New composite piers benefit marine environment
Vol. 16, No. 38Aug. 7, 1997

Practical application
New composite piers benefit marine environment

On July 17, officials of the Delaware River and Bay Authority (DRBA)-joined by representatives of the University, Hardcore DuPont Composites, the Federal Highway Administration and local dignitaries-dedicated a new composite pier fendering system at the L ewes terminal pier, the largest marine fender application of composite technology in the world.

The system was developed by Hardcore, a New Castle, Del.-based company whose president and CEO is George Tunis, Delaware '87. Hardcore has worked with researchers in the University's Center for Composite Materials (CCM) for the past several years in the d evelopment and testing of composites for this application and others, including bridge decks and rail cars.

The project involved replacing more than 1,000 wood piles with a composite system of 44 fiberglass tubular piles, a stay-in-place fiberglass framework and seven fiberglass fender panels.

The new structure is part of a larger system that includes more than 20 composite fenders surrounding the ferry pier, which were installed last year. More than 60 similar fenders were installed around the pier in Cape May, N.J., at the same time.

"The ferry plays an integral role in both transportation and tourism for Sussex County," said DRBA Commissioner Richard Derrickson, referring to the 393,000 vehicles and nearly 1.3 million passengers the ferry handled last year. "With this type of innovat ive improvement, the ferry system will continue to effectively serve our region well into the next century."

"This project is an excellent example of how composites are being commercialized for transportation-related applications," Jack Gillespie, technical director of CCM, said. "The new, lightweight ferry fendering system offers ease of installation as well as lower acquisition and life-cycle costs over traditional materials like wood. The system is projected to pay for itself over time through reduced maintenance costs."

Tunis said, "The Hardcore pile will outlast the replaced wood system by a factor of 10. These piles are guaranteed never to rot, rust or be attacked by any biological element, including marine borers and termites.

Elimination of the need for creosote and pesticides has had an immediate effect on the aquatic environment; water clarity and quality have improved to virgin levels.

"Working together, the DRBA, Hardcore DuPont Composites, Hudson Engineers, the University of Delaware and Martin Imbach Inc. created a state-of-the-art composite system to protect the public and the assets of the DRBA against ship docking forces," Tunis c ontinued.

"The team approach resulted in record development time, lower acquisition costs and fast, efficient, safe construction."

Gillespie commended Tunis for his innovativeness and entrepreneurship, which have resulted in Hardcore becoming the world leader in large-scale composite structures and bringing dozens of new jobs to Delaware, many of them filled by UD grads. The company has grown from three to more than 80 employees since 1994; of Hardcore's 32 professional staff members, 14 are UD alumni.

--Diane Kukich<