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CHAMPION SPLICER HP – 30000

Champion Splicers – approved and used to extend H-piles in New York City as early as 1955. They have been utilized across the country and around the world for the past forty years, with no failures. Tests at New York State "Campus" Site on HP 14x73 driven to 200-ft. depth with three Champion Splicers and loaded to 400 tons led to approval of the Splicer for 3,000 piles in 1962.

There have been many unusual and repeated projects; a few have been recorded in PILETIPS. Here are some condensations:

THREE RETURNS TO POWER PLANT
For a power plant along the Ohio River, Stanley Consultants, with Dames & Moore, specified Pruyn Points and approved Champion Splicers, HP-30000 for 14in. H-piles to be driven into heavy clay and boulders. In 1972, Richard Goettle used a 60,000 ft-lb hammer to drive, then a Foster 275E vibratory to pull test piles. Despite hard driving to over 115-ft. depth – and harder pulling -- the piles, points and splicers were intact. This was observed very closely as the piles were partially installed with the vibratory.

In 1974, Goettle was back to drive 600 HP 14 and HP 10 with specified APF points and splicers. In 1976, E.E. Gillen Co. drove 1200 piles with specified Pruyn Points and Champion Splicers. In 1977, Goettle returned to drive 350 piles, many of which had two Champion Splicers. Repeat use of APF points and splicers over several years proves their value for design and their economy for contractors.

GE TURBINE TEST PLANT
Support for a General Electric turbine test facility where NO settlement could be tolerated is on 400 HP 14x73 driven by Carter Pile Driving, Inc. A 60-ft length was driven to convenient working height above the ground. The HP-30000 splicer was slipped on the driven length. A 30-ft. section was set into the splicer and corners welded. The crane moved on to the next pile while single-pass groove welds were made along flanges.

FOUR PIERS AT GROTON SUB BASE
Champion Splicers, HP-30000, have been approved for four successive pier installations at the U.S. Submarine base at Groton-New London, CT. Navy personnel designed one of the piers. Different consultants prepared plans for others. All projects used APF's cast steel points to secure a toe-hold on sloping rock with piles battered as steeply as 1:2-1/2.

Water is deep, piles are long, one or two Champion Splicers, HP-30000, were used for each pile with APF Pruyn Point protection. Splicers were especially advantageous as driving was done from floating rigs where there is continuous movement. With the Champion fixed on one length, the added section could be quickly positioned and held securely while welds were made along each flange and at each corner of the splicer.

INDICATOR PROVES STRAIGHT DRIVING
HP 14x73 driven to 200 ft depth at a 1:3 batter stayed within two percent of plan location despite use of three lengths and two Champion Splicers. The project is a power plant along the Hudson River designed and built by Burns & Roe as a turnkey project for a power consortium.

With Champion Splicers pre-attached almost continuous driving could be achieved. In this and others, soils friction sets-up quickly requiring extra blows and time to get the pile moving.

To verify that the piles were in proper location to carry 100 tons design loads checking with a Digitilt Slope Indicator was required on several piles. Deviation from specific batter averaged under 2% on either axis.

The HP 14x73 were protected by Pruyn Points for driving into boulders and hard clays to irregular rock at 150 to 200 ft depth. Driving was done with a Vulcan 0-10(32,000ft-lb) hammer.

TEST GAINS ACCEPTANCE
Engineers who had no previous experience with Champion Splicers were reluctant to accept the HP-30000 unit as equivalent to the specified full penetration butt weld. Structures were high and hurricanes occur at the northeast Florida site.

The APF Champion H-pile Splicer has been proven by use, tests and observation over many years in practically every state and in all types of soils. Many piles with APF Splicers have been driven, test loaded and pulled. Observations have been analyzed by job forces and reported by APF engineers. There are no known failures of APF Champion Splicers.

Tests made at the highly qualified Fritz Engineering Laboratory at Lehigh University proved the Champion Splicer to be a strong, effective splice. Tests were made on HP 14x89 and HP 10x42 on both XX and YY axis to provide complete proof of the integrity of the splicer. These tests cover the full range of H-piles; loading on the YY weak axis is of top importance as the loads may come on the pile in any direction.

Piles were prepared for testing by regular workmen following APF details for making the splice. Under loading to destruction, failure in each case occurred by crippling of the pile outside of the splice area. This is to be expected as the tight fitting, strong Champion Splicer supports the flanges against bending and failure.

The sketches and chats show the results of loading to failure. The loads applied on the weak and strong axis corresponding closely to the full moment capacity of identical unspliced beams. The test pieces, with the Champion steel H-pile splicer, had sufficient strength and ductility to develop the full capacity of the member when loaded on either the YY or XX axis. The elongation across the tension side of the splice translates into tension value of the connection. Since this is only one side, the uplift resistance across the joint is actually double the value shown.

