Amendment 001_Attachment C 2017 Sector Buffalo Waterfront Inspection Report.pdf

Distribution limited to U.S. Government agencies and their contractors; administrative/operational use.

Other requests for this document shall be referred to the United States Coast Guard CEU Cleveland.

USCG Project No. PSN 8593084 Task Order No. HSCG83-17-J-PCR038 Contract No. HSCGG1-16-D-PRV005

UNITED STATES COAST GUARD

SECTOR BUFFALO

BUFFALO, NEW YORK

WATERFRONT INSPECTION AT

UNITED STATES COAST GUARD CEU CLEVELAND

Cleveland, OH 44199-2060

Prepared for:

United States Coast Guard Civil Engineering Unit Cleveland 1240 East 9th Street Cleveland, Ohio 44199-2060

September 2017

By:

Appledore Marine Engineering, LLC 600 State Street, Suite E Portsmouth, New Hampshire 03801

WATERFRONT FACILITY

INSPECTION AND ASSESSMENT

At

UNITED STATES COAST GUARD

SECTOR BUFFALO

BUFFALO, NEW YORK

Shore Asset Management System Data

INSTALLATION NAME: Sector Buffalo

INSTALLATION NUMBER 37210

CEU: Cleveland

DISTRICT: 9

SECTOR: Buffalo

FCADATE: 08/21/2017

FCASOURCE: Appledore Marine Engineering, LLC

September 2017

By:

Appledore Marine Engineering, LLC

600 State Street, Suite E Portsmouth, New Hampshire 03801

Prepared for:

United States Coast Guard Civil Engineering Unit – Cleveland

1240 East 9th Street Cleveland, OH 44199-2060

2017 Waterfront Facility Inspection and Assessment ii

Sector Buffalo Buffalo, New York

USCG SECTOR BUFFALO

EXECUTIVE SUMMARY

A Routine Waterfront Facility Inspection (WFI) was performed on the waterfront structures at Sector Buffalo between August 21st and 23rd, 2017. This investigation included above water and underwater structural inspection of the waterfront structures at this facility. The inspected structures are shown on the Overall Site Plan, Figure 1.

The inspection and assessment results for the various components of each structure are presented in this report including a Condition Assessment Index Rating, which is based on engineering judgment of the observed defects impact on the structural condition of each asset.

The following summarizes the findings at Sector Buffalo:

1. The Floating Dock (RPUID 843888) is overall in Serious condition. The Floating Dock was installed circa 2014 and all guide pile assemblies have failed. There is a significant list to the float modules, all of the shore side guide pile support connections into the concrete cap are either cracked, spalled or loose and the wale is failed in four locations.

2. The Haulout Finger Pier (RPUID 71883) is in overall Fair condition. There is one bent stiffener plate and one of the pile grout pads is spalled.

3. The Finger Pier (RPUID 11508) is in overall Fair. Minor to moderate defects were observed which included loose or missing deck connectors, two loose vertical timber fender elements, one bent cleat and one missing cleat.

4. The Shore Erosion Protection Bulkhead (RPUID 811834) consists of three sections. The steel sheet pile (SSP) within the basin is in Good condition with only minor defects observed. The North Cells 1‐9 are in Fair condition. The timber cribbing at the west wave break is in Poor condition with significant defects to the timber cribbing and voids at its north and south ends, and significant concrete deterioration. The arch sheeting is in Fair condition with significant pitting over 1/8 inch deep. Cells A‐E are in Fair condition with concrete cap settlement and minor pitting of the SSP.

5. The Shore Erosion Protection Riprap (RPUID 811870) is overall in Fair condition. Defects observed included isolated voids, settlement, and missing stones in the back of the wall.

6. The river bottom is soft silty mud with isolated areas of debris. No berthing restrictions due to water depths were observed.

Inspection and Assessment v

Figure 3

ASCE Condition Assessment Ratings

Rating Description

Good No visible damage or only minor damage noted. Structural elements may show very minor deterioration, but no overstressing observed. No repairs are required.

Satisfactory Limited minor to moderate defects or deterioration observed but no overstressing observed. No repairs are required.

Fair All primary structural elements are sound but minor to moderate defects or deterioration observed. Localized areas of moderate to advanced deterioration may be present but do not significantly reduce the loadbearing capacity of the structure. Repairs are recommended, but the priority of the recommended repairs is low.

Poor Advanced deterioration or overstressing observed on widespread portions of the structure but does not significantly reduce the load‐bearing capacity of the structure. Repairs may need to be carried out with moderate urgency.

Serious Advanced deterioration, overstressing, or breakage may have significantly affected the load‐bearing capacity of primary structural components. Local failures are possible, and loading restrictions may be necessary. Repairs may need to be carried out on a high‐priority basis with urgency.

Critical Very advanced deterioration, overstressing, or breakage has resulted in localized failure(s) of primary structural components. More widespread failures are possible or likely to occur, and load restrictions should be implemented as necessary. Repairs may need to be carried out on a very high‐priority basis with strong urgency.

Inspection and Assessment vii

TABLE A

FLOATING DOCK (RPUID 843888)

Condition Assessment Index Rating

Serious Operational Restrictions

None

Remaining Service Life (with repairs)

<5 Years

Remaining Service Life (without repairs)

10 Years

Date of Previous Inspection n/a Next Inspection Due

Immediate Repair Cost $229,209

Short Term Repair Cost ‐

Long Term Repair Cost ‐

Engineering Study Cost ‐

TABLE B

HAULOUT FINGER PIER (RPUID 71883)

Index Rating

Fair Operational Restrictions

None

Remaining Service Life (with repairs)

10+ Years

Remaining Service Life (without repairs)

10+ Years

Date of Previous Inspection

Next Inspection Due

Immediate Repair Cost $3,594

Short Term Repair Cost ‐

Inspection and Assessment viii

TABLE C

FINGER PIERS (RPUID 11508)

Index Rating

Fair Operational Restrictions

None

Remaining Service Life (with repairs)

10+ Years

Remaining Service Life (without repairs)

10+ Years

Date of Previous Inspection

Next Inspection Due

Immediate Repair Cost ‐

Short Term Repair Cost $9,523

TABLE D

SHORE EROSION PROTECTION FACILITY BULKHEAD SYSTEM (RPUID 811834)

