RFQ-25-7_Bulkhead_Inspection.pdf

Port Canaveral Bulkheads Condition Assessment Report

Routine Level Inspection

Cape Canaveral, Florida

Document Number: 24CPA002-0

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Port Canaveral – Condition Assessment

24PCA002-0 2

Canaveral Port Authority

Port Canaveral

Cape Canaveral, Florida

ROUTINE LEVEL INSPECTION

Document Number: 24CPA002-0

Submitted By:

Jacobs

445 Challenger Road Suite 130

Cape Canaveral, FL 32920

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Executive Summary Jacobs Engineering Group Inc. (Jacobs) performed an above water and underwater Routine Level

Inspection of Port Canaveral marine bulkhead facilities between March 4, 2024, and July 26, 2024. The following facilities were included in this work:

North Cargo Piers 1 and 2

North Cargo Berths 5, 6, and 8, South Cargo Piers 1, 2, 3, and 4, The Marina, the Cove, and the Tug Berth

Cruise Terminals 1, 2, 3, 5, 6, 8, and 10.

This Inspection was performed in accordance with the American Society of Civil Engineers (ASCE) MOP-130

Waterfront Facilities Inspection and Assessment Guidelines Manual. The general condition assessment ratings for the entire facility as well as its individual structures and element groups are based on a six-point assessment scale developed by the ASCE. The six condition assessment ratings are:

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

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

Fair: All primary structural elements are sound; but minor to moderate defects or deterioration observed. Localized areas of moderate to major deterioration may be present but do not significantly reduce the load-bearing 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 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. The capacity of the structure is critically deficient relative to the structural requirements. Repairs may need to be carried out on a very high priority basis with strong urgency.

In general, the condition of all the bulkhead facilities was found to be Good to Fair except for the North

Cargo Pier 2 Bulkhead and the Marina Bulkhead which are in Poor condition. It should be noted that many of these ratings are driven by the condition of the protective and structural concrete caps and that the steel sheet piles and steel combi walls are relatively free of significant defects except where noted.

Comparing ultrasonic thickness readings from the previous inspection in 2016 indicates minimal uniform section loss of all steel elements below water. For a comparison of overall ratings between 2016 and 2024 see Table 1 below.

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Table 1 Port Canaveral Bulkheads Condition Rating Summary

Report

Section # Bulkhead Structure

Approx. Year of

Construction

2016 Condition

Rating

2024 Condition

Rating

3.1

North Cargo Pier 1

Bulkhead

Fair Fair

North Cargo Pier 2

Bulkhead Poor Poor

North Cargo Pier 1 & 2

Toe Wall Satisfactory Satisfactory

3.2 North Cargo Berth 5 & 6

Bulkhead 2015 N/A Satisfactory

3.3 Tug Berth Bulkhead 1973 Fair Fair

3.4 North Cargo Berth 8

Bulkhead 2019 N/A Good

3.5 Cruise Terminal 5 Bulkhead 1990 Good Satisfactory

3.6 Cruise Terminal 6 Bulkhead 2016 N/A Fair

3.7

Cruise Terminal 8 Bulkhead

Fair Fair

Cruise Terminal 8 Toewall Fair Fair

3.8

Cruise Terminal 10 Bulkhead

Fair Fair

Cruise Terminal 10 Toewall Fair Fair

3.9 Marina Bulkhead 1970 Poor Poor

3.10 The Cove Bulkhead 2000 Fair Fair

3.11 Cruise Terminal 1 Bulkhead 2014 N/A Satisfactory

3.12 South Cargo Pier 4 Bulkhead 1999 Fair Fair

3.13 South Cargo Pier 3 Bulkhead 1980 Fair Fair

3.14 South Cargo Pier 2 Bulkhead 2005 Good Good

3.15 South Cargo Pier 1 Bulkhead 1990 Good Good

3.16 Cruise Terminal 2 Bulkhead 1973 N/A Fair

3.17 Cruise Terminal 3 Bulkhead 2020 N/A Satisfactory

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Bulkheads Rated Good

The North Cargo Berth 8, South Cargo Pier2, and South Cargo Pier1 Bulkheads are in Good condition overall with only minor deficiencies noted.

