Choosing the right type of sheet piles can often be confusing, especially when determining what best suits your needs for soil protection against erosion or resistance to water pressure. At ESC, we're committed to guiding you in selecting the most economical and long-lasting solution tailored to your requirements.
Steel sheet piling began its journey over a century ago as flat sheets, primarily used in cellular cofferdams and similar structures. Over time, the evolution of hot-rolled sheet piles advanced from these initial flat designs to U-shaped profiles and, eventually, to the Z-shaped sections that dominate modern installations.
The patenting of the Larssen interlocking system in 1914 marked a pivotal moment in the development of sheet piles. This innovative system was revolutionary because it integrated interlocks directly onto the sheet pile along its neutral axis during manufacturing, as opposed to earlier methods where interlocks were added post-production. The Z-shaped profile, combined with integrated interlocks, has proven so effective that it remains the industry standard. This enduring design continues to be a reliable and essential construction solution, poised to serve the industry for years to come.
On the other hand, cold-formed steel sheet piles entered the market and were first sold around the mid-1970s. They were sold to a client in quantities exceeding half a mile, with shapes similar to those of hot-rolled sheet piles. However, there are notable differences, particularly in their manufacturing methods.
Manufacturing Methods: Hot-Rolled vs Cold-Formed Sheet Piles
The manufacturing process of hot-rolled sheet piles involves heating pre-rolled steel beam blanks to extreme temperatures, enabling straightforward molding and shaping through a one- or two-step procedure.
The process begins with a large rectangular steel beam, known as a billet, which is heated to temperatures exceeding 1,700 degrees Fahrenheit. At this intense heat, the steel becomes highly malleable, making it ideal for shaping into sheet pile configurations. The heated billet is first flattened into a large roll during the initial production phase.
Finally, while maintaining these extreme temperatures, the steel roll passes through a series of rollers that meticulously shape and form it to achieve the precise dimensions and profile required for the sheet pile.
Unlike its counterpart, cold-rolled sheet piles, the production of cold-formed sheet piles follows a distinct two-phase manufacturing process. The first phase begins similarly to hot-rolled production, where a steel billet is heated and rolled into coils.
However, unlike hot-rolled sheet piles, these coils are allowed to cool completely before undergoing further processing. In the second phase, the cooled coils are fed through a specialized mill at room temperature, where they are shaped into their final configuration. This room-temperature forming process allows for the creation of various profiles, including flat, U-shaped, and Z-shaped sections. This method differs significantly from hot-rolled production, as the final shaping occurs after the steel has completely cooled, rather than while it is still at high temperatures.
While both hot-rolled and cold-formed steel sheet piles meet the ASTM 572 Grade 50 specifications and share similar material properties, their primary distinction lies in their interlocking systems. Cold-formed sheet piles feature standardized interlocks that are largely universal across different manufacturers, allowing them to be easily connected regardless of their origin. In contrast, hot-rolled sheet piles typically utilize manufacturer-specific interlocking systems, which can lead to compatibility issues when attempting to connect sheet piles from different suppliers. As a result, hot-rolled sheet piles generally need to be sourced from the same manufacturer to ensure proper interlocking and prevent connection problems during installation.
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Installation
With differences in manufacturing methods, cold-formed and hot-formed sheet piles also have different approach in driving into the ground. Where some would say that cold-formed are hard to drive out but easier to thread and drive, while other contractors says that it takes more precision to drive cold-formed in piling vertically, where veteran or experienced pile drivers are needed.
Cold formed easy to use on temporary projects. because it is better in multiple driving and pulling. As to water tightness, there’s not much to differentiate as these depends on the pressure exerted on the wall and other elements occurring in the interlocks.
Cold-rolled sheet piles offer significantly greater flexibility in positioning thanks to their interlocking system that allows for a 25-degree rotation. This is a considerable advantage over hot-rolled sheet piles, which use ball-and-socket interlocks that only permit a more limited 7-to-10-degree rotation. This enhanced rotational capability makes cold-rolled sheet piles more adaptable when installing curved walls or navigating challenging alignments.
While on the other hand, Hot-rolled sheet piles feature thicker and tighter interlocking systems that operate very effectively in difficult soil conditions. These robust interlocks give the sheet piles enhanced structural integrity and durability, making them particularly well-suited for hard driving conditions. When compared to cold-rolled sheet piles, this stronger interlocking system allows hot-rolled sheet piles to better withstand the intense forces encountered during installation in tough ground conditions.
Hot-rolled or Cold-Formed?
Now that we’ve talked about on how it was manufactured and installed. Here’s some additional advantages depending on which sheet piles fits your needing:
The robust design of hot-rolled sheet pile interlocks enables multiple cycles of driving and extraction without significant wear, making them ideal for reusable applications.
With thicker and tighter interlocks compared to cold-rolled alternatives, hot-rolled sheet piles demonstrate superior strength when driving through challenging ground conditions.
Hot-rolled sheet piles contain nearly 100% recycled steel content, surpassing cold-rolled's typical 80% recycled content, making them more advantageous for projects with LEED certification requirements.
The tighter interlocking system of hot-rolled sheet piles provides superior performance in seepage tests, resulting in better water-tightness compared to cold-rolled alternatives.
Greater Availability where usually available in two weeks, this product is produced in greater quantities with a wider range of rolling dates.
Lower the Cost where cold-formed sheet piles have been selling for approximately 200 to 400 dollars a ton less that hot-rolled. Which can save a lot of clients into their sheet piling projects.
Lower Transportation Costs, an increased number of manufacturers increases the likelihood of locating a local supplier. Additionally, providing more size alternatives aids in aligning with design requirements without significantly increasing weight
Greater Flexibility with Interlocks allow for a 25-degree rotation, compared to the 7-10 degrees of hot-rolled sheet piles.
Now that you have read out the different qualities and characteristics on Hot-rolled or Cold-formed Steel Sheet Piles, We at ESC offers a lot of sizes and shapes varying in thickness and in weight that can cater your construction piling needs. Contact us now at www.escpile.com and we can serve you with the finest product available globally.