Index Rating

Good to Poor

Operational Restrictions

None

Remaining Service Life (with repairs)

10+ Years

Remaining Service Life (without repairs)

10+ Years/ 10 Years

Date of Previous Inspection

Next Inspection Due

Immediate Repair Cost ‐

Short Term Repair Cost $1,294

Long Term Repair Cost $2,494,063

Engineering Study Cost $64,688

Basin

North Cells 1‐9

West Wave Break

Inspection and Assessment ix

TABLE E

SHORE EROSION PROTECTION FACILITY RIPRAP (RPUID 811870)

Index Rating

Fair Operational Restrictions

None

Remaining Service Life (with repairs)

10+ Years

Remaining Service Life (without repairs)

10+ Years

Date of Previous Inspection

Next Inspection Due

Immediate Repair Cost ‐

Short Term Repair Cost ‐

Based on the observed defects and the condition of the facility, repairs are recommended. The following table summarizes the recommended repair items and includes each item’s associated priority level and estimated construction cost:

Inspection and Assessment x

TABLE F

SUMMARY OF RECOMMENDED REPAIRS AND COSTS

PRIORITY RPUID STRUCTURE RECOMMENDATION

ESTIMATED

CONSTRUCTION

COSTS*

Immediate

843888 Floating Dock

Replace guide pile frame assemblies $172,500

Replace dock hinge assemblies $43,125

Replace timber wale and rub strip sections $5,534

Repair guide pile support connections to deck

$7,475

Tighten loose cleats $575

71883 Haulout Finger Pier Repair bent stiffener plate $1,797

Repair spall in grout pad at inboard pile. $1,797

Subtotal $232,803

Short Term

11508 Finger Piers

Replace missing deck clips, approximately 10.

$1,078

Replace missing deck edge angles, approximately 43 feet.

$4,636

Replace missing cleat. $863

Repair bent cleat angle connection. $719

Tight loose vertical timber fender in two locations.

$431

Replace bent ladder. $1,797

811834 Shore Erosion

Protection Facility Bulkhead

Basin: Fill settlement areas at stations 13+56 and 17+55

$1,294

Subtotal $10,817

Long Term 811834 Shore Erosion

Protection Facility Bulkhead

West wave break: Install SSP on perimeter of timber crib & fill void w/ concrete

$1,919,063

West wave break: Install cathodic protection system to 340 ft. of PDA 27 SSP

$575,000

Subtotal $2,494,063

Station 843888 Floating Dock Tighten loose fender and replace failed section of fender.

Subtotal ‐

Engineering Studies

811834 Shore Erosion

Protection Facility Bulkhead

West wave break: Special Inspection and Rehabilitation evaluation

$64,688

Subtotal $64,688

Total $2,802,371

*Backup data for all cost estimates is provided in Appendix B.

Immediate

System or element is in failure, or is expected to fail in the next 1 year.

Inspection and Assessment xi

Short Term

System or element is currently functional, but has a high probability of failing in the next 3 years and before the next schedule inspection and/or deterioration will progress such that it may result in a condition that will make asset impractical to repair in the future.

Long Term

System or element is expected to remain functional in next 5 years until the next scheduled inspection and defects are not anticipated to progress in a manner that will make future maintenance impractical.

Station Routine maintenance that can be completed by the Station.

Engineering

Studies To perform detailed testing or investigation of a structure required to understand the nature and/or extent of deterioration prior to determining the need for and type of repairs required.

Inspection and Assessment xii

TABLE OF CONTENTS

PAGE NO.

TABLE OF CONTENTS ................................................................................................................................... xii

1. INTRODUCTION ............................................................................................................................. 1‐1

2. INSPECTED STRUCTURES ............................................................................................................... 2‐1

2.1 Floating Dock (RPUID 843888) ...................................................................................... 2.1‐1

2.2 Haulout Finger Pier (RPUID 71883) ............................................................................... 2.2‐1

2.3 Finger Piers (RPUID 11508) ........................................................................................... 2.3‐1

2.4 Shore Erosion Protection Facility Bulkhead System (RPUID 811834) ........................... 2.4‐7

2.5 Shore Erosion Protection Facility Riprap (RPUID 811870) .......................................... 2.5‐16

APPENDIX A STRUCTURAL DATA .............................................................................................................. A‐1

APPENDIX B COST ESTIMATE BACKUP DATA ............................................................................................ B‐1

Inspection and Assessment 1‐1

1. INTRODUCTION

This report summarizes a condition assessment of the waterfront structures at the United States Coast

Guard Sector Buffalo, located in Buffalo, New York. The condition assessment was performed as part of the USCG Waterfront Facility Inspection (WFI) program and included above water and underwater structural inspections of the waterfront structures at this facility.

This inspection included a condition assessment of the waterfront structures in order to recommend short and long term repairs and provide estimated costs for each item. These services, including preparation of this report, were provided by Appledore Marine Engineering, LLC (AME) in accordance with Task Order No. HSCG83‐17‐J‐PCR038 under Contract No. HSCGG1‐16‐D‐PRV005.

The Scope of Work required all labor, consultation, equipment, instruments, transportation, materials, professional services, and incidentals required to execute a Waterfront Structural Inspection at USCG

Sector Buffalo. AME mobilized a team of professional‐engineer divers and conducted the inspection on

August 21 to 23, 2017. The inspection team utilized commercial SCUBA equipment and followed the inspection procedures outlined in UFC 4:150‐07, Operation and Maintenance: Maintenance of

Waterfront Facilities and NAVFAC Maintenance and Operation and Maintenance Guide MO‐322. Level 1 and Level 2 investigations were completed in accordance with requirements of the Scope of Work.

The inspection and assessment results for the various components of each structure are presented in this report including a Condition Assessment Index Rating, which is based on engineering judgment of the observed defects impact on the structural condition of each asset.

The repair recommendations contained herein are preliminary and are to be used for general budgeting purposes only. The data collected during this investigation is intended to generally characterize the condition of the structure and is not intended to be used for design purposes. Prior to commencing with a repair project, a Design Level Inspection should be completed to determine quantity, location and repair method in accordance with the ASCE Manual of Engineering Practice No. 130, “Waterfront

Facilities Inspection and Assessment.” The actual method of repair must be left to subsequent Design

Level Inspections and the discretion of the Engineer of Record for the repair design.

