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Dry Dock #2 Structural Assessment Report August 2017

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Dry Dock #2 Structural Assessment Report August 2017 Port of San Francisco Dry Dock #2 Structural Assessment Report August 2017 Table of Contents 1. Executive Summary ............................................................................................................................ 4 2. Introduction .......................................................................................................................................... 4 2.1 Scope of Work .......................................................................................................................... 4 2.2 Description ................................................................................................................................ 5 2.3 Basis of Condition Assessment .............................................................................................. 10 3. Timeline of Dry Dock #2 .................................................................................................................... 11 4. Dry Dock Visual Observations .......................................................................................................... 11 4.1 Pontoon Exterior Observations ............................................................................................... 12 4.2 Interior Compartment Conditions ............................................................................................ 13 4.3 Hull Condition .......................................................................................................................... 17 5. Structural Assessment ...................................................................................................................... 18 5.1 Structural Assessment Summary ........................................................................................... 18 5.2 Load Cases ............................................................................................................................. 18 5.3 Structural System Summary ................................................................................................... 21 5.4 Maximum Differential Pressure ............................................................................................... 22 5.5 Maximum Vessel Load ............................................................................................................ 26 5.6 Overall Structural Condition .................................................................................................... 27 5.7 Structural Repair Recommendations ...................................................................................... 29 6. Corrosion Evaluation ......................................................................................................................... 29 6.1 Original Design Corrosion Protection ..................................................................................... 29 6.2 Corrosion Zones and Average Loss Calculation .................................................................... 30 6.3 Corrosion Protection Recommendations ................................................................................ 32 7. Recommended Repairs .................................................................................................................... 33 7.1 Repair Description .................................................................................................................. 33 7.2 Recommended Inspection and Maintenance Program .......................................................... 34 8. Cost Estimates for Recommended Repairs ...................................................................................... 35 9. Conclusions and Recommendations ................................................................................................ 35 Figure Index Figure 1: View from Pontoon Deck ................................................................................................................ 5 Figure 2: Dry Dock #2 Plan ........................................................................................................................... 7 GHD-Telamon Engineering Consultants, Inc | Port of San Francisco – Dry Dock #2 Structural Assessment Report | i Figure 3: Typical Floating Dry Dock Section ................................................................................................. 7 Figure 4: Isometric Cross Section View ........................................................................................................ 8 Figure 5: Section of Drydock ....................................................................................................................... 12 Figure 6: Typical Pontoon Deck Corrosion ................................................................................................. 12 Figure 7: Deck Plan of Repairs and Holes .................................................................................................. 13 Figure 8: Typical condition of pontoon ballast tanks (Heger Dry Dock Inc.) ............................................... 14 Figure 9: Mud and sediment in the ballast tanks (Heger Dry Dock Inc.) ..................................................... 14 Figure 10: Looking up at the wing wall. Note extensive corrosion on maintenance platform (Heger Dry Dock Inc.) ............................................................................................................. 15 Figure 11: Typical condition of a buoyancy chamber. Paint failure and rust film beginning in lower 10 feet of tank with paint 70% intact in upper 10 feet (Heger Dry Dock Inc.) ............... 16 Figure 12: Dry Dock #2 Plan for Underwater Inspection ............................................................................. 17 Figure 13: Max Load Cases (Figure from Heger Dockmaster’s Training Manual Fig. 5.14) ...................... 19 Figure 14: Typical relationship between head pressure and ballast level generated from near- capacity vessel ........................................................................................................................ 20 Figure 15: Transverse Bending Moment Diagram ...................................................................................... 21 Figure 16: Pontoon Deck Framing–Transverse and Longitudinally Stiffened Panels ................................. 22 Figure 17: Partial Load with Max Hydrostatic Head .................................................................................... 24 Figure 18: Dry Dock #2 vessel load and ballast conditions that generate a differential pressure of 28 feet ..................................................................................................................................... 25 Figure 19: SAP2000 Model of Pontoon Frame ........................................................................................... 27 Figure 20: Map of Elevation and Transverse Zones ................................................................................... 31 Table Index Table 1: Dry Dock #2 Displacement .............................................................................................................. 9 Table 2: Summary of Condition and Ratings .............................................................................................. 11 Table 3: Dry Dock #2 maximum differential pressure for capacity vessels................................................. 23 Table 4: Average Section Loss by Structural Member/Elevation Zone ....................................................... 31 GHD-Telamon Engineering Consultants, Inc | Port of San Francisco – Dry Dock #2 Structural Assessment Report | ii Appendix Index Appendix A: Preliminary Estimate of Probable Repair Costs Report Appendix B: Underwater Inspection Report Appendix C: Photos Appendix D: Pontoon Deck Inspection Field Notes GHD-Telamon Engineering Consultants, Inc | Port of San Francisco – Dry Dock #2 Structural Assessment Report | iii 1. Executive Summary In its current condition, Dry Dock #2 cannot be rated to safely lift the design capacity vessel load of 55,800 LT. At numerous locations, the pontoon deck plate and wing wall shell plates exhibit significant section loss due to corrosion and general use, along with cracks and through holes in plates. Because of the holes, the dock cannot hold draft without periodic ballast pumping. The thinned shell plating limits the dock’s ability to resist differential head pressure between the external water level and ballast during submergence. Our finding is in general agreement with conclusions stated in the 2016 “Control Inspection” conducted by Heger Dry Dock, Inc. (Ref. 1) 2. Introduction 2.1 Scope of Work GHD-Telamon Engineering Consultants, Inc (TECI) Joint Venture was retained by the Port of San Francisco (Port) to perform an independent inspection and analysis of Dry Dock #2 to estimate its lifting capacity and confirm necessary repairs. The inspection and analysis would consist of a limited visual review of the above-water dock areas, confirmation of ultrasonic thickness (UT) meter readings at selected locations on the pontoon deck, a dive team for underwater assessments, and structural engineers analyzing the structure using finite element modelling. Additionally, GHD-TECI was tasked to review and summarize the previous reports and certifications. The Port owns two floating dry docks at Pier 68/70 that are included in long term lease agreements with ship repair contractors (tenant). Dry Dock #2 is an 800-foot by 186-foot by 69-foot steel floating dry dock originally designed by Earl and
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