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 Process: Inventory Prioritize 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 8 Concrete Pile Cap Distress 9 Pile Cap Aging Apron Deck Uncracked pile cap 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 and surface cleaned Formwork installed Formwork removed Concrete placed Scaffolding and plastic 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: $930,600 BERTH 6: $2,376,400 BERTH 4: $14,405,800 BERTH 5: $5,047,800 BERTH 2: $3,010,000 BERTH 3: $2,823,000 Berth 1: $4,031,600 $600,000 $500,000 $400,000 $300,000 $200,000 $100,000 301 281 261 241 221 201 181 161 141 121 101 81 61 41 21 1 $- *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