Cost estimates included throughout this report are intended to provide an approximate value to use for future budgetary purposes. For these estimates, it is assumed that the projects will be scheduled to optimize contractor mobilization and demobilization; that the projects will be completed without major interruptions to schedule; and that the contract will be awarded through a competitive bid environment. Changes to these assumptions would affect the accuracy of the cost estimates. The cost estimates for Station classified work are only for anticipated contracted items and no costs were carried for Station supplied labor or miscellaneous materials. The table below indicates the Key Personnel associated with this Task Order.

Inspection and Assessment 1‐2

TABLE 1‐1 KEY PERSONNEL

CIVIL ENGINEERING UNIT – CLEVELAND

1240 EAST 9TH STREET

CLEVELAND, OHIO 44199‐2060

Bill Henkelman Project Manager martin.w.henkelman@uscg.mil

CWO James Waskiewicz Facility POC James.a.waskiewicz@uscg.mil

APPLEDORE MARINE ENGINEERING, LLC

600 STATE STREET, SUITE E

PORTSMOUTH, NH 03801

(603) 766.1870

Robert Snover, P.E. Principal in Charge ‐ Diver rsnover@appledoremarine.com

Stephanie Baratt, P.E. Project Lead Engineer – Diver sbaratt@appledoremarine.com

Benjamin Cook Engineer ‐ Diver bcook@appledoremarine.com

Inspection and Assessment 2‐1

2. INSPECTED STRUCTURES

United States Coast Guard Sector Buffalo is located in Buffalo, New York. As part of the Routine

Waterfront Inspection, the following waterfront structures were inspected:

TABLE 2‐1 SUMMARY OF INSPECTED STRUCTURES

STRUCTURE RPUID

CONSTRUCTION

MATERIAL

YEAR

BUILT/MODIFIED

STRUCTURE SIZE

WATER

DEPTHS

Floating Dock 843888 Steel/Concrete 2014 305’ x 8’ 13’‐14.5’

Haulout Finger Pier 71883 Steel Unknown 52’ x 7’ 9’‐12’

Finger Piers 11508 Steel Unknown 115’ x 6’ 10’‐13’

Shore Erosion Protection Bulkhead

System 811834 Steel/Concrete

2014/2015/ unknown

Basin: 1,767 LF West Wave Break:

515 LF

North Cells: 9 Cells

4’‐19’

Shore Erosion Protection Riprap

811870 Stone/Concrete Unknown 1,110 LF n/a

The Scope of Work for this facility required a Routine Level Inspection, which includes above water and underwater inspection of the substructure, superstructure, deck components, ladders and mooring/berthing systems. Utility sizes and connections were identified and general condition was assessed. No code compliance evaluations or detailed testing of utilities was completed. Handrails and above deck structures were not included in this inspection.

AME performed a Level 1, visual‐tactile inspection on 100 percent of the inspected elements. This inspection effort is intended to identify gross defects and confirm as‐built conditions. Level 2 inspections were performed to quantify the typical levels of deterioration observed on each asset type.

Level 2 inspection efforts involved cleaning the asset to remove any biofouling, excessive corrosion product, or debris in order to allow for a more detailed inspection. In accordance with the Scope of

Service, Section 2.4.2, Level 2 inspections were performed on 10 percent of all piles, which included removal of marine growth in one foot bands at the mudline, midwater, and waterline. On bulkheads, Level 2 inspections were complete at 50‐foot intervals and included removal of growth in one‐half square foot sections. In addition, at all Level 2 locations, either ultrasonic thickness measurements were completed to determine remaining steel section or hammer soundings to determine competence of material (timber and concrete).

The figure below presents an aerial view of the facility.

Inspection and Assessment 2.1‐1

2.1 FLOATING DOCK (RPUID 843888)

The Floating Dock was constructed circa 2014. The Floating Dock is constructed of concrete float modules with timber wales, and a timber rub strip on the inboard side and a plastic rub strip on the outboard side. A rubber fender runs along the outboard face. The Floating Dock is secured by 12 14‐inch diameter spiral welded steel pipe piles. At each inboard guide pile location, a steel 12x12 HSS member is bolted into the bulkhead concrete cap. The guide pile and HSS member are connected by a steel channel and W member.

The guide pile assemblies are located on the interior of the dock. The floating dock is constructed of three segments, each approximately 100+/‐ feet long and eight feet wide. The segments were designed to be connected with a hinge connection.

Access to the Floating Dock is provided by an aluminum gangway at each end. Each gangway is connected to a concrete platform, which is supported by two steel piles.

The Floating Dock is used to provide berthing to USCG vessels and the border patrol vessel.

Overall Photo:

Assessment Summary:

Condition Assessment Index Rating: Serious

Operational Restrictions: None

Remaining Service Life (without repairs): <5 Years

Remaining Service Life (with repairs): 10 Years

Next Inspection Date: 2022

Inspection and Assessment 2.1‐2

Observed Conditions:

INSPECTION

AREA

ELEMENT DESCRIPTION

General General

The Floating Dock was installed circa 2014 and damaged shortly after installation. The damage to the Floating Dock is a result of both wind and ice. The configuration of the floating dock guide piles does not allow for the system to be removed in the winter time.

Substructure

Guide Piles

The steel guide piles are 14‐inch diameter uncoated spiral welded pipe piles.

Ultrasonic thickness measurements did not indicate any significant section loss underwater. Above water, isolated piles have minor abrasion damage from contact with the guide pile assembly steel frame.

Gangway Platform

Support Pile

Each gangway platform is supported by two spiral welded steel pipe piles.

The piles area uncoated and have no significant deterioration above or underwater.

Gangway Platform Pile

Cap

The gangway platform concrete cap/deck has no significant deterioration observed.

Mooring Hardware

Cleats There are 19, 18‐inch cleats on the Floating Dock. The cleats are coated with isolated areas of minor coating loss. There are 16 loose cleats.

Fender System Extruded Fender

There are two locations where the three inch extruded fender is loose. In one location it is also shredded most likely from abrasion with a vessel.

