ST KILDA PIER

INFRASTRUCTURE MANAGEMENT

ST KILDA PIER

REPAIR PROJECT

1.0 INTRODUCTION AND PROJECT BRIEF

The St Kilda Pier will undergo a series of repairs based on the results of site investigation. We as a group will develop a repair strategy to determine and value our repair options. The repair strategy will be focusing on two.

sections of:

Part 1: Slabs

Part 2: Substructures (Piles and Crosshead Beams)

The repair options for slabs are as follow:

Option 1: Patching (Patch + Epoxy + Cementitious Coating)

Option 2: Patching + Silane

Option 3: Replacement

The repair options for piles and crossheads are as follows:

Option 1: Patching

Option 2: CP (with patching)

Option 3: Replacement

Group Number LIFETIME(YEAR) SLAB

1 SLAB

2 SLAB

3 Total slabs

46 85 D K S 52

Part 1: Slabs

Slab D

17 slabs in section

Table of Quantities for Slabs

1.1.1 Table of Defects for Slabs

Defect No . Description Size

1. Crack < 5mm 0.45mm x 4.6m

2. Crack > 5mm 25mm x 30mm x 4.6m

3. Crack > 5mm 25mm x 30mm x 1.75m

4. Rust Stains 0.06m x 0.8m

5. Rust Stains 0.07 x 0.13m

6. Exposed Aggregate 25% x 4m x 4.6m

7. Heavy Rust Stains 0.2m x 0.45m

8. Heavy Rust Stains 0.2m x 0.3m

9. Heavy Rust Stains 0.2m x 0.55m

10. Map Cracking 25% x 4m x 4.6m

11. Concrete damage along edge 0.13m x 0.5m

Slab K

17 Slabs in section

Defect No. Type Size(m) Repair Option Volume/Area/Length Repair

1 Crack<0.5 0.0004 Epoxy 4.6 M3

2 Rust Staining Cementitious Coating 18.4 M2

3 Crack<0.5 0.00045 Epoxy 4.6 M3

4 Crack>0.5 0.0006 Patch 0.0000828 M3

5 Map Cracking Cementitious Coating 18.4 M2

Total Cementitious coating 18.4 M2

Example of Calculation for:

Epoxy (Defect 1 Crack- entire length) = 4.6m

Cementitious Coating (Defect 2 Rust staining) = 4 x 4.6 = 18.4 m2

Slab S

18 Slabs in section

Defect No . Description Size

1. Crack >5mm 25mm x 30mm x 1.45m

2. Heavy Rust Stains 0.2m x 0.3m

3. Spall/Damage 0.15m x 0.21m x 0.03

4. Heavy Rust Stains 0.2m x 0.25m

5. Spall/Damage 0.04 x 0.6m

0.02x0.12m

0.03x0.1m

6. Crack>5mm 25mm x 30mm x 4.6m

7. Spall/Damage 0.05m x 0.2m

8. Heavy Rust Stains 0.2x 0.11m

9. Spall/Damage 0.05m x 0.35m

10. Map Cracking %33.3x 4x 4.6 m

11. Salt Scaling %33.3x 4x 4.6 m

12. Rust staining %33.3x 4x4.6m

13. Salt Scaling 0.1 m x 0.15 m

14. Expose aggregates 4x 4.6x %75

15. Spall/Damage 0.07mx0.15m

16. Spall/Damage 0.04 m x 0.07 m

Lifetime: 85 Years

1.1.2 Slab Defect Repair Cost

Slab D

Defect description Repair dimension Repair option Cost ($)

1.Crack < 5mm 4.6 m Epoxy Crack Injection $2300

2.Crack > 5mm 0.00345 m3 Patch Repair $2.42

3.Crack > 5mm 0.0013125 m3 Patch Repair $0.92

4.Rust Stains 0.0048 m2 Cementitious Coating 5.Rust Stains 0.0091 m2 Cementitious Coating 6.Exposed Aggregate 4.6 m2 Cementitious Coating 7.Heavy Rust Stains 0.09 m2 Cementitious Coating 8.Heavy Rust Stains 0.06 m2 Cementitious Coating 9.Heavy Rust Stains 0.11 m2 Cementitious Coating 10.Map Cracking 4.6 m2 Cementitious Coating 11.Concrete damage along edge 0.0065 m2 Patch Repair $1.3

Total cementitious coating 18.4 m2 Cementitious Coating $3,680

Total Cost $5,984.63

Total area to be covered by cementitious coating is more than 50% of the total surface area, thus, cementitious coating must be applied.

to whole surface area.

Total cementitious coating = 9.46 sqm > 9.2 sqm, thus, apply cementitious coating to whole slab

Slab K

Defect No. Type Size(m) Repair Option Volume/Area/Length Repair Cost ($)

1 Crack<0.5 0.0004 Epoxy 4.6 M3 $2300

2 Rust Staining Cementitious Coating 18.4 M2 -

3 Crack<0.5 0.00045 Epoxy 4.6 M3 $2300

4 Crack>0.5 0.0006 Patch 0.0000828 M3 $0.5796

5 Map Cracking Cementitious Coating 18.4 M2 -

Total Cementitious coating 18.4 $3680

Total cost $8,280.5796

Total area to be covered by cementitious coating is more than 50% of the total surface area, thus, cementitious coating must be applied.

to whole surface area.