Bulkheads Rated Satisfactory

The North Cargo Pier 1 Toewall, the North Cargo Berth 5 & 6 Bulkhead, the Cruise Terminal 5 Bulkhead, the Cruise Terminal 1 Bulkhead, and the Cruise Terminal 3 Bulkhead are in Satisfactory condition overall.

The North Cargo Pier 1 Toewall is in Satisfactory condition overall due to minor to moderate corrosion of the steel sheet piles and some lateral displacement.

The North Cargo Berth 5 & 6 Bulkhead is in Satisfactory condition overall due to areas of voids in the concrete cap with exposed reinforcing steel. Additionally, two safety ladders and several fender retention chains are broken.

The Cruise Terminal 5 Bulkhead is in Satisfactory condition overall with limited moderate defects, including spalling and voids in the concrete cap and localized areas of concrete scour mattress displacement or undermining.

The Cruise Terminal 1 Bulkhead is in Satisfactory condition overall with minor to moderate defects including several voids in the concrete cap with exposed reinforcing steel.

The Cruise Terminal 3 Bulkhead is in Satisfactory condition overall due to areas of minor spalling and localized areas of undermined concrete scour mattresses.

Bulkheads Rated Fair

The North Cargo Pier 1 Bulkhead, the Tug Berth Bulkhead, the Cruise Terminal 6 Bulkhead, the Cruise

Terminal 8 Bulkhead and Toe Wall, the Cruise Terminal 10 Bulkhead, the Cove Bulkhead, the South Cargo

Pier 4 Bulkhead, the South Cargo Pier 3 Bulkhead, and the Cruise Terminal 2 Bulkhead are in Fair condition overall.

The North Cargo Pier 1 Bulkhead is in Fair condition overall due to moderate to major corrosion of the steel sheet piles and widespread spalling and voids with exposed reinforcing steel in the concrete cap.

The Tug Berth Bulkhead is in Fair condition overall due to numerous areas of spalling throughout the concrete pile cap typically with exposed severely corroded reinforcing steel.

The Cruise Terminal 6 Bulkhead is in Fair condition overall with moderate to major defects identified.

Defects observed include areas of moderate to major concrete voids with exposed reinforcing steel in areas of latent concrete on the bottom of the concrete pile cap.

The Cruise Terminal 8 Bulkhead is in Fair condition overall due to moderate to major defects including widespread voids and spalling with exposed reinforcing steel throughout the concrete cap. Additionally, undermining of the concrete scour mattresses has caused displacement up to 8 ft from the design depth to an elevation of 35 ft below MLW.

The Cruise Terminal 8 Toe Wall is in Fair condition overall due to two major defects. The toe wall is out of plumb, with the top of the wall rotated towards the channel, from Station 8+70 to 9+25. At Station 9+00 the toe wall is leaning against the adjacent pier pile. At the bulkhead corner, the toe wall sheeting is not engaged with the bulkhead sheeting with a gap up to 2 in. wide.

The Cruise Terminal 10 Bulkhead is in Fair condition overall with moderate to major defects including isolated voids, spalling, and delamination throughout the concrete cap and widespread undermining and

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displacement of the concrete scour mattresses. The steel toe wall is in Fair condition due to sheet pile overlap repairs with open gaps and one open interlock with a gap up to 15 in. wide.

The Cove Bulkhead is in Fair condition overall with moderate defects throughout including voids and spalling. Below water, the steel sheet piles have several noted corrosion holes and widespread coating loss and section loss.

The South Cargo Pier 4 Bulkhead is in Fair condition overall due to cracking and extensive spalling in the concrete pile cap as well as sinkholes between Station 2+45 and 3+35, just inshore of the concrete pile cap.

The South Cargo Pier 3 Bulkhead is in Fair condition overall due to several voids and spalling in the concrete cap. The steel sheets and king piles have most of the coating intact, with isolated areas of coating loss with minor corrosion. The mooring and berthing system is in Serious condition overall due to major to severe corrosion throughout the bollard fittings and spalling up to 4 in. in the concrete foundations and several broken arch fenders.