Appurtenances

Guide Pile Assemblies

All guide pile assemblies have failed. The guide pile assemblies are constructed of steel frames bolted to the wale. Square UHMW elements with a circular cutout for the pile are located at each pile and bolted to the steel frame. In seven locations, the bolted connection for the UHMW has failed. The UHMW elements are reportedly a modification to the original design, which also failed. Where the UHMW connections have failed, the steel pile has direct contact with the steel frame. Major abrasion damage to the steel frames was observed as well as failed welds, broken members and failed connections. Two steel frames have completely become detached and can be found around the pile underwater. In several locations the connection through the timber wale has failed by pulling out through the top of the wale. This has also caused damage to the wales.

Guide Pile Supports

The guide pile supports for the inboard piles are coated. There is minor to moderate corrosion at the connection of the 12x12 HSS members and the channel, and the guide pile and the channel. All of the connections to the bulkhead cap are loose, cracked or spalled as a result of the floating dock movement.

Gangway and Transition Plate

The gangways are 40‐feet long by four feet wide and have no significant defects observed.

Float Modules The concrete float modules have isolated areas of hairline cracking. There is an approximate six inch list between the north side and the south side of the float modules.

Wales and Rub Strips

The 4x12 timber wale is broken in four locations due to the guide pile assembly connection pulling out from the top of the wale.

There are three locations were the 2x12 rub strip is missing. The 3x12 plastic rub strip has no significant defects.

Hinges The hinge connections between the three segments of dock have failed. The rubber element is completely missing.

Utilities n/a n/a

Inspection and Assessment 2.1‐3

Water Depth Water Depth The water depth along the Floating Dock at the time of inspection was between 13 and 14.5 feet.

Lake Bottom Lake Bottom

The lake bottom consists of soft, silty mud. There was a timber pile stub and 20‐foot long timber member along the bottom near bent 12 on the outboard face. The pile stub extends approximately seven feet off the bottom.

For a complete list of observed defects, including size and location see Appendix A.

Photographs:

Photo 1: Typical steel guide pile, bent 12 shown, looking northeast.

Photo 2: Typical guide pile brace support at bulkhead, bent 1 shown, looking northeast.

Photo 3: Gangway support platform, west platform shown, east platform similar.

Photo 4: Typical aluminum gangway, west gangway shown.

Inspection and Assessment 2.1‐4

Photo 5: Typical gangway connection at platform, west gangway shown.

Photo 6: Typical 18‐inch cleat, bent 7.3 shown.

Photo 7: Typical timber wale, rubber rub strip and rubber fender along outboard face, looking southwest.

Photo 8: Loose fender and shredded fender at bent 1.8, looking northeast.

Photo 9: Failed guide pile assembly at bent 1. Failed welds in frame and bent steel frame member.

Photo 10: Failed guide pile assembly at bent 2. Broken steel framing member.

Inspection and Assessment 2.1‐5

Photo 11: Missing UHMW connections at bent 5 guide pile assembly.

Photo 12: Cracked/spalled grout pad in the shore side guide pile support at bent 5.

Photo 13: Failed timber wale at bent 6 due to failed guide pile assembly connection hardware pulling up.

Photo 14: Failed guide pile assembly at bent 7. Guide pile assembly found around pile underwater.

Photo 15: Failed timber wale and missing timber rub strip at bent 10.

Photo 16: Failed guide pile assembly at bent 11 with spalling in adjacent concrete.

Inspection and Assessment 2.1‐6

Photo 17: Failed connection and cracked/spalled grout pad at the shore side guide pile support at bent 11.

Photo 18: Failed timber wale and guide pile assembly at bent 12.

Photo 19: Failed hinge connection between bents 8 and 9, looking west.

Recommendations:

It is recommended that the Coast Guard work with the concrete floating dock manufacturer to develop the best long term repair method for the Floating Dock system failures. Environmental conditions, specifically wind and ice, are important design elements to consider in the repair design.

It is recommended that the concrete floating dock manufacturer provide replacements for all 12 failed guide pile assemblies with ones that incorporate multiple rollers at each guide pile and replacement of 2 floating dock hinge assemblies, to help protect the piles and floating dock.

It is recommended that the floating dock manufacturer review the listing of the floating dock and provide any repair recommendations to correct the issue.

The broken timber wale sections will also need to be replaced.

Consideration should also be given to reconfiguring the pile arrangement so that the entire concrete floating dock system can be removed in the winter, to avoid ice damage.

Inspection and Assessment 2.1‐7

SUMMARY OF RECOMMENDED REPAIRS

PRIORITY LEVEL ELEMENT REPAIR COSTS

Immediate

Guide Pile Assemblies

Replace guide pile frame assemblies $172,500

Hinges Replace dock hinge assemblies $43,125

Wale & Rub Strip Replace timber wale and rub strip sections $5,534

Guide Pile Supports

Repair guide pile support connections to deck $7,475

Cleats Tighten loose cleats $575

Subtotal $229,209

Short Term ‐ None ‐

Subtotal ‐

Long Term ‐ None ‐

Subtotal ‐

Station Extruded Fender Tighten loose fender and replace failed section of fender.

Subtotal ‐

Engineering Studies

‐ None ‐

Subtotal ‐

STRUCTURE TOTAL $229,209

Inspection and Assessment 2.2‐1

2.2 HAULOUT FINGER PIER (RPUID 71883)

The Haulout Finger Pier is approximately 52‐feet long by seven feet wide and consists of a travel lane and a walkway. The west side on the pier is the travel lane for the Marine Haulout. The travel lane is one beam with web stiffener plates supported by two steel pipe piles. The shore side pier end is supported by a steel angle, which is bolted into the concrete bulkhead cap. The walkway is cantilevered on the east side and consists of steel grating supported by steel angle framing.

The facility currently operates a Marine Travelift with a 110,000 pound capacity on the pier.

Condition Assessment Index Rating: Fair

Operational Restrictions: None

Remaining Service Life (without repairs): 10+ Years

Remaining Service Life (with repairs): 10+ Years

Inspection and Assessment 2.2‐2

AREA

ELEMENT DESCRIPTION

Substructure Piles

The concrete filled steel pipe piles are coated with isolated small areas of coating loss. Ultrasonic thickness measurements did not reveal any significant section loss underwater. The grout pad on the inboard pile is spalled.

Superstructure Beams

The web stiffener plate north of the first steel pipe pile is buckled. The beam is coated with isolated areas of minor coating loss.