Slab S

Defect description Repair dimension Repair option Cost ($)

1.Crack >5mm 0.0010875m3 Patch Repair $7.61

2.Heavy Rust Stains 0.06 m2 Cementitious Coating -

3.Spall/Damage 0.000945 m3 Patch Repair $6.615

4.Heavy Rust Stains 0.05 m2 Cementitious Coating -

5.Spall/Damage 0.001755 m2

0.000357 m2

0.00036m2 Patch Repair $ 12.285

$ 2.499

$ 2.52

6.Crack>5mm 0.00345 m3 Patch Repair $ 24.15

7.Spall/Damage 0.00075 m3 Patch Repair $5.25

8.Heavy Rust Stains 0.022 m2 Cementitious Coating -

9.Spall/Damage 0.0175m2 Patch Repair $122.5

10.Map Cracking 6.1272 m2 Cementitious Coating -

11.Salt Scaling 6.1272 m2 Cementitious Coating -

12.Rust staining 6.1272 m2 Cementitious Coating -

13.Salt Scaling 0.015 m2 Cementitious Coating -

14.Expose aggregates 13.8 m2 Cementitious Coating -

15.Spall/Damage 0.00072 m3 Patch Repair $5.04

Spall/Damage 0.000324 m3 Patch Repair $2.268

Total cementitious coating 18.4 m2 Cementitious Coating $3,680

Total Cost $6,136.469

Total area to be covered by cementitious coating is more than 50% of the total surface area, thus, cementitious coating must be applied.

to whole surface area.

Total cementitious coating = 32.3286sqm > 9.2 sqm, thus, apply cementitious coating to whole slab

Option1.Patching (Patch + Epoxy + Cementitious Coating)

1.1.2 Summarized Quantities of Table of Defects for Slabs:

SLAB D

Slab Total

Volume/Area/length

Repair Cost/Unit ($) Repair Cycles (No.) Total Cost over Repair Cycles

Crack < 0.5mm 4.6m 500 6 $13,800

Crack > 0.5mm 0.0047625m3 7000 17 $ 566.7375

Spalls - - - -

Rust staining 0.0069 m2 - - -

Exposed

Aggregate 4.6 - - -

Salt Scaling - - - -

Other types of

Defect 0.0065 m2 200 9 -

Cementitious

Coating 18.4 m2 200 9 $33,120

Total Cost - - - $47,486.7375

SLAB K

Slab Total

Volume/Area/length

Repair Cost/Unit ($) Repair Cycles (No.) Total Cost over Repair Cycles

Crack < 0.5mm 9.2 500 6 $27,600

Crack > 0.5mm 0.0000828 m3 7000 17 $9.8532

Spalls - - - -

Rust staining 18.4 m2 - - -

Exposed

Aggregate - - - -

Salt Scaling - - - -

Other types of

Defect - - - -

Cementitious

Coating 18.4 m2 200 9 $33120

Total Cost - - - $60,774.8532

SLAB S

Slab Total

Volume/Area/length

Repair Cost/Unit ($) Repair Cycles (No.) Total Cost over Repair Cycles

Crack < 0.5mm - - - -

Crack > 0.5mm 0.0045375 m3 7000 17 $539.9625

Spalls 0.022711 m3 7000 17 $2702.69

Rust staining 18.4 m2 - - -

Exposed

Aggregate 13.8 m2 - - -

Salt Scaling 6.1422 m2 - - -

Other types of

Defect 6.1272 m2 - - -

Cementitious

Coating 18.4 m2 200 9 $33120

Total Cost - - - $36,362.5715

Total cost for 3 slabs is $144,624.1622 which the average is $ 48,208.05407 per slab. Multiplying by 52 slabs gives a total cost over 85 years of all slabs:

$ 2,506,818.812

Repair Option 2 Patching Plus Silane

Repair Option 3 Replacement

Replacement of a slab will involve the whole area of the slab, each slab has a length and width of 4.0m X 4.6m, leading to an area of 18.4m2. Cost of replacement is $1,400 per m2, therefore each slab will cost $25,760. Slab sections D and K have 17 slabs each and will cost $437,920 for the whole section each. Slab section S has 18 slabs, but will cost the same per slab, this section will cost $463,680 for the whole section. The total cost of the replacement slabs will be $1,339,220. These repairs will last only 50yrs and thus the repairs will need to be conducted a second time to reach the lifecycle of 85yrs. This will make a final cost for replacement slabs up to the 85yr lifetime target be $2,678,440.

Breakdown of cost analysis for Option 3

Stage 1 Costs to replace slabs.

Slab letter Dimensions of Slab Area of Slab m2 Cost to replace slab per m2 Cost to replace whole slab Number of Slabs in section Cost to replace all slabs in section

D 4.0m X 4.6m 18.4m2 $1400 $25,760 17 $437,920

K 4.0m X 4.6m 18.4m2 $1400 $25,760 17 $437,920

S 4.0m X 4.6m 18.4m2 $1400 $25,760 18 $463,680

Stage 2 Costs to reach target lifetime.

Slab letter Cost to replace all slabs in section Lifetime of replaced slabs Number of cycles needed to reach goal lifetime Final cost of Slab section for 85yrs Final Total cost of slab replacement for 85 years

D $437,920 50yrs 2 Cycles $875,840 $2,678,440

K $437,920 50yrs 2 Cycles $875,840 S $463,680 50yrs 2 Cycles $927,360