ITEM NO:       7d_Supp
DATE OF MEETING: May 10, 2011

TERMINAL 18 PILE CAPS
Seaport Asset Stewardship Strategy
MAY 10, 2011


1

Seaport Asset Stewardship Strategy
Condition
Assessment
Inventory     Prioritize
Process:


Maintain      Inspect

2

Inventory
Docks
(30,950 Lineal Feet)
Buildings
(1,259,836 Square Feet)
Yards (969 Acres)

3

Prioritize
Age (30-50 Years)
Condition (Known Issues)
Value (Revenues)

4

Inspect
Docks
Berth Depth
Bulkhead
Deck
Pile Caps
Piles
Utilities

5

Concrete Dock Concerns



Concrete Pile Cap Distress
DEF in Concrete Piles
6

Container Terminal    Crane Rail
Crane Rail
Pile Cap Beam    Support Pile
Structural Piles
Paving            Dock Apron                            Fender System


Soil

Seawall

Slope
Slope Armor
Toe Wall


7

"o'fSEat'the






8

Concrete Pile Cap Distress



9

Pile Cap Aging
Apron
Deck
Pile Cap                 Uncracked pile cap
Minor cracking begins
Water enters, corrosive
concrete starts forming
Cracks grow, concrete
is corrosive, reinforcing
corrodes, and concrete
spalls.
Pile

10

Pile Cap Repairs
Apron
Deck
Pile Cap                Cracking and corrosive
concrete
Corrosive concrete
removed
Surface chipped clean
New concrete placed
Pile

11

Repair Logistics
Corrosive concrete removed   Concrete
and surface cleaned        placed
Formwork  Formwork
Scaffolding and plastic
installed    removed
barrier installed
Scaffolding and plastic
barrier removed



Tidal
fluctuation

12

Seaport Facilities Comparison

Relative Structural Condition*
by Facility



T18    T46    T30    P66    T25    P90    T115    T5    P91
FACILITY
*Condition metric combines percentage of distressed areas and severity of distress.
(Distress does not include DEF testing results.)
13

T18 Pile Cap Repair Costs*
Total Estimated Costs = $32.6 Million
$700,000
UNDESIGNATED BERTH:   BERTH 6:      BERTH 5:        BERTH 4:       BERTH 3:        BERTH 2:         Berth 1:
$930,600   $2,376,400     $5,047,800       $14,405,800      $2,823,000       $3,010,000        $4,031,600
$600,000

$500,000

$400,000

$300,000

$200,000

$100,000

$-
1     21     41     61     81     101     121     141     161     181     201     221     241     261     281     301
*Preliminary estimates are in 2011 dollars and include design, permits, sales tax, contingency and other soft costs.
14

T18 Pile Cap Repair Risks
$30M - $50M
Access Issues
Work in Low Tides
Disrupts Operations
DEF Unknown
Other Unknowns
Pilot Project
Recommended

15

Delayed Ettringite Formation
DEF in Concrete Piles



16

DEF in Concrete Piles
Concrete
Steel
reinforcing bars
Typical concrete
cracking
DEF expansion
and cracking
DEF is Delayed Ettringite Formation. Ettringite crystals
form some number of years after the concrete is cast. They
break up the concrete as they grow and significantly
decrease the concrete's structural integrity.
Pile replacement is necessary.
17

Delayed Ettringite Formation
DEF in Concrete Piles
Recent pile inspections
confirmed DEF in two piles
Additional inspections and
testing underway
Results expected by
August 2011
Pile Cap issue secondary if
DEF is confirmed

18

T18 Pile Caps Repair Pilot Project
$1M to Repair Several Pile Caps in 2012
More Accurately Estimate Material and Labor Costs
Refine Repair Procedure to be More Time and
Cost-Efficient
Identify Impact of Access Issues
Document Contractor Production Rate
Find Ways to Reduce Disruption to Operations
Results will Benefit Pile Cap Repairs Needed at
Other Terminals as well as T18
19

TERMINAL 18 PILE CAPS
Seaport Asset Stewardship Strategy
MAY 10, 2011
20