Professional Documents
Culture Documents
Abstract
The port and harbour are one of the main sources of economic for many countries because
it is known as a place where import and export activities happen. Therefore, design and
construction of ports are important. It requires great attention to provide an adequate
structures. Futhermore, maintenance also play a very important roll in ensuring the
effeciency of the port operation in a certain period of time. This paper discusses the routine
survey, inspection, rehabilitation and repair of Sapangar Bay Oil Terminal, fourth biggest
tonnage in Sabah state after Kota Kinabalu, Sandakan and Tawau. The rehabilitation
consisted of structural repair and reconstruction to the pier structural. Both a condition
survey and a detailed structural survey were usually performed to gather information for
development of the structural repairs. The structural repairs were designed to extend the life
of the structure an additional twenty years. This paper will also discuss the common types
of problem, common causes of problems, maintenance work involved and materials or
equipments used according specification. The methodology used to conduct this study
includes literature search and interviews with the professional involved in port
maintenance.
Keywords: pier maintenance, pier repair, pier survey, port pier
1. INTRODUCTION
Maritime transportation has generally been
the most convenient and least expensive
means of transporting goods and this is why
mankind, since ancient times, has been
steadily extending its activities into this area.
Over centuries, transport of goods by means
of water transporting has been evolved in
steps with the needs of world trade and
technical capabilities to build larger ships
and ships/cargo handling facilities.
2. BACKGROUND STUDY
ix.
x.
II
III
Purpose
General
visual
to
confirm as
built
conditions
and severe
damage
Defect
surface defect
normally
obscured
by marine
growth
Detect
hidden and
imminent
damage
Detectable Defects
Steel
Concrete
Extensive
Major
corrosion
spalling
and
cracking
Severe
mechanical Severe
damage
reinforce
ment
corrosion
Moderate
mechanical
damage
Major
pitting
Reduced
thickness
of material
Broken
piles
Surface
cracking
and
crumbling
Rust
staining
Exposed
rebar
and/or
prestresse
d strands
Location
of rebar
Beginning
corrosion
of rebar
Internal
voids
Dynamic Testing
General
Pulse Velocity
Conditions
ft/sec
Excellent
Above 15 000
Good
12 000-15 000
Questionable
10 000-12 000
Poor
7000-10 000
Very Poor
below 7000
Generally, the degree of damage is related to
a reduction in pulse velocity.
Visual
observations
will
identify
deteriorated paint films that could developed
a common type of failure with certain types
of surface morphological features in terms
of peelings, delaminations, and flaking
pattern (Figure 13).
6. MAINTENANCE METHODS
During field inspections, damages on
concrete (Table 3) and steel pier (Table 4
were identified. Repairing works were then
performed accordingly. Typical types of
maintenance
were
specified
using
combination
of
materials
including
fiberglass jackets and pile wrapping.
Corrosion is primarily controlled by the
surface coating systems and sacrificial
cathodic protection systems.
Table 3: Summary Method of Repair, Damage
and Material/Equipment for Concrete
Methods
of repair
Damage
Pile Jacket
Deterioration
Patching
Spalling
Crack
injection
Cracks
Materials/
Equipments
Fibreglass reinforced
polymer (FRP)
jackets and Portland
cement based grouts/
concrete
1. Polymer mortar
Ex: Barra Mortar
L
2. Epoxy
Ex: Expocrete
1. Epoxy resin
Ex: Brutem 1100
2. Epoxy paste
Ex: Concressive
1441
Damage
1.
2.
3.
4.
Coating
Corrosion
Pile wrap
1.
2.
3.
4.
Corrosion
Rusting
Peeling
Pitting
Corrosion
Rusting
Peeling
Pitting
Materials/
Equipments
1.Epoxy
grout
Ex:
Sea
Shield 500
2.Marine
epoxy
Ex:
Sea
Shield
525
Epoxy
Petrolatumcoated tapes
Ex: Densyltape
Retrowrap
7. REPAIRING MATERIALS
Generally material used depending on the
size, location and various materials that are
available for repair. The following
influences the selection of materials; the
compatibility of the material to the original
concrete, environmental considerations,
including aesthetics, cost effectiveness,
expected service life, availability, and
familiarity of the contractors with the
product.
6.3 Coating
Non-metallic coatings are by far the leading
method for protecting steel in hostile
environments. They are usually cheaper on a
first cost basis than metalising or sacrificial
thickness and more reliable than cathodic
protection alone. Cathodic protection
functions only in the fully immersed zone
and may be difficult to maintain, over an
extended length of time.
7.1
Fiberglass
Jacket/Encapsulation
Repair Material
The fiberglass jacket thickness shall be of
minimum of 1/8 inch (3 millimeters),
constructed of layers of woven roving and
mat. The jacket shall be translucent to
provide visual inspection during the
injection of the epoxy grout. The jacket
shall have minimum one-inch injection ports
spaced at intervals not to exceed five feet.
To provide even distribution of the epoxy
grout, the injection ports shall be placed on
alternate sides. The jackets shall have standoffs adhered to the inside of the jacket to
provide a minimum of a 3/8 inch (8
millimeters) annulus between the pile and
the jacket.
a. Densyl Tape
Synthetic fiber-reinforced tape impregnated
and
coated
with
a
specially
formulated petrolatum-based
compound
containing inert filters, water displacing
agents, and wide spectrum biocides. The
tape provides a long lasting, anti-corrosion
membrane for steel and concrete surfaces.
Applied spirally, and with sufficient tension,
Denso Tapes displace water and develop a
water resistant bond. It provides the
corrosion protection.
8. DISCUSSION
There are suggested solutions to overcome
the current problems:
i. It is important to choose the best
construction/repair method as well as
experienced contractor to ensure the
quality of pier is constructed according
to the requirement. On the other hand,
timely and effective maintenance can
extend a piers life.
ii. To obtain the best result during repair,
using the right equipments and
materials with experienced can give the
best result and prevent any serious
damage in the future. Otherwise, the
same damage will occur after the repair.
a. Retrowrap
Retrowrap is a wrap around corrosion
protection system specifically designed to
provide an easily installed retrofit
installation for use on sub-sea jetty piles
through the splash zone.
Retrowraps
elastomeric properties and flanged closure
system provides the unique facility of
removal and subsequent replacement to
facilitate routine inspection of the substrate
and replacement of damaged sections
throughout the service life.
The Retrowrap system also has the facility
to act as a carrier, when required, for the
ACKNOWLEDGMENT
The authors would like to thank Suria
Capital
Holdings
Berhad
(SCHB),
Engineering Services Sdn. Bhd. and Sabah
Port Authorities for their assistance.
REFERENCES
1. Gaythwaite. (1990). Design of Marine
Facilities. New York: Van Nostrand.
2. Method Statement for
Repairs.
(1993).
(MALAYSIA) Sdn. Bhd.
Underdeck
Corroless
9. CONCLUSION
This maintenance solution are not just about
patching, crack/grout injection, a paint
coating or steel patch plate, but encompass
the whole picture, the structure, damage,
access, shipping, engineering, timing, tides,
environment, resources, and many more.
Every case requires an open mind, lateral
thinking and a start with a clean sheet of
paper as no two sites are the same. It needs
to be done efficiently, safely and cost
effectively a working knowledge of a
port/marine environment in addition to pier
condition and reading the signs is a distinct
advantage.
10
Coastal
London: