length of the slit  30 . 
     With particular reference to  FIGS. 1 and 2 , the collar  10  is provided with a support strap  34  at the upper end  18  of the collar  10 . The support strap  34  maintains the shape of the upper end  18 , and may be adjustable to secure the upper segment  12  against the extension during repair of the pile, extension, and connection. The support strap  34  may be a strip of spring material, such as metal, that is sufficiently long and flexible such that the support strap  34  may be bent into a shape (e.g., circular) that conforms to the shape of the upper end  18  of the collar  10 . In the embodiment of FIGS.  1  and  2 , the length of the support strap  34  is greater than the length of the perimeter of the upper end  18 . In some embodiments, the support strap  34  is made from metal (e.g., a corrosion-resistant metal, such as stainless steel), but other materials, such as reinforced plastics, may be used instead. 
     The support strap  34  is secured within the collar  10  by a flap  36 . The flap  36  is positioned to at least partially cover the support strap  34 , and secured to the upper segment  12 . The edge  38  of the flap  36  may be secured to the fabric of the upper segment  12  by sewing, or other means of securing the flap  36  may be used. The flap  36  may be an extension of the fabric of the upper segment  12 , or may be a continuous strip of fabric folded over the support strap  34  at the perimeter of the upper end  18 . In the embodiment of  FIG. 1 , a single continuous flap  36  is shown, but two or more flaps, or strips of fabric positioned along the perimeter of the upper end  18 , may be used in other embodiments of the invention. 
     The collar  10  is provided with means by which flowable repair materials, such as grout or epoxy, may be delivered into the interior of the collar  10  during a repair operation carried out according to an embodiment of the present invention. Continuing to refer to  FIGS. 1-9 , one such means is a plurality of funnels, such as funnels  40 ,  42 ,  44 ,  46 , provided around the perimeter of the upper end  18 . In the embodiment of  FIGS. 1-9 , the funnels  40 ,  42 ,  44 ,  46  are similarly constructed, each having a pocket (such as pockets  48 ,  50 ,  52 ,  54 , respectively) secured to the outside of upper end  18  (e.g., by sewing), and an opening, such as opening  56  of funnel  42 . The pocket (e.g., pocket  50 ) and the opening (e.g., opening  56 ) are arranged to provide hydraulic communication between the interior of the upper segment  12  and the environment external to the collar  10 , or to allow the end of an injection tube (not shown) to be inserted into the interior of the collar  10 . Although four funnels  40 ,  42 ,  44 ,  46  are shown in  FIGS. 1-9 , any number of funnels may be used as is appropriate to the size of the collar  10 , the properties of the repair material to be used, and the amount of repair material to be delivered. 
     With particular reference to  FIG. 2 , the collar  10  is shown with the zipper  32  unzipped and the collar  10  in a partially opened condition. In such a condition, free ends  58 ,  60  of the support strap  34  are withdrawn from beneath the flap  36 . In the embodiment of  FIG. 2 , the support strap  34  is longer than the perimeter of the upper end  18 , such that, when inserted under the flap  36 , the free ends  58 ,  60  may extend to the funnels  40 ,  46 . 
     Turning now to  FIG. 10 , an exemplary marine support  100  includes a pile  102 , a concrete extension  104 , and a connection  106  between the pile  102  and extension  104  after preparation for repair according to embodiments of the present invention. As may occur during the original installation, or from removal of damaged or deteriorated material, there is a hollowed-out space  108  in the pre-existing concrete fill  110  between the pile  102  and extension  104 , and an open bolt hole  112  through the pile  102 . Other defects that may be present in existing piles and extensions, include, but are not necessarily limited to cracks, gaps or eroded volumes in the piles or extensions themselves, holes from boring insects or marine life, openings left by corroded fixtures, etc. 
     Turning now to  FIG. 11 , the marine support  100  has been repaired using a collar  10  and method of the present invention. Pile  102  and extension  104  are visible, as is a strap  114  used to close the lower end  20  of the collar  10  against the pile  102 . Anchor bolts  116  may also be seen securing the upper end  18  of the collar  10  to the extension  104 . Referring to the method and resulting composite structure generally, the materials and fabrication of the collar, and the other materials and techniques used in the method of repair may, in some embodiments, be such that the collar  10  is installed under low tide conditions at geographic locations where the collar  10  is normally partially or completely submerged at high tide. 
     A repair method performed in accordance with the present invention, as well as the resulting composite structure of the repaired marine support  100 , are discussed herein with respect to the cross-sectional views of the repaired marine support in  FIGS. 12 and 13 . In the repair method of the present invention, deteriorated or damaged materials (not shown) are removed from the pile  102 , extension  104 , and connection  106  by methods known in the art (e.g., abrasion or cutting with manual or power tools, or the use of water jets). The collar  10  is then placed around the pile  102  and extension  104 , and closed using the zipper  32  or other means (not shown) for closing the collar  10 , as discussed with respect to  FIGS. 1 and 2 . The collar  10  of  FIGS. 12 and 13  has been fabricated such that the upper segment  12  and lower segment  14  cover the full extent of the damaged or deteriorated areas of the pile  102 , extension  104 , and connection  106  that are to be repaired. 
     After the collar  10  has been closed around the pile  102  and extension  104 , the upper end  18  of the collar  10  is closed securely (e.g., by tightening the support strap  34 ) along the perimeter of the extension  104 , and the lower end  20  of the collar  10  is closed securely along the perimeter of the pile  102 . 