The Cruise Terminal 2 Bulkhead is in Fair condition overall with moderate to major defects including, widespread delamination and spalling of the concrete sheet piles. Additionally, the concrete sheet piles exhibit widespread erosion on the bottom 2 ft. of the bulkhead that is up to ¾ in. deep. The upland portion of the facility contains a sinkhole at Station 3+34 and a broken fence support at Station 6+78.

Bulkheads Rated Poor

The North Cargo Pier 2 Bulkhead and the Marina Bulkhead are in Poor condition overall.

The North Cargo Pier 2 Bulkhead is in Poor condition overall due to severe corrosion throughout the steel sheet piles and widespread spalling and voids with exposed reinforcing steel in the concrete cap. The area of the most severe corrosion is in the splash zone, which is the top 6 ft of the sheet piles and has up to

40% section loss with numerous corrosion holes.

The Marina Bulkhead is in Poor condition overall due to severe defects including large voids in the concrete cap with severely corroded steel reinforcing steel. Below water, the steel sheet piles widespread

100% coating loss and two corrosion holes.

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3. 2024 Inspection Findings

3.1 North Cargo Pier 1 & 2

3.1.1 Description of Structure

North Cargo Piers 1 and 2 were constructed in 1987. They are oriented north to south and are located along the west side of the Middle Turning Basin at Port Canaveral. For the purpose of this inspection, the bulkhead walls at North Cargo Piers 1 and 2 were stationed continuously since the main bulkhead is constructed as one continuous wall behind the piers. The majority of the bulkhead runs north to south with the exception of a return wall at the northernmost portion of the wall that runs approximately 300 ft to the east, terminating at the Space Force Station property line. Station 0+00 begins at the easternmost point of the return wall. The North Cargo Pier 1 return wall is constructed of steel sheet piles with a concrete cap that extends down to elevation -1.0 MLW. The tieback system has one level of anchor rods centered at elevation +1.0 MLW with the outboard connections encapsulated by a concrete encasement on the bulkhead face. The anchor rods are connected to concrete deadman anchors.

The North Cargo Pier 1 bulkhead continues from Station 3+10 to Station 11+20, which is the interface with the northern end of the North Cargo Pier 2 bulkhead (Photos 3.1-1 and 3.1-2). The North Cargo Pier

1 bulkhead is constructed of steel sheet piles with a concrete cap that extends down to an elevation of -

1.0 MLW. The tieback system has anchor rods centered at +1.0 MLW and +2.0 MLW with the outboard connections encapsulated in a concrete encasement. The North Cargo Pier 2 bulkhead begins at Station

11+20 and extends to Station 17+75, which is the interface with the recently reconstructed North Cargo

Pier 3 Bulkhead. The North Cargo Pier 2 bulkhead is constructed of steel sheet piles with a short concrete cap leaving the steel piles exposed in the splash zone. The tieback system has one level of anchor rods at elevation +1.0 MLW, and the outboard connections are exposed. The anchor rods here are connected to a continuous steel sheet pile anchor wall.

The mooring system at the bulkheads consists of various secondary T-head, single-bit, and double-bit bollards located along the upland portion of the bulkhead (Photos 3.1-4). The majority of mooring fittings supporting this facility are on the NCP1 and NCP2 Piers themselves.

The North Cargo Pier 1 Toewall runs parallel to the North Cargo Pier 1 bulkhead and is located approximately 100 ft offshore of the bulkhead, between the third and fourth offshore pier pile rows. The toe wall stationing corresponds to the main bulkhead stationing. At the north end of the toe wall, the steel sheet piles are buried into the slope and the exposed sheets begin at Station 4+20. The top of the steel sheet piles are generally cut at the same elevation and the sloped fill on the inshore side of the wall meets the top of the toe wall. There is a change in the geometry of the toe wall at Station 10+50 where the toe wall turns 6 ft to the east before returning south. Along the southernmost portion of the toe wall, from

Station 11+20 to 11+65, the sheeting tapers down in elevation. The toe wall is comprised of steel sheet piles and the top of the wall is submerged at an elevation of -15.0 MLW.

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Photo 3.1-1. Overall view of North Cargo Pier 1 Bulkhead looking west.

Photo 3.1-2. Overall view of North Cargo Pier 2 Bulkhead looking south.

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Photo 3.1-3. Typical condition of concrete cap.

Photo 3.1-4. Typical condition of double-bit bollards.