Angle The beam is supported by a steel angle bolted into the concrete cap of the steel sheet pile. The steel angle has no significant deterioration.

Deck Components

Deck The steel deck grating is intact with no significant defects observed.

Deck Framing The steel members supporting the cantilevered decking have no significant defects observed.

Curb The steel angle curb has no significant defects observed; however, there are isolated areas of minor coating loss.

Mooring Hardware

Cleats The three steel cleats mounted to the bottom flange of the beam have no significant defects observed.

Fender System n/a n/a

Utilities n/a n/a

Water Depths Water Depths The water depth along the Haulout Finger Pier is between 10 and 12 feet at the time of this inspection. The distance from the top of deck to the waterline was approximately 60 inches.

Lake Bottom Lake Bottom The lake bottom consists of soft, silty mud. No debris was found in the vicinity of the haulout pier during this inspection.

For a complete list of observed defects, including size and location see Appendix A.

Photographs:

Photo 1: Typical steel pile with isolated area of minor coating loss and surface corrosion. Outboard pile shown, looking east

Photo 2: Spall in the grout pad of the inboard pile, looking east.

Inspection and Assessment 2.2‐3

Photo 3: Buckled flange, approximately one foot before inboard steel pile, looking east.

Photo 4: Typical underdeck condition, looking north.

Photo 5: Isolated areas of minor coating loss and surface corrosion on steel rail, looking west.

Photo 6: Typical top of deck condition, looking south.

Photo 7: Typical cleat, first cleat, looking east.

Inspection and Assessment 2.2‐4

The following repairs should be implemented to address the noted defects and deterioration. The costs indicated below represent estimated construction costs and do not include engineering fees for design and permitting. Defects noted in preceding sections that are not included in these recommendations have not risen to a level that warrants repairs.

SUMMARY OF RECOMMENDED REPAIRS

PRIORITY LEVEL ELEMENT REPAIR COSTS

Immediate Beam Repair bent stiffener plate $1,797

Pile Repair spall in grout pad at inboard pile. $1,797

Subtotal $3,594

Short Term ‐ None ‐

Subtotal ‐

Long Term ‐ None ‐

Subtotal ‐

Station ‐ None ‐

Subtotal ‐

Engineering Studies

‐ None ‐

Subtotal ‐

STRUCTURE TOTAL $3,594

Inspection and Assessment 2.3‐1

2.3 FINGER PIERS (RPUID 11508)

The Finger Pier is approximately 115‐feet long by six feet wide. The pier is supported by 11 concrete filled steel caissons. Each caisson has two steel H piles in the interior, which extend one foot above the top of the caisson and are buried in the mudline. Steel channel beams support the steel deck grating. Cleats are located along the pier, which provides mooring to the 45‐foot response boat and the 49‐foot buoy tender. There is one 240volt/60amp and one 120volt/100amp shore power connection located on the pier.

Operational Restrictions: None

Remaining Service Life (without repairs): 10+ Years

Inspection and Assessment 2.3‐2

AREA

ELEMENT DESCRIPTION

General General The structure was marked with the RPUID number 811848. This did not match the RPUID number in the SOW, which is 11508.

Substructure Caissons/H Piles

The steel caissons are uncoated with light surface corrosion. At five caisson locations, the bottom is scoured and the H piles are exposed within the caisson interior. A total of seven H piles are exposed. The exposed H piles have light surface corrosion; however, ultrasonic thickness measurements did not reveal any significant section loss. The length of exposed H pile ranged from three feet, observed at bent 8 to six inches, observed at bent 6.

Ultrasonic thickness measurements of steel caisson did not show any significant section loss.

Superstructure Beams The steel channel beams are bolted to the H piles extending from the caisson and run the length of the Finger Pier. The beams are uncoated with light surface corrosion.

Deck Components

Grating Approximately 10 steel grating connection clips are missing. The steel angle at the deck edge is missing in six locations, approximately 43 feet.

Mooring Hardware

Cleats

The cleat angle connection at bent 2.5 on the south side is bent and the cleat at bent 2.5 on the north side is missing. The cleat connection on the north side at bent 11 has light surface corrosion as well as the base and stem of the cleat. The remaining cleats have no significant defects.

Fender System

Vertical Fenders The outboard two vertical fenders on the south side are loose. The timber vertical fenders generally have minor checking approximately ¼ inch wide.

Horizontal Timber Fender

Panel No significant defects were notes on the timber horizontal fender panel.

Appurtenances Ladders The ladder on the south side of the pier is bent most likely from impact. The ladder on the north side of the pier has no significant defects.

Utilities Utilities The 240volt/60amp and 120volt/100amp shore power connections do not have any significant structural defects.

Water Depths Water Depths The water depths along the Finger Pier are between seven and 13 feet at the time of this inspection. The distance from the top of deck to the waterline was approximately 42 inches.

Lake Bottom Lake Bottom The lake bottom consists of soft, silty mud. Timber debris was observed between bents 9 and 10 and measured six feet long and six inches in diameter.

For a complete list of observed defects, including size and location see Appendix A.

Inspection and Assessment 2.3‐3

Photographs:

Photo 1: Typical steel caisson, bent 7 shown, looking south.

Photo 2: Exposed steel H pile at bent 8.

Photo 3: Typical steel channel beam with surface corrosion, bents 1:A to 2:A shown, looking northwest.

Photo 4: Missing steel angle and steel grating connection.

Photo 5: Missing steel deck edge angle, bent 4.25:A shown, looking south.

Photo 6: Bent cleat located at bent 2.5:A.

Inspection and Assessment 2.3‐4

Photo 7: Missing cleat located at bent 2.5:B. Photo 8: Steel cleat located at 10.5:B with surface corrosion on connection, and base and stem of fitting.

Photo 9: Typical checking in vertical timber fender elements, approximately ¼ inch wide, 4:B shown.

Photo 10: Typical horizontal timber fender panel, bent 10:A‐11:A shown.

Photo 11: Bent ladder located at bent 3.5:A. Photo 12: Shore power connection located at bent 7.5:B, 100A/120V.

Inspection and Assessment 2.3‐5

Photo 13: Shore power connection located at bent 7.25:A, 60A/240V.