NOTE:  IN ORDER TO ACHIEVE    
THE FULL VALUE OF THE PILE

IN BENDNG, SPECIAL WELDING

INSTRUCTIONS ARE REQUIRED

 

In all cases, failure was simply loss of capacity under increasing deformations-not a catastrophic collapse. More than adequate capacity to resist rotation was provided by the Champion H-pile Splicer as evidenced by the large deflections sustained before failure-which occurred outside the splice area.

The Champion Splicer is fabricated with close control of the space for insertion of each weight of the H by a heavily welded bar. With tight fit against the flanges and accurately formed corners for easy entry, the HP-30000 is best for load carrying ability and speed of construction. The strength and integrity of a splice is jeopardized if there is a loose fit. A loose fit is dangerous to workmen, especially where they have come to rely on the security of the APF Champion Splicer.

Owners and their engineers can benefit form the exceptional strength capability of the Champion Splicer. Contractors gain from its uniformity, dependability and prompt availability to speed construction.

APF Champion Splicer is the safest and fastest means to extend H-piles. It is approved by public agencies and is accepted by federal authorities. The Champion Splicer is the time-saving favorite of knowledgeable engineers and foundation contractors. Specify and use the APF Champion Splicer, HP-30000, for the best solution to extending H-piles.

 


The Federal Highway Administration, other U.S. government agencies, state transportation departments and almost all jurisdictions accept and approve the APF Champion Splicer for H-piles when attached as recommended by Associated Pile & Fitting Corp. This is simple, rapid and economical.

A simple bevel is burned along the outside of each flange of the section of H to be added. A 2x2in. angle can be used as a guide for the torch. A notch for the heavily welded spacer is cut in the web of the H. This can be in either length of H as the spacer is offset to require only one cut.

The Champion Splicer is slipped on the H and a 2-1/2 in. length of 5/16-in. weld made near each corner of the splicer. Doing this in advance saves time for the crew as it quickly aligns and holds the added length. Safety is greatly improved as the top section is held securely against wind gusts or crane movement. Use of the APF Champion Splicer speeds the connection and release of the handling equipment. Positioning lugs are not needed. Exact alignment of the pile is assured.


KEEP PILE STRAIGHT
Keep the added length of H in axial alignment. If the lower section drives a little out of position accept that and add in a straight line. The Illinois Department of Transportation estimates a 1:12 batter pile to have 98.8% bearing value, 2:12 is 97%; 3:12 is 94.6% and even a sharp 4:12 is 91.7%. (PILETIPS July - August 1980) This is well within usual safety factors and will be far better than welding in a dog-leg at the splice.

The simplest solution for correct location is to always start the pile in accurate position and careful alignment. Check with a long carpenter's level and re-check as driving starts. For batter piles, plywood cut to the slope is attached to the level.

FULL PENETRATION ALTERNATE
Prior to introduction of the Champion Splicer, the slower and more costly butt weld was the accepted method of extending H-piles. This alternative to the quickly installed and safer Champion Splicer requires a full penetration butt weld across both flanges and the web. To attain full penetration welds, plates should be used to back up the weld or the weld should be back gouged to good metal and filled in. For welding, flanges should be accurately aligned with plates and wedges. (Bethlehem Steel /corp. H-pile book.)

Small details make a Big Difference
APF HP-30000 Champion Splicers are
die-formed for consistent sizing
and precise fit.
Others are not.

THE CHAMPION SPLICER
JOB SAFETY, SPEED, ECONOMY
Associated Pile & Fitting Corp. developed, tested and proved the one H-pile splicer that is safest to install, economical and most dependable of all means of extending driven H-piles. The Champion Splicer, HP-30000, is precision formed and accurately sized for each size and weight of H-pile. It is available for stock for immediate shipment.

The Champion is imitated but never duplicated. Bends and even beveling do little to ease or speed installation. Only the Champion has been proven by professional laboratory testing plus forty years of use.

CHAMPION H-PILE SPLICER
The Champion Splicer speeds production. It is placed in advance on one length of pile. The outside bottom edge of each flange of the top section is scarfed to accommodate a bevel weld. The new piece is quickly positioned over the driven pile and slipped into the accurately flared Champion. The heavily welded spacer holds the splicer components strongly; it accurately aligns the web and flanges of the added length. This firm connection eliminates the need for alignment lugs and wedges that must otherwise be welded on the pile and later removed.

The Champion Splicer adds to job safety. It is already in place on one length of pile and slides quickly on the other section. This prevents wind gusts or sudden crane movement swinging the pile dangerously as workmen move in to make simple welds along each flange and short fillet welds near the corners of the splicer. The Champion Splicer is especially helpful when driving from floating equipment where there is always movement. Connection is speeded and the piles kept in accurate alignment for welding, with safety.