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3.1.2 Observed Conditions

3.1.2.1 NCP 1 Bulkhead

The steel sheet piles and concrete cap at the North Cargo Pier 1 Bulkhead are in Fair condition due to moderate to major deterioration. The concrete cap exhibits major spalling and voids throughout. At

Station 2+07, a spall is present approximately 2 ft from the top of the concrete cap measuring 12 in. long by 24 in. high, and up to 3 in. deep. Additionally, a 24-in. high by 18-in. deep void is present from Station

6+15 to 7+00 exposing multiple reinforcing bars with major to severe corrosion (Photo 3.1-5). Refer to

Table 3.1-A for a detailed list of defects at the NCP 1 Bulkhead.

Table 3.1-A. North Cargo Pier 1 Bulkhead Defects

Defect # Repair Action Station Elevation Defect Description

1 Routine 0+20 to

0+75

Below Cap Corrosion Exposed steel sheet piles (approx. 1.5 ft high) have major to severe corrosion.

2 No Repair 0+20 to

2+07

Conc. Cap Cracking Transverse hairline cracking with efflorescence in concrete cap spaced at approximately 5 ft.

3 Routine 2+07 Conc. Cap Spall Spall is located 2 ft from the top of the concrete cap measuring 12 in. long, 24 in. high, and 3 in.

deep.

4 Routine 5+02 -1.0 MLW Spall Spall on the underside of concrete encasement that measures 8 in. high, 8 in. wide, and 15 in.

deep with no rebar exposed.

5 Routine 5+75 +3.0 MLW Spall Spall on the top corner of concrete encasement measuring 5 ft. long, 12 in. high, and 3 in. deep with one exposed rebar with minor corrosion.

6 Routine 6+18 -1.0 MLW Void Void on the underside of concrete cap that measures 8 in. high, 8 in. wide, and 36 in. deep to the inner flange of the steel sheet piles.

7 Routine 6+15 to

6+25

-1.0 MLW Voids Intermittent voids between the steel sheet piles and the inboard face of the concrete cap. The voids measure 8 to 24 in. high and 2 to 4 in.

wide.

8 Priority 6+25 to

6+35

0.0 MLW Large Void Large void in concrete cap measuring 10 ft.

long, 10 in. high, and 15 in. deep with 7 rebars exposed that have moderate corrosion.

9 Priority 6+15 to

7+00

Conc. Cap Large Void Failed repair caused a void in the concrete cap measuring 85 ft. long, 24 in. high, and up to 18

in. deep with multiple bars exposed with severe corrosion.

9-1 Priority 6+00 to

8+00

-9.0 MLW Corrosion Exposed steel sheet piles (approx. 2.5 ft high) have major to severe corrosion.

10 Priority 9+75 Below Enc. Void Void in repair exposes one layer of tie rod below the concrete encasement.

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Photo 3.1-5. Void in concrete cap at Station 7+00.

Below water, the steel sheet piles exhibited moderate to major corrosion with 100% coating loss throughout (Photo 3.1-6). Additionally, ultrasonic thickness measurements revealed the average section loss of the steel sheets is approximately 15%. Stations 6+00 and 7+00 have up to 33% section loss with pitting up to 1/16 in. deep at these locations with isolated areas of corrosion holes. Refer to Table 3.1-B below for the detailed steel thickness data that was collected on the North Cargo Pier 1 Bulkhead.

Table 3.1-B. North Cargo Pier 1 Bulkhead Ultrasonic Thickness Readings

Location

Readings (in.)

Nominal

Thickness (in.)

Percent

Thickness Lost

Approx.

Section Lost Station Depth

(ft) Sheet Pile Loc

4+00 -5

Outer Flange 0.425 0.460 8%

6% Web 0.327 0.350 7%

Inner Flange 0.442 0.460 4%

5+00 -6

Outer Flange 0.418 0.460 9%

7% Web 0.323 0.350 8%

Inner Flange 0.442 0.460 4%

6+00 -6

Outer Flange 0.297 0.460 36%

33% Web 0.225 0.350 36%

Inner Flange 0.328 0.460 29%

7+00 -6

Outer Flange 0.320 0.460 30%

24% Web 0.245 0.350 30%

Inner Flange 0.412 0.460 11%

8+00 -6

Outer Flange 0.397 0.460 14%

13% Web 0.265 0.350 24%

Inner Flange 0.452 0.460 2%

9+00 -6

Outer Flange 0.397 0.460 14%

13% Web 0.265 0.350 24%

Inner Flange 0.452 0.460 2%

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Location

Readings (in.)