Inspection and Assessment 2.3‐6

The exposed H‐piles have approximately 75‐percent of the coating remaining and over 0.4‐inches thickness remaining. At this time, there no repair recommendations for the exposed H‐piles.

The following repairs should be implemented to address the noted defects and deterioration. The costs indicated below represent estimated construction costs and do not include engineering fees for design and permitting. Defects noted in preceding sections that are not included in these recommendations have not risen to a level that warrants repairs.

SUMMARY OF RECOMMENDED REPAIRS

PRIORITY LEVEL ELEMENT REPAIR COSTS*

Immediate ‐ None ‐

Subtotal ‐

Short Term

Deck Replace missing deck clips, approximately 10. $1,078

Deck Replace missing deck edge angles, approximately 43 feet.

$4,636

Cleat Replace missing cleat. $863

Cleat Repair bent cleat angle connection. $719

Vertical Fender Tight loose vertical timber fender in two locations. $431

Ladder Replace bent ladder. $1,797

Subtotal $9,523

Long Term ‐ None ‐

Subtotal ‐

Station ‐ None ‐

Subtotal ‐

Engineering Studies

‐ None ‐

Subtotal ‐

STRUCTURE TOTAL $9,523

Inspection and Assessment 2.4‐7

2.4 SHORE EROSION PROTECTION FACILITY BULKHEAD SYSTEM (RPUID 811834)

The Shore Erosion‐Bulkhead consists of three sections; 1765 feet of newer SSP in the basin area (0+00 to 17+65), the older north 9 SSP cells (1‐9) and 550 feet of older west wave break.

The newer (circa 2012‐2014?) SSP bulkhead in the basin area is constructed of uncoated PZ27, AZ36 & AZ40 steel sheet pile’s (SSP) with a concrete cap (approximately 7 feet above the water during the inspection), 18‐ inch cleats and bollards and adjacent concrete decks. The AZ SSP had a tie rods spaced approximately 15 feet O.C. Steel ladders are spaced along the bulkhead and some SSP sections have vertical 8 x 8 timber fender elements (6’ O.C.). Utilities include pole lighting, 100 & 200 amp shore ties, 3 ½” sewer connections and ¾” water connections. There is a fueling station that includes a 3,000 gallon gas tank and a 3,000 gallon diesel tank with dispensers.

The older north 9 SSP cells are constructed of PSA 28 steel sheet piles and filled with soil.

The older west break water is constructed of 340 feet of PDA 27 SSP, 5‐33’ø PSA 28 SSP cells (A‐E) with concrete decks (10 feet above water during inspection) and 210 feet of timber crib supported concrete cap (16 feet wide, 2 feet above water during inspection) and wall (9 feet wide at base) with 5‐24 inch bollards.

Condition Assessment Index Rating: Good to Poor

Operational Restrictions: None

Remaining Service Life (without repairs): 10+ Years/10 Years

Basin

North Cells 1‐9

West Wave Break

Inspection and Assessment 2.4‐8

Observed Conditions ‐ Basin:

AREA

ELEMENT DESCRIPTION

Substructure Sheet Pile

The steel sheet piles are uncoated with light corrosion. Ultrasonic thickness measurements indicate minimal loss of steel section. Two small areas of settlement were observed.

Cap No significant or only minor defects

Deck Components n/a n/a

Mooring Hardware

Cleats No significant or only minor defects.

Bollards No significant or only minor defects.

Fender System Timber Fender

Elements No significant or only minor defects.

Appurtenances Ladders No significant defects observed.

Utilities Utilities No structural deterioration was noted on the utilities.

Water Depth Water Depth 4 to 16 ft. during inspection

Lake Bottom Lake Bottom The basin bottom is silt, sand and gravel with some debris.

For a complete list of observed defects, including size and location see Appendix A.

Observed Conditions – North Cells 1‐9:

INSPECTION

AREA

ELEMENT DESCRIPTION

Substructure Sheet Pile

The flat steel sheet piles typically with only light corrosion. There was one isolated areas of 1/8 inch section loss at cell 4 at the mudline.

Cap

The top of the stone fill within the cells was approximately 8” to 15” below the top of the adjacent SSP, indicating the concrete decks had been removed.

Deck Components n/a n/a

Mooring Hardware n/a n/a

Fender System n/a n/a

Appurtenances n/a n/a

Utilities n/a n/a

Water Depth Water Depth 13 to 15 ft. during inspection

Lake Bottom Lake Bottom The lake bottom is silt, sand and gravel with some debris.

For a complete list of observed defects, including size and location see Appendix A.

Inspection and Assessment 2.4‐9

Observed Conditions – West Wave Break:

AREA

ELEMENT DESCRIPTION

Substructure

Sheet Pile

The arch steel sheet piles (SSP) typically exhibited light to moderate surface corrosion from the pile cap, down approximately five feet. Below this level, down to the mudline, the steel exhibited moderate to heavy corrosion with significant pitting (1/8”± deep) of the surface. Remaining steel thickness measurements approximately 5 to 13 feet below the top of the pile cap were as low as ¼”±, indicating an 1/8”± of steel section loss. The SSP anchor system was not observable. The area immediately behind the SSP is gravel and stone.

The steel sheet piles on cells A‐E exhibited only light corrosion.

Cap

The concrete cap on all 5 cells has settled 2” to 5”.

The concrete cap on the timber crib has advanced deterioration including large spalls and significant scaling (over 1”) on over 1/3 of the surface.

The steel cap on the SSP exhibited light to moderate surface corrosion.

Cribbing

The timber cribbing typically exhibited light to moderate deterioration, except at the north end and south west corner, where advanced deterioration has allowed large voids to develop and undermine the concrete cap

Deck Components

Wall The concrete wall has moderate deterioration including a spalls with exposed reinforcing steel and scaling

Mooring Hardware

Bollards Light to moderate surface corrosion.

Fender System n/a n/a

Appurtenances n/a n/a

Utilities n/a n/a

Water Depth Water Depth The water depth was between 10 and 17 feet at the time of this inspection.

Lake Bottom Lake Bottom The lake bottom is silt, sand and gravel with some debris.

For a complete list of observed defects, including size and location see Appendix A.

Photographs ‐ Basin:

Photo 1: Typical view of bulkhead between station 0+00 and 5+00, looking southeast.

