Sheet Piles vs. Bored Secant Piles: Structural Insights with ESC Steel
- ESC Steel LLC
- 7 hours ago
- 7 min read
In the realm of geotechnical and foundation engineering, retaining wall systems serve as the backbone of safe, efficient, and cost-effective construction practices. Among the most widely applied solutions are bored secant piles and steel sheet piles. While both systems offer structural support and excavation protection, their design characteristics, construction methodologies, and performance capabilities differ significantly.
This article explores the functional distinctions between bored secant piles and sheet piles, highlights the advantages of sheet pile foundations, and spotlights a major international case study—ESC Steel’s contribution to Haiti’s Port Lafito, the country’s first Panamax port.
Understanding Bored Secant Piles and Sheet Piles
Bored Secant Piles
Bored secant piles are deep foundation elements constructed by drilling overlapping concrete piles. The term “secant” refers to the intersecting design where each pile partially overlaps with the previous one, forming a continuous subterranean wall. This method typically involves a primary pile followed by secondary piles, which may include steel reinforcement to enhance structural performance.
Key Features:
Ideal for deep excavations
Effective as groundwater barriers
Minimizes ground movement
Installed via rotary drilling rigs
Typically, more expensive due to time, equipment, and curing requirements
Steel Sheet Piles
Sheet piles are prefabricated steel sections with vertical interlocks that allow the panels to form a continuous wall when driven into the ground. These are widely used for both temporary and permanent applications, such as quay walls, basements, cutoff barriers, slope protection, and cofferdams.
ESC Steel, a global distributor of sheet pile products, supplies one of the world’s most expansive ranges of sheet pile solutions. The company offers over 450 profiles across 13 different design series, varying in thickness from 3mm to 22mm and widths ranging from 400mm to 1800mm. ESC’s portfolio includes hot rolled, cold rolled, and cold formed sheet piles—making it a pioneer in wide-profile cold formed piles backed by global patents.
Key Features:
Rapid installation
High water seepage resistance
Efficient use of space
Flexible configurations
Available in steel, vinyl, and composite materials
Comparative Analysis: Bored Secant vs. Sheet Pile Systems
Feature |
Bored Secant Piles |
ESC Steel Sheet Piles |
Material | Reinforced concrete | Steel, vinyl, composite |
Installation Method | Drilled, overlapped | Driven or vibrated into the ground |
Structural Depth | Suited for deep foundations | Optimized for shallow to medium-depth applications |
Water Resistance | Excellent, especially with full overlap | High, enhanced by ESC’s interlock and clutch systems |
Speed of Installation | Slower, due to curing and complexity | Rapid, efficient, scalable |
Cost Efficiency | Higher costs due to labor and materials | Cost-effective and reusable |
Environmental Impact | Low vibration but heavy equipment | ESC designs minimize noise and site disruption |
The Benefits of Sheet Pile Foundations
Sheet piles offer a wealth of advantages that make them suitable for diverse engineering conditions:
Speed and Efficiency:
Sheet pile installations are typically faster than cast-in-place systems. Prefabricated sections are delivered to site ready for driving, minimizing on-site labor and eliminating the need for excavation prior to wall placement.
Versatility:
ESC sheet piles perform reliably across various soil types and geotechnical environments. Whether installed in loose sand, clay, or gravel, sheet piles offer consistent earth retention and groundwater protection.
Water Seepage Control:
Interlocking designs greatly reduce the permeability of the wall. For flood defenses, waterfront developments, and basements, ESC’s advanced interlock engineering plays a crucial role.
Space Optimization:
Sheet pile walls occupy minimal footprint—crucial for tight construction zones, especially in urban environments where maximizing usable space is imperative.
Economic Value:
ESC's sheet piles can be reused, reducing lifecycle costs. For temporary structures, the ability to remove and redeploy piles enhances sustainability and cost-effectiveness.
Durability and Performance:
ESC sheet piles have been tested and validated in projects worldwide for their long-term structural resilience and resistance to corrosion and settlement.
Zoning Compliance and Commercial Flexibility:
In the evolving commercial building industry, updating facilities to meet zoning requirements is commonplace. Sheet pile foundations offer a practical solution, especially for below-grade parking areas and basements, by delivering strength, speed, and spatial efficiency.
ESC’s Global Legacy in Sheet Pile Applications
ESC Steel has demonstrated unparalleled expertise in steel sheet pile design, manufacture, and delivery. The company has supplied projects ranging in size from just 8 tons up to over 20,000 tons and has delivered to every continent—including Antarctica. ESC’s sheet piles are manufactured to industry standards such as BS EN 10248 and BS EN 10249 and are available in a variety of steel grades suited to demanding environments.
ESC offers sheet piles manufactured via two key methods:
Hot Rolled Sheet Piles:
Rolled at elevated temperatures
Tighter interlock clutches
Greater profile thickness
Cold Rolled / Cold Formed Sheet Piles:
Formed at room temperature
Uniform thickness
Wide range of widths and depths
Cold forming allows production in discrete lengths, offering flexibility
ESC Case Study 1: Port Lafito, Haiti
A testament to ESC Steel’s engineering and logistical capabilities is its pivotal role in the construction of Haiti’s Port Lafito—a landmark infrastructure project with profound economic implications for the Caribbean region.