Nominal

Thickness (in.)

Percent

Thickness Lost

Approx.

Section Lost Station Depth

(ft) Sheet Pile Loc

10+00 -6

Outer Flange 0.343 0.460 25%

13% Web 0.293 0.350 16%

Inner Flange 0.467 0.460 -1%

11+00 -7

Outer Flange 0.425 0.460 8%

7% Web 0.305 0.350 13%

Inner Flange 0.458 0.460 0%

Photo 3.1-6. Typical steel sheet pile condition at NCP1 Bulkhead. Note corrosion holes.

3.1.2.2 NCP 2 Bulkhead

The NCP 2 Bulkhead is in Poor condition due to areas of severe corrosion and holes in the steel sheet piles

(Photo 3.1-7) and moderate to major voids and spalls throughout the concrete cap. Spalling at Stations

13+00 and 14+00 exposes the top of the steel sheet pile. Refer to Table 3.1-C for a detailed list of defects at the NCP 2 Bulkhead.

Table 3.1-C. North Cargo Pier 2 Bulkhead Defects

Defect # Repair Action Station Elevation Defect Description

11 Priority 11+63 to

14+08

Top 6 ft. of exp. SSP

Severe

Corrosion

Major to severe corrosion with heavy delaminations and intermittent corrosion holes up to 12 in.

diameter near the bottom of the concrete cap.

12 Routine 11+72 to

12+75

Btm of Cap Delam. Horizontal crack/delamination in the bottom of the concrete cap up to 1/8 in. wide.

13 Routine 13+00 Btm of Cap Spall Spall on the bottom of the cap that measures 18 in.

high, 6 ft. long, and 9 in. deep with the outer flange of the steel pile exposed and heavily corroded.

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Defect # Repair Action Station Elevation Defect Description

14 Routine 13+75 to

14+40

Btm of Cap Spalling Intermittent spalling along the bottom of the cap measuring up to 2 ft. high and 10 in. deep with exposed outer flanges of sheet piles.

15 Priority 14+08 to

17+50

Top 4 ft. of exp. SSP

Major

Corrosion

Major corrosion of the exposed steel sheet piles from the bottom of the cap down 4 ft.

16 Priority 17+50 to

17+75

Top 4 ft. of exp. SSP

Severe

Corrosion

Severe corrosion of the top 4 ft of steel sheet piles with corrosion holes above and below water, typically in the webs, at 1 ft. & 7 ft. below cap.

Photo 3.1-7. Severe corrosion of steel sheet piles at Station 17+75. Note corrosion holes.

Below water, the steel sheet piles exhibit major to severe corrosion with 100% coating loss and numerous corrosion holes (Photo 3.1-8) throughout the splash zone, which extends from the bottom of the concrete cap down 6 ft. Additionally, ultrasonic thickness measurements revealed the average section loss of the steel sheets is approximately 20%. Stations 16+00 and 17+00 exhibit over 40% section loss with pitting up to 1/8 in. deep and corrosion holes isolated throughout the splash zone. Refer to Table 3.1-D below for the detailed steel thickness data that was collected on the North Cargo Pier 2 Bulkhead.

Table 3.1-D. North Cargo Pier 2 Bulkhead Ultrasonic Thickness Readings

Location 2024 Readings

(in.)

Nominal

Thickness (in.)

Percent

Thickness Lost

Approx.

Section Lost Station Depth (ft) Sheet Pile Loc

12+00 -3

Outer Flange 0.445 0.460 3%

10% Web 0.265 0.350 24%

Inner Flange 0.450 0.460 2%

12+00 -8 Outer Flange 0.383 0.460 17%

11% Web 0.273 0.350 22%

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Location 2024 Readings

(in.)

Nominal

Thickness (in.)

Percent

Thickness Lost

Approx.

