To construct such piers in the ordinary manner behind coffer-dams, and in such an exposed location, was to involve expenditure far beyond that which the owner cared to incur. The writer's attention had shortly before been called to the successful use of reinforced concrete caissons on the Great Lakes for breakwater construction, by Major W.V. Judson, M. Am. Soc. C.E., and under patents held by that officer. It seemed that here was a solution of the problem. These caissons are constructed on the shore, preferably immediately adjoining the work. After thorough inspection and seasoning, they are usually launched in a manner somewhat similar to a boat, are towed into position, sunk in place, and then filled with rip-rap.
In this case what was needed was a structure that could be constructed safely and cheaply in the air, could then be allowed to harden thoroughly, and could finally be placed in accurate position. The weights to be supported were not great, the beach was good gravel and sand, fairly level, and, under favorable circumstances of good weather, the placing of the caissons promised to be a simple matter. Therefore, detailed plans were prepared for this structure.
An effort was made to preserve some element of the yachting idea in the design, and bow-string trusses, being merely enlarged gang planks, were used to connect the caissons.
The pier was originally laid out as a letter "L," with a main leg of 300 ft. and a short leg of 36 ft. The pier head consisted of eight caissons in close contact, and was intended to form a breakwater, in the angle of which, and protected from the wave action, was to be moored the float and boat landing. After the first bids were received, the owner wished to reduce the cost, and every other caisson in the pier head was omitted, so that, as built, the pier contains eight caissons and five 53-ft. trusses. The caissons supporting the trusses are 8 ft. wide and 12 ft. long, and those in the pier head are 12 by 12 ft. On account of the shoal water and the great height of the outer caissons in comparison with their cross-section, it seemed advisable to mould them in two sections. The reinforcement in the side walls consisted of round 1/2-in. rods horizontally, and 3/8-in. rods vertically, spaced as shown on [Fig. 1], together with cross-diaphragms as indicated.
The caissons were reinforced for exterior pressures, which were to be expected during the launching and towing into position, and also for interior pressures, which were to be expected at low tide, when the water pressure would be nothing, but the filling of the caissons would be effective. The corners were reinforced and enlarged. In order to secure a proper bedding into the sand foundation, a 12-in. lip was allowed to project all around the caisson below the bottom. In the bottom there was cast a 3-in. hole, and this was closed by a plug while the lower section was being towed into place.
The question of the effect of sea water on the concrete was given much thought. The writer is unable to find any authoritative opinions on this subject which are not directly controverted by equally authoritative opinions of a diametrically opposite nature. He thinks it is a question that this Society might well undertake to investigate promptly and thoroughly. There can be no question that there are many distressing instances of failures due to the action of sea water and frost on concrete, and that many able and experienced engineers in charge of the engineering departments of the great transportation companies have simply crossed concrete off their list of available materials when it comes to marine construction. It is a subject too large in itself to be discussed as subsidiary to a minor structure like the one herein described, and though many have rejected concrete under these conditions, other engineers equally conservative are using it freely and without fear.
The writer consulted with his partner and others at some length, and, considering all the advantages to accrue by the use of these concrete caissons, decided to do so after taking all known precautions.
Fig. 1.
These precautions consisted in: