orion marine construction, inc. - port manatee · 2015. 12. 22. · • new electrical distribution...

ORION MARINE CONSTRUCTION, INC.

• The main reason = CORROSION.• The existing cell wall structures have holes corroding through the waterside face of the bulkhead wall

which allowed the soil under the concrete deck and fuel vaults to erode into the basin.• The existing concrete deck was not structurally sound to accommodate heavy loading with the voids

underneath.• The waterside face of the wall and concrete deck could have collapsed due to the corrosion if not

replaced.

• Lump Sum Contract not to exceed: $9,139,099.00

• Contract Start Date: December 22, 2015

• Contract Completion Date: April 25, 2017

• Schedule Status: On track – we anticipate completing in March.

• Project Safety Record: Incident free; zero injuries.

• Equipment Damage: Lightning strike to excavator during Tropical Storm Hermine; No employees onsite during the storm.

• Demolition and disposal of the existing concrete deck and asphalt roadway.• Installation of a concrete transfer beam and associated tie rods and soil anchors.• Installation of a new combination (“Combi”) wall bulkhead in front of the existing bulkhead.• Placement of Flowable fill between the new and existing bulkhead walls.• Vibro compaction of the existing soil beneath the existing concrete deck.• Furnish and Install a new concrete bulkhead cap on top of the new combi-wall.• Civil work including installation of new potable water lines, new electrical distribution, and

new storm water drainage.• Installation of a new concrete deck and asphalt roadway.• Installation of new mooring fenders and mooring bollards.• Installation of cathodic protection in the form of sacrificial anodes at Berths 4, 5, 12 and 14.• SO WHAT ARE SOME OF THESE COMPONENTS?

• 603’ Long x 47’ Wide x 36” Thick • Demolished by way of saw cutting and 10,000 pound jackhammer attachments mounted on

excavators.• Over 300 truck loads of concrete hauled offsite.• Concrete blocks were loaded onto flatbed trucks while the debris from jackhammering was loaded

into dump trucks.• All demolished concrete was recycled by way of crushing and used for road base material.• Accu-Cut Concrete Services = Saw cutting Subcontractor.• Woodruff & Sons = Hauling and Recyling Subcontractor.• 2.5 month duration.

• TRANSFER BEAM – PROVIDES LATERAL STABILITY FOR THE NEW COMBI WALL.

• Cast in place concrete beam 6’ wide x 3’ tall x 600’ long.

• Transfers the load of a ship pulling against the berth to the tie rods, soil anchors, and existing sheetpiling.

• Disperses the force of a ship pulling against the mooring bollards.

• Bottom of the transfer beam is approximately 8’ below the existing pavement.

• South face of transfer beam is within 2 feet of an active fuel line. Special care and precaution was taken every day and every step to ensure safety.

• PVC sleeves were embedded inside the transfer beam at special spacing and angles to allow for passage of tie rods and soil anchors.

• 6 week duration.

• Soil Anchors help anchor the transfer beam.

• 119 EA.

• Installation process for each anchor: A 7” Diameter hole is drilled 70’ into the ground. 3 half inch steel strands are inserted into the hole which is then filled with grout.

• 6 week duration to drill and install the anchors – completed.

• After the grout has cured, each anchor is tensioned in excess of 100,000 lbs to ensure structural integrity and prevent lateral movement of the transfer beam.

• Installation performed by specialty subcontractor Hayward Baker.

• 2 week duration to complete tensioning of all anchors – begins next week.

• The new wall is installed 9” in front of the existing bulkhead.• Called a combination wall due to its’ alternating pattern: pipe pile, sheet pile, pipe pile, sheet pile…

• The new wall consists of 66 pipe piling which are 5’ wide by 71 long and 70 sheetpiling that are 51’ long. The sheetpiling were installed between the pipe piling.

• Pipe Piles were delivered by ship to Berth 14 and unloaded by FMT (Federal Marine Terminal).• Materials were trucked from storage/laydown yard to jobsite as needed.• Sheetpiling were delivered by truck as needed.• Wall was installed using a vibratory hammer and or impact hammer.• Alignment of piles was maintained by using a jig or template temporarily anchored in place.• 6 week duration – activity complete.

• Tie rods transfer the lateral force of a moored ship docked at the combi wall to the transfer beam and soil anchors.

• 3.5” Diameter steel rods that run from the pipe piling to the transfer beam.

• Locked in place and tensioned using plate washers and nuts. One end encapsulated in concrete inside of pipe piling; the other end pulls against the face of the transfer beam.

• Wrapped in petrolatum tape for corrosion protection.

• Encased in a PVC sleeve for additional protection.

• Quantity – 77ea.

• Activity will complete next week.

• 7 Week duration.

• Similar to grout. This material will be placed between the new and existing bulkhead walls.

• Estimated Quantity is more than 450 concrete truck loads.

• Material Supplier = Argos Ready Mix

• Placed using a boom pump and tremmie pipe.

• Anticipated production = 50 loads per day.

• Activity will begin end of next week.

• This is the concrete apron or seawall poured on top of the new combi-wall.

• Roughly 600 feet long.

• This is the only part of the wall you will see above water when the project is completed. The encapsulation extends underwater to elevation -4.0.

• Will be poured in 50’ sections using a boom pump, crane, and large steel forms.

• Estimated quantity is more than 150 concrete truck loads.

• Anticipated duration is 10 weeks.

• New electrical distribution will be installed to several ship’s service stations located on the bulkhead.

• New potable water lines will be installed to the same service stations.

• 25’ wide strip of asphalt pavement will be installed between concrete deck and existing warehouse.

• 10 new mooring fenders will be installed on Berth 10. Existing truck tire fenders will be installed on Berth 9.

• 10 pairs of new mooring bollards will be installed on Berth 9.

• 147 sacrificial anodes will be installed on Berths 4, 5, 12 and 14. Installed by divers to provide corrosion protection to the existing steel walls.

• Deck will be placed directly over the tie rods in the open area between the transfer beam and combi-wall.

• 603’ long x 47’ wide x 22” thick.

• Fill material and a rock aggregate base course must be imported, placed, and compacted before placing concrete to prevent future settlement.

• Estimated quantity is more than 200 concrete truck load.

• New storm drain trench will be installed with the concrete deck – full length of project.