Section Lost Station Depth (ft) Sheet Pile Loc

Inner Flange 0.488 0.460 -6%

13+00 -8

Outer Flange 0.367 0.460 20%

20% Web 0.237 0.350 32%

Inner Flange 0.427 0.460 7%

13+15 -8

Outer Flange 0.405 0.460 12%

11%Web 0.318 0.350 9%

Inner Flange 0.405 0.460 12%

14+00 -8

Outer Flange 0.417 0.460 9%

11% Web 0.292 0.350 17%

Inner Flange 0.430 0.460 7%

15+00 -11

Outer Flange 0.330 0.460 28%

19% Web 0.263 0.350 25%

Inner Flange 0.447 0.460 3%

16+00 -3

Outer Flange 0.308 0.460 33%

43% Web 0.113 0.350 68%

Inner Flange 0.335 0.460 27%

16+00 -7

Outer Flange 0.427 0.460 7%

19% Web 0.255 0.350 27%

Inner Flange 0.362 0.460 21%

17+00 -3

Outer Flange 0.417 0.460 9%

13% Web 0.285 0.350 19%

Inner Flange 0.408 0.460 11%

17+00 -8

Outer Flange 0.212 0.460 54%

41% Web 0.175 0.350 50%

Inner Flange 0.373 0.460 19%

17+50 -3

Outer Flange 0.410 0.460 11%

16% Web 0.233 0.350 33%

Inner Flange 0.438 0.460 5%

17+50 -8

Outer Flange 0.305 0.460 34%

33% Web 0.150 0.350 57%

Inner Flange 0.422 0.460 8%

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Photo 3.1-8. Corrosion hole in steel sheet pile below water with active fill loss at Station 15+50.

3.1.2.3 NCP 1 Toewall

The NCP 1 Toewall is in Satisfactory condition due to minor to moderate deterioration in the steel sheets.

At Station 5+20, there are local deformations on the top edge of the sheets up to 3 in. deep. Additionally, at Station 9+58, the top of the steel sheet pile toewall has laterally displaced up to 6 in. from vertical to the east and is in contact with the adjacent concrete piles (Photo 3.1-9). Refer to Table 3.1-E below for the detailed defect notes for the NCP 1 Toewall.

Table 3.1-E. North Cargo Pier 1 Sheet Pile Toewall Defects

Defect

Repair Action Station Elevation Defect Description

17 No Repair 5+20 -16 MLW Impact

Damage

Indentations up to 3 in. deep and 8 in.

wide along the top 10 in. of sheet pile.

17-1 No Repair 9+58 Top of

Toewall

Deflection Top of toewall laterally displaced 6 in.

towards east and it is in contact with adjacent concrete pile.

The NCP 1 Toewall exhibits minor to moderate defects with isolated areas of coating loss throughout

(Photo 3.1-10). Ultrasonic thickness measurements revealed the average section loss of the steel sheet piles is approximately 9%. Refer to Table 3.1-F below for the detailed steel thickness data that was collected on the North Cargo Pier 1 Toewall.

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Table 3.1-F. North Cargo Pier 1 Toewall Ultrasonic Thickness Readings

Location 2024 Readings

(in.)

Nominal

Thickness (in.)

Percent

Thickness Lost

Approx.