     The upper end  18  of the collar  10  may be secured to the extension  104  by the concrete anchor bolts  116 . Other suitable securing devices (e.g., ratchet straps, screw anchors, clamps, and powder-actuated fasteners, etc.) are known in the art and may be used in combination with, or instead of, the anchor bolts  116 . The securing or attachment devices may be of types that permanently secure the upper end  18  of the collar  10  to the extension  104 , or they may be of types that may be removed from the collar  10  and/or extension  104  once the repair is completed. The securing means may allow gaps (not shown) between the upper end  18  of the collar  10 , such that air or water displaced by the placement of fill material  110  between collar  10  and the pile  102  and extension  104  may exit the interior of the collar  10 . The securing devices, such as the anchor bolts  116 , may be placed below the support strap  34 , so that they support the support strap  34 , which distributes the weight of the collar  10  and repair material  118 . 
     The lower end  20  of the collar  10  is secured against the pile  102  by the strap  114 , such that the lower end  20  of the collar  10  is securely held against the perimeter of the pile  102 , without gaps. Other securing means which may be used include clamps, ratchet straps, hose clamps, tie straps, tensioning straps, etc. The securing means, such as the strap  114 , and the lower end  20  of the collar  10  may be arranged such that they will bear the weight of the repair material  118  without allowing leakage of the repair material  118  or damaging the lower end  20  of the collar  10 . The strap  114  and/or other securing means may be of a type that can be left in place after the repair of the pile  102  and extension  104  has been completed. 
     When the upper end  18  and lower end  20  of the collar  10  have been secured around the extension  104  and pile  102 , the repair material (e.g., an epoxy or grout) is delivered in a flowable state into a gap  120  formed between the collar  10  and the pile  102  and extension  104  through one or more of the funnels  40 ,  42 ,  44 ,  46  present around the perimeter of the upper end  18  of the collar  10 . The flowable repair material  118  may be delivered into the gap  120  by gravity-driven flow through the funnels  40 ,  42 ,  44 ,  46 , or by other means, which may include gravity-driven flow through tubes (not shown) inserted into the gap  120  through the funnels  40 ,  42 ,  46 ,  48 , or positive-pressure injection through such tubes. 
     The repair material  118  has such a composition that it hardens in place. While the repair material  118  is still flowable (i.e., before it hardens), it is manipulated into place by hand or by tools to fill the gap  120  from the lower end  20  of the collar  10  to the upper end  18  of the collar  10 . The composition of the repair material  118  may be such that, while still in a flowable state, the repair material flows into any gaps, spaces, or holes in the pile  102 , extension  104 , or connection  106 , so as to fill such gaps, spaces, or holes (e.g., bolt hole  112  or the hollowed-out space  108 ). When the repair material  118  has hardened, it provides structural strength to the marine support  100  by strengthening the pile  102  and/or extension  104 , and the connection  106  between the pile  102  and the extension  104 . 
     In some embodiments, the repair material  118  penetrates and/or bonds with the material of the pile  102 . In some embodiments, the repair material  118  penetrates and/or bonds with the material of the extension  104 . In some embodiments, the repair material  118  penetrates and/or bonds with the fabric of the collar  10 . Such bonding may occur through chemical bonding between the repair material  118  and the fabric of the collar  10 . Suitable repair materials may have one or more of the following properties: high strength (e.g., compressive strength, tensile strength, shear strength, compressive strength, etc.); low viscosity in its flowable form; early high strength and adhesive ability; low heat build-up while hardening; non-corrosive to the materials of the collar  10  or marine support  100 ; freeze and thaw resistant; and little to no shrinkage while hardening. A suitable grout for use in the present invention is SikaGrout® 300 PT (Sika Corporation, 201 Polito Avenue, Lyndhurst, N.J. 07071). A suitable epoxy for use in the present invention is Sikadur® 35, Hi-Mod LV (Sika Corporation, 201 Polito Avenue, Lyndhurst, N.J. 07071). Methods of preparing and handling such grouts and epoxies in the field are known in the art. 
     Continuing to refer to  FIGS. 12 and 13 , in an embodiment of the present invention, the repaired support  100  comprises the pile  102 , the extension  104 , the connection  106 , the collar  10 , and the repair material  118  in combination. In some embodiments of the combination, the collar  10  is fabricated and placed such that the upper segment  12  and lower segment  14  of the collar  10  cover the full extent of the damaged or deteriorated areas of the extension  104  or pile  102 . The repaired support  100  may include the support strap  34  and the auxiliary securing means, such as the anchor bolts  116 , for the upper end  18  of the collar  10 . The repaired support  100  may also include the securing means, such as the strap  114 , for the lower end  20  of the collar  10 . In some embodiments, the repair material  118  penetrates and/or is bonded to one or more of the pile  102 , the extension  104 , the connection  106 , and the fabric of the collar  10 , thereby binding the pile  102 , extension  104 , connection  106 , collar  10 , and repair material  118  into a composite structure. 
     The collar  10  and the method of the present invention may be used with piles and/or extensions of timber, concrete, metal, or other structural materials. The flexibility of the collar  10 , as well as the flowability of the repair material, allow the collar  10  and the method of the present invention to be used to repair marine supports where the pile has become displaced such that it is no longer centered in the extension, or where the pile was originally installed off center. Further, although  FIGS. 1, 8, 9, and 11  show the upper segment  12  and lower segment  14  of the collar  10  as having circular cross-sections, the collar  10  can readily be fabricated to accommodate piles and extensions having non-circular cross-sections by shaping the upper segment  12 , lower segment  12 , middle segment  16 , and/or the support strap  34  to match the perimeter of the cross-section. Such cross-sections include square cross-sections, non-square rectangular cross-sections, non-circular elliptical cross-sections, and cross-sections having other regular or irregular shapes. 
     It should be understood that the embodiments of the invention described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the invention, as described in the claims appended hereto.