Overview:
Port Lafito is Haiti’s first Panamax port, built with state-of-the-art equipment and infrastructure. The port was developed to revitalize the nation’s logistics, employment, and trade sectors. It serves over 10 million people and is set to generate thousands of jobs. In collaboration with SSA Marine, the world’s largest privately held marine terminal operator, the port has been positioned as a premier regional hub.
In addition, Port Lafito signed an International Sister Seaport agreement with Port Miami to foster bilateral cooperation in logistics and maritime operations.
ESC’s Scope of Supply:
Agro Products and Services, representing the GB Group’s interests in the port, awarded ESC Steel a comprehensive sheet pile contract for berth and quay wall construction. The supply included:
2,410 tons of ESC-CRZ26-635 sheet piles made from ASTM A572 Grade 50 steel, with lengths between 12m and 25m, including three custom corner piles
193 sets of 20.9m tie rods and 136 sets of 6.5m tie rods, manufactured to Grade 700 and M85 specifications
191 tons of hot rolled C Channel waling beams in 12m sections
8 cast T-Horn mooring bollards rated at 50-ton Safe Working Load (SWL)
Project Impact:
Port Lafito is part of a larger initiative—Lafito Global—an economic zone encompassing the port, industrial free zones, a business park, and residential developments. The development is expected to create more than 25,000 jobs, attract international investment, and establish Haiti as a logistical and industrial hub in the Caribbean.
ESC’s contribution was critical to enabling:
Water-tight earth retention systems for quay walls
Structural support for marine berthing facilities
Rapid and efficient installation under challenging tidal and geotechnical conditions
This project is a model of how advanced engineering, logistical precision, and high-performance materials converge to produce meaningful economic transformation. ESC Steel’s ability to design, manufacture, and deliver tailored sheet pile solutions made Port Lafito’s construction successful under complex requirements.
ESC Case Study 2: Melaka River Beautification Works – Malaysia
The Melaka River Beautification Project stands as a testament to how infrastructure can transform urban environments and restore cultural heritage. Melaka, a historic city in Malaysia, had long been a popular destination for both domestic and international tourists. However, years of unauthorized construction and industrial waste dumping had severely degraded the river’s condition, making it unsuitable for tourism and public use.
In response, the Government of Melaka launched a comprehensive initiative to rehabilitate the river, improve water quality, and create a pedestrian-friendly waterfront stretching over 5 kilometers from the river mouth. The goal was not only environmental restoration but also urban revitalization—making the river a centerpiece of the city’s tourism and community life.
ESC’s Role and Scope of Supply
In 2005, Pesona Metro Sdn Bhd approached ESC Steel for assistance in designing, manufacturing, and installing a sheet pile solution that would support the ambitious beautification plan. The project required a long-term structural solution with a design life of 50 years, while also accommodating new sewage infrastructure along the riverbanks.
ESC supplied over 3,000 metric tons of sheet piles, with profiles tailored to the varying conditions and aesthetic requirements of each section. Some piles were hot-dip galvanized, while others were coated with coal tar epoxy, depending on environmental exposure and design specifications. The sheet piles were primarily used to form an aesthetic river frontage, with reinforced concrete piles supporting the pedestrian walkways—allowing the sheet piles to serve a non-load-bearing but visually critical role.
Collaborative Execution and Long-Term Impact
The project was executed in close collaboration with consultants SMHB of Malaysia and the Government of Melaka. Over a four-year period, ESC worked alongside all stakeholders from the design phase through to completion, ensuring that the sheet pile systems met both technical and aesthetic goals.
Beyond the engineering achievement, the project included a major cleanup of the river and an educational campaign for residents and industries to prevent future pollution. The revitalized river now accommodates larger tourist boats and offers uninterrupted pedestrian access, helping restore Melaka’s reputation as a cultural and tourism hub.
ESC’s cost-effective design and locally manufactured sheet piles were instrumental in securing the scope of work and delivering a solution that balanced durability, environmental sensitivity, and visual appeal.
Conclusion
The structural differences between bored secant piles and sheet piles present a clear choice depending on project demands, site conditions, and performance expectations. While secant piles excel in deep excavation and groundwater retention, sheet piles—particularly those engineered by ESC Steel—offer unmatched advantages in speed, versatility, and global adaptability.
ESC Steel has consistently demonstrated its leadership in the sheet pile market through innovation, scale, and reliability. Its contribution to Port Lafito underscores the role of smart foundation systems in building modern infrastructure that drives economic growth and resilience.
For contractors, engineers, and developers exploring below-grade solutions for commercial buildings, ports, or urban expansions, ESC Steel offers an exceptional portfolio backed by real-world results.
To explore ESC’s complete product range or to receive expert consultation tailored to your project, Visit our website - www.escsteel.com reach out today and build with confidence.
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