Photo 2: Typical view of bulkhead between station 14+15 and 17+65, looking north.

Inspection and Assessment 2.4‐10

Photo 3: Typical view of AZ SSP and anchor. Photo 4: Typical view of PZ SSP.

Photo 5: Level 2 cleaning on PZ SSP at station 0+50. Photo 6: Level 2 cleaning on steel pipe pile supporting the fuel platform station 5+15.

Photo 7: Sinkhole at station 13+65. Photo 8: Sinkhole at station 17+55.

Inspection and Assessment 2.4‐11

Photo 9: Typical concrete cap. Photo 10: Typical bollard.

Photo 11: Typical cleat. Photo 12: Level 2 cleaning on timber fender pile at fuel platform at 5+12.

Photographs – North Cells 1‐9:

Photo 13: Typical view of North Cells 1‐9. Cell 1 shown looking northeast.

Photo 14: Typical settlement in North Cells 1‐9. Cell 1 shown.

Inspection and Assessment 2.4‐12

Photographs – West Wave Break:

Photo 15: Overall view of arch SSP, station 0+00 to 2+15, looking northwest.

Photo 16: Station 0+00E to 2+15E arch SSP, looking northwest.

Photo 17: Level 2 cleaning in arch SSP at station 0+25E. Photo 18: Overall view of SSP cell, looking northwest.

Photo 19: Level 2 cleaning on steel cell A. Photo 20: Overall view of west cell A‐E decks, looking northeast.

Inspection and Assessment 2.4‐13

Photo 21: Typical concrete deck settlement on west cells A‐E.

Photo 22: Crack in concrete deck at cell B.

Photo 23: Station 3+40 to 5+50, concrete cap supported underwater by timber cribbing, looking north.

Photo 24: Spall with exposed reinforcing steel on top of timber crib concrete wall, station 4+25.

Photo 25: Typical concrete deck spall at timber cribbing. Photo 26: Typical concrete deck scaling at timber cribbing.

Inspection and Assessment 2.4‐14

Photo 27: Typical condition of timber cribbing. Photo 28: Timber crib deterioration and void at station 3+30W.

Photo 29: Timber crib deterioration at station 3+30W. Photo 30: Typical gap in timber crib, station 4+50E.

The following repairs should be implemented to address the noted defects and deterioration. The costs indicated below represent estimated construction costs and do not include engineering fees for design and permitting. Defects noted in preceding sections that are not included in these recommendations have not risen to a level that warrants repairs.

Place fill in settlement areas at stations 13+56 and 17+55 and monitor for progression.

Monitor progression of soil settlement in north cells 1‐9.

Monitor progression of concrete deck crack and settlement in west cells A‐E.

In order to better determine the best means to stabilize the failures of the timber cribbing on the west wave break, a more detailed Special Inspection should be completed so that various rehabilitation concept options can be evaluated. One rehabilitation concept is to install steel sheet piles on the outside

Inspection and Assessment 2.4‐15 face of the wall and then pump concrete fill into the voided areas, entirely encasing the timber elements below.

The older steel sheet piles on the west wave break have section losses in some areas in excess of a nominal 1/16” design corrosion allowance and as such it is recommended that the original steel pile design plans be reviewed and evaluated to determine if the existing deteriorated condition is adequate for its current loadings. If the existing condition of the steel is adequate for its current loading, then the recommended repair is to arrest this progressive corrosion and associated reduction in capacity. The common methods to accomplish this are; jacketing, coatings, or cathodic protection. For submerged areas, jacketing typically is the most expensive initial cost, but has a low future maintenance cost.

Coatings are less expensive than jacketing initially, but typically last only 8‐10 years, before they need to be reapplied. Cathodic protection is typically the least expensive initial cost, but has some recurring future maintenance costs.to either replace galvanic anodes or power the impressed current system.

While the actual method of repair must be left to subsequent Design Level Inspections and the discretion of the Engineer of Record for the repair design, we have assumed that a cathodic protection system will provide the best value for this application.

SUMMARY OF RECOMMENDED REPAIRS

PRIORITY LEVEL ELEMENT REPAIR COSTS*

Immediate ‐ None ‐

Subtotal ‐

Short Term SSP Basin: Fill settlement areas at stations 13+56 and 17+55

$1,294

Subtotal $1,294

Long Term Cribbing

West wave break: Install SSP on perimeter of timber crib & fill void w/ concrete

$1,919,063

SSP

West wave break: Install cathodic protection system to 340 ft. of PDA 27 SSP

$575,000

Subtotal $2,494,063

Station ‐ None ‐

Subtotal ‐

Engineering Studies

Cribbing West wave break: Special Inspection and Rehabilitation evaluation

$64,688

Subtotal $64,688

STRUCTURE TOTAL $2,560,044

Inspection and Assessment 2.5‐16

2.5 SHORE EROSION PROTECTION FACILITY RIPRAP (RPUID 811870)

The riprap is located along the north end of the facility along the Buffalo River. It is constructed of stone riprap in front of a stone block wall. The structure is approximately 1,110 feet long and provides shore protection to the USCG facility.

Operational Restrictions: None

Remaining Service Life (without repairs): 10+ Years

Inspection and Assessment 2.5‐17

AREA

ELEMENT DESCRIPTION

Shore Protection

Riprap

The riprap is approximately 1,110 feet long and generally appears to be stable. The top of the riprap was typically located around the water line. The riprap is a mixture of stone and concrete. Station 0+00 to 0+47 is approximately 15‐feet wide and is constructed of stone riprap with concrete. At the corner, station 0+47, there is a large void under the concrete where stones have washed out. At station 0+38 there is a six foot long section of subsidence. Around station 9+50 there is a 100‐foot section where the riprap is below the water line.

Block Wall

The stone block wall extends from station 0+47 to the station 12+00. Along the back face of the stone block wall, approximately 75‐percent of the joints are open, leaving gaps between the blocks. Isolated voids are located along the top of the wall where stones are missing. The stone wall appears stable with no substantial signs of movement. There is one location of subsidence at approximately station 4+85. The stone wall is fractured due to tree roots at station 1+45.

For a complete list of observed defects, including size and location see Appendix A.

Photographs:

Photo 1: Settlement at station 0+38. Photo 2: Void at station 0+47.