Section Lost Station Depth (ft) Sheet Pile Loc

5+00 -18

Outer Flange 0.532 0.581 8%

10% Web 0.388 0.440 12%

Inner Flange 0.523 0.581 10%

5+00 -25

Outer Flange 0.538 0.581 7%

10% Web 0.393 0.440 11%

Inner Flange 0.510 0.581 12%

6+00 -19

Outer Flange 0.537 0.581 8%

8% Web 0.407 0.440 8%

Inner Flange 0.533 0.581 8%

6+00 -25

Outer Flange 0.542 0.581 7%

7% Web 0.410 0.440 7%

Inner Flange 0.537 0.581 8%

7+00 -18

Outer Flange 0.530 0.581 9%

9%Web 0.393 0.440 11%

Inner Flange 0.528 0.581 9%

7+00 -23

Outer Flange 0.532 0.581 8%

9% Web 0.395 0.440 10%

Inner Flange 0.528 0.581 9%

7+00 -27

Outer Flange 0.535 0.581 8%

8% Web 0.407 0.440 8%

Inner Flange 0.540 0.581 7%

8+00 -19

Outer Flange 0.530 0.581 9%

9% Web 0.398 0.440 9%

Inner Flange 0.535 0.581 8%

8+00 -25

Outer Flange 0.532 0.581 8%

8% Web 0.403 0.440 8%

Inner Flange 0.535 0.581 8%

8+90 -20

Outer Flange 0.463 0.581 20%

15% Web 0.397 0.440 10%

Inner Flange 0.493 0.581 15%

8+90 -26

Outer Flange 0.513 0.581 12%

10% Web 0.393 0.440 11%

Inner Flange 0.528 0.581 9%

10+00 -20

Outer Flange 0.530 0.581 9%

9% Web 0.398 0.440 9%

Inner Flange 0.523 0.581 10%

10+00 -25

Outer Flange 0.533 0.581 8%

9% Web 0.393 0.440 11%

Inner Flange 0.535 0.581 8%

10+00 -29

Outer Flange 0.532 0.581 8%

9% Web 0.398 0.440 9%

Inner Flange 0.537 0.581 8%

11+00 -20

Outer Flange 0.532 0.581 8%

11% Web 0.377 0.440 14%

Inner Flange 0.528 0.581 9%

11+00 -25

Outer Flange 0.540 0.581 7%

9% Web 0.395 0.440 10%

Inner Flange 0.527 0.581 9%

11+00 -29

Outer Flange 0.533 0.581 8%

9% Web 0.397 0.440 10%

Inner Flange 0.527 0.581 9%

11+50 -25

Outer Flange 0.543 0.581 6%

7% Web 0.408 0.440 7%

Inner Flange 0.532 0.581 8%

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Photo 3.1-9. Toewall (arrow) in contact with adjacent concrete pile at Station 9+58.

Photo 3.1-10. Typical condition of steel sheets at NCP 1/2 Toewall.

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The upland portion of North Cargo Piers 1 & 2 is in Fair condition with moderate to major defects. Map cracking up to 1/16 in. wide was observed throughout the concrete cap and concrete encasement.

Additionally, isolated sinkholes are present inshore of the concrete cap from Stations 3+10 to 4+97 and at

Station 9+40.

The mooring system is in Fair condition due to minor to moderate corrosion. The T-head bollards exhibit

5% coating loss with minor corrosion on the fittings and bases. The single-bit and double-bit bollards exhibit up to 50% coating loss with moderate corrosion on the fittings.

3.1.3 Conclusions and Recommendations

The North Cargo Pier 1 Bulkhead is in Fair condition overall due to widespread spalling and voids with exposed reinforcing steel in the concrete cap. Below water, the steel sheet piles exhibit moderate corrosion with pitting in the steel up to 1/16 in. deep. Based on the ultrasonic thickness measurements, the average section loss of the steel sheet piles is approximately 15% with a maximum section loss of

33%.

The North Cargo Pier 2 Bulkhead is in Poor condition overall due to severe corrosion throughout the steel sheet piles and widespread spalling and voids with exposed reinforcing steel in the concrete cap. The area of the most severe corrosion is in the splash zone, which is the top 6 ft of the sheet piles and has up to

40% section loss with numerous corrosion holes. Based on the ultrasonic thickness measurements, the average section loss of the steel sheet piles is approximately 20%.

The structural capacity of the NCP 2 Bulkhead was analyzed in 1998 using the 20% section loss observed at that time, and the factors of safety were found to be less than the acceptable industry standard values.

Routine monitoring of the wall is recommended, and the wall should be replaced when the funds are available.

The North Cargo Pier 1 Toewall is in Satisfactory condition overall due to minor corrosion of the steel sheet piles. Based on the ultrasonic thickness measurements, the average section loss of the steel sheet piles is approximately 9%.

Based on the conditions observed during the field inspection, the following Priority level repairs are recommended:

Repair spalls and voids in the concrete cap at North Cargo Pier 1 & 2 Bulkheads.

Clean and recoat mooring bollards that have greater than 50% coating loss.

Based on the conditions observed during the field inspection, the following Additional Investigations are recommended:

Continue with the established measures of controlling surcharge loading adjacent to the wall and monitor the condition of the steel sheet piles on an annual basis.