Sheet pile components and process for making the same

1. A method for manufacturing a sheet pile wall component having a longitudinal edge and at least one interlock at the longitudinal edge; the at least one interlock being a profiled section that is integral with a remaining section of the sheet pile wall component, the at least one interlock having a uniform cross-section extending across an entire length of the sheet pile wall component, for engaging an interlock of an additional sheet pile wall component, said method comprising the steps of:

producing a preliminary product through forming, wherein a material accumulation is formed during the forming of the preliminary product at a section that is to be provided with the at least one interlock while the remaining section is free of material accumulation; and

shape-cutting the at least one interlock at a section of the preliminary product that is to be provided with the at least one interlock, wherein the cross-section of said material accumulation is dimensioned sufficiently upon forming such that dimensional deviations caused by the forming of the preliminary product are taken into account for the shape-cutting of the at least one interlock.

2. The method as set forth in claim 1 , wherein the material accumulation is molded during the forming of the preliminary product such that the material accumulation has a basic shape of the at least one interlock to be produced when viewed cross-sectionally.

3. The method as set forth in claim 2 , further comprising, after the step of shape-cutting, forming the section of the preliminary product that is to be provided with the at least one interlock to a final interlock shape.

4. The method as set forth in claim 3 , wherein the step of forming the section after shape-cutting to form the final interlock shape includes heating to a heat forming temperature.

5. The method as set forth in claim 1 , wherein the shape-cutting of the at least one interlock is carried out through several chip-removing tools, in several successive processing steps.

6. The method as set forth in claim 1 , wherein the shape-cutting is performed using at least one cutting tool with a geometrically defined cutting edge.

7. The method as set forth in claim 1 , wherein said section of the preliminary product is guided past a stationary processing station for shape-cutting.

8. The method as set forth in claim 1 , wherein the at least one interlock is created using a mobile processing station.

9. The method as set forth in claim 1 , wherein the shape-cutting is carried out through at least one of form-milling and form-grinding.

10. The method as set forth in claim 1 , wherein the shape-cutting is carried out immediately following the forming of the preliminary product.

11. The method as set forth in claim 1 , wherein said at least one interlock is introduced in said material accumulation through shape-cutting.

12. The method as set forth in claim 11 , wherein the at least one interlock is formed into a final interlock shape after shape-cutting through subsequent forming.

13. The method as set forth in claim 12 , wherein the formed final interlock is selected from the group consisting of a Larssen interlock, a Hoesch claw, a Hoesch button, a ball interlock, a socket interlock, a flat profile interlock, a trapezoidal groove, a trapezoidal interlock, a trapezoidal flange and a dovetail groove.

14. The method as set forth in claim 1 , wherein the sheet pile wall component is a wedge-shaped carrier.

15. The method as set forth in claim 1 , wherein shape-cutting is performed using at least one cutting tool in the form of a grinding disk.