Inspection and Assessment 2.5‐18

Photo 3: Overall view of riprap and stone block wall at station 0+75.

Photo 4: Fracture in top of wall at station 1+45.

Photo 5: Overall view of the riprap and wall at station 3+00.

Photo 6: Settlement in wall at station 4+85.

Photo 7: Missing stones in back of block wall. Photo 8: Open joints in back of stone block wall.

Inspection and Assessment 2.5‐19

Photo 9: 100 foot section where riprap is submerged, station 9+00 to 10+00.

The Riprap has no significant defects and therefore no repairs are recommended at this time.

APPENDIX A

STRUCTURAL DATA

Inspection and Assessment A‐2

APPENDIX A: TABLE OF CONTENTS

ITEM PAGE NO.

NOMENCLATURE SHEET............................................................................................................................ A‐3

FLOATING DOCK (RPUID 843888) ............................................................................................................. A‐4

HAULOUT FINGER PIER (RPUID 71883) ................................................................................................... A‐10

FINGER PIERS (RPUID 11508) .................................................................................................................. A‐15

SHORE EROSION PROTECTION BULKHEAD SYSTEM (RPUID 811834) ..................................................... A‐20

SHORE EROSION PROTECTION SYSTEM RIPRAP (RPUID 811870) ........................................................... A‐28

Inspection and Assessment A‐3

NOMENCLATURE SHEET

Defect Center: The location of the defect within the asset. Colon (:) indicates “at” Facility Section: The section (or area) within the facility where the defect is located, i.e. wharf, dolphin, trestle, etc.

Defect Types: The type of deterioration observed in the field, see below:

Timber Concrete Steel

ABS Abrasion damage ABS Abrasion Damage BNT Bent

CHK Checking CCS Closed corrosion spall CHW1 Chain Wear with <= 25% loss

CRU Crushing CMS Closed mechanical spall CHW2 Chain Wear with > 25% loss FCN Failed Connection CRF Crack Face COR Corrosion FDT Fastener Deterioration FRS Fracture Spall CTL Coating loss

FUN

Fungal decay with % loss

HCR Horizontal cracking FAT Fatigue Cracks

FWR Failed wrap LCR Longitudinal cracking FCN Failed Connection

MBD

Marine borer damage with % loss

OCS Open corrosion spall FDT Fastener deterioration

OSC Overstressing crack OMC Open mechanical crack FW Failed Weld SPL Split OMS Open mechanical spall KNE Knife Edge WEA Weathered OSC Overstressing Crack PCR Pattern cracking SFT Soft concrete underwater VCR Vertical cracking underwater

Other Defects

BRK Broken LST Listing CDF Construction Defect MSG Missing DSP Displaced NBR Non‐bearing ERS Erosion SHL Shoaling FRR Failed Repair SNK Sinkhole LOS Loose VOD Void DBR Debris

Inspection and Assessment A‐4

FLOATING DOCK (RPUID 843888)

Defect List

Sector Buffalo INSPECTION DATE: 08/21/2017

Floating Dock

Depth

Bent Row L (ft) W (Ft) L (ft) W (in.) D (in.)

1 Guide Pile Assembly 1 B BRK

2 Guide Pile Assembly 2 B BRK

3 Guide Pile Assembly 3 B LOS

4 Guide Pile Assembly 4 B MSC

5 Guide Pile Assembly 5 B BRK

6 Guide Pile Assembly 6 A BRK

7 Guide Pile Assembly 7 B MSG

8 Guide Pile Assembly 8 B MSC

9 Guide Pile Assembly 9 A BRK

10 Guide Pile Assembly 10 B MSG

11 Guide Pile Assembly 11 B BRK

12 Guide Pile Assembly 12 A BRK

13 Wale 6 A BRK 2

14 Wale 10.2 B BRK 10

15 Wale 11 B BRK 8

16 Wale 12 A BRK 2

17 Guide Pile Support 1 B.9 CRK Cracked grout pad on concrete cap connection

18 Guide Pile Support 2 B.9 CRK Cracked grout pad on concrete cap connection

19 Guide Pile Support 4 B.9 CRK Cracked grout pad on concrete cap connection

20 Guide Pile Support 5 B.9 CRK Cracked grout pad on concrete cap connection

21 Guide Pile Support 7 B.9 CRK Cracked grout pad on concrete cap connection

22 Guide Pile Support 8 B.9 CRK Cracked grout pad on concrete cap connection

23 Guide Pile Support 10 B.9 CRK Cracked grout pad on concrete cap connection

24 Guide Pile Support 11 B.9 CRK/MSC

25 Rub Strip 5.5 B MSG 10

26 Rub Strip 6.5 B MSG 10

27 Rub Strip 10.2 B MSG 16

28 Extruded Fender 1.8 A LOS/BRK 3.33

29 Extruded Fender 2 A LOS/BRK 2

30 Cleat 1.25 A LOS

31 Cleat 1.75 A LOS

Defect ID No.

Defect Type

Defect Size

CommentsP (ft) Exp Bars

N (#)

Area (sf) or % Loss

Location

Asset Type

Crack

SITE NAME:

RPUID NAME:

RPUID #: 843888

Floating Dock

Depth

Bent Row L (ft) W (Ft) L (ft) W (in.) D (in.)

Defect ID No.

Defect Type

Defect Size

CommentsP (ft) Exp Bars

N (#)

Area (sf) or % Loss

Location

Asset Type

Crack

SITE NAME:

RPUID NAME:

RPUID #: 843888

32 Cleat 2.6 A LOS

33 Cleat 3.8 A LOS

34 Cleat 4.25 A LOS

35 Cleat 5.25 A LOS

36 Cleat 5.75 A LOS

37 Cleat 6.25 A LOS

38 Cleat 6.75 A LOS

39 Cleat 7.75 A LOS

40 Cleat 8.75 A LOS

41 Cleat 9.25 A LOS

42 Cleat 9.75 A LOS

43 Cleat 10.4 A LOS

44 Cleat 11.2 A LOS

45 Cleat 11.8 A LOS

46 Hinge Connection 4.5 A.5 BRK 8

47 Hinge Connection 8.5 A.5 BRK 8

48 Lake Bottom 12 A DBR Timber pile stub 7'…