Item #: 6d_Supp 
Date: August 7, 2012 

Terminal 18 Pilot Pile Cap Repairs 
August 7, 2012 



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Progress Update 
MONTHS          ACTIVITY 
May-December 2011      Design & Permitting 
March-July 2012         50% Construction 
August-November 2012    100% Construction 
November-December 2012  Report & Closeout 



2

Knowledge Gained 
What has been learned so far from the pilot project? 
Concrete demolition  initially took longer than originally expected. The Pilot is
helping us develop means & methods to reduce the amount of material to
remove, and to speed up demolition where it is called for. 
Re-bar sandblasting - initially slower than expected. The Pilot allows 
experimenting with different equipment to improve and speed it up. 
Splicing in of new re-bar - initially the number of locations was unknown until
demolition and sandblasting were completed. The Pilot is helping estimate
future need for splices, and to improve efficiency of splicing. 
Grout placement into forms - has been challenging. The Pilot is enabling us to
refine the specs for grout, and to match the grout to pumping equipment. 
The Pilot has demonstrated that areas with greatest distress correlate to
percussion testing. The Pilot is also identifying other ways to predict problem
areas  such as location of "dobies", which supported re-bar in forms during
original construction. 
3

T18 Pilot Pile Cap Repair Breakdown 

Longitudinal
cracking only 

Delamination only 


Longitudinal
cracking and
delamination 

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Benefits to Completing 4 Bents 
What additional knowledge can be gained from the pilot project? 
The first two bents under the Pilot provided production rates for initial set up,
mobilization and repairs. Including the second two bents under the Pilot will
demonstrate how much production rates accelerate once set up and running. 
Application of knowledge and skills gained repairing the first two pile caps will
be applied on the next two caps to further improvements and efficiencies. 
Repairing all four pile caps will enable us to more accurately correlate exterior
conditions from percussion testing and other means with actual conditions
inside the caps. This stands to reduce repair costs by foregoing repairs where
they are not needed. Likewise, it ensures repairs are performed where needed. 

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