Schedule is a critical element of any project, yet when dates are already established for ships to dock at an unbuilt pier, time is of the utmost importance. Located in Baltimore, the Locust Point marine terminal was undergoing an expansion to handle additional cargo. The expansion project involved extending an existing pier, and this expansion required the strengthening of existing pier caps. The contractor for the expansion project brought Structural Preservation Systems (SPS) onto the team because of the firm's extensive experience installing strengthening systems.
The initial scope of work involved installing carbon-fiber reinforcement systems on eight pier caps each measuring approximately 30 feet long at the new terminal. However, a complete survey of the existing conditions revealed additional repairs to the existing concrete were necessary to ensure the carbon-fiber reinforcement would perform as designed. As such, the scope of work expanded to include concrete repairs and epoxy injections in the cracks in the pier caps.
Working on a project exposed to the elements and over water created tremendous challenges. Because it is an epoxy-based system, the carbon-fiber reinforcement system cannot be installed when the ambient or substrate temperature falls below 40 degrees Fahrenheit. The winter timeframe of the project made it extremely difficult to find days in which the temperature was higher than 40 degrees in Baltimore.
To combat the weather challenge, SPS carefully discussed the issues with the general contractor and accounted for the weather challenges when budgeting and scheduling. In an additional effort to overcome the weather difficulties, SPS crews performed all preparation work - which could be executed regardless of temperature - before beginning the carbon-fiber reinforcement installation. As the thermometer climbed to the desired temperature, weekend shifts were scheduled when needed to meet the project's timeframe. Extensive preplanning was critical to managing workflow amidst constantly changing weather conditions.
Access to the working area provided another challenge, as the pier caps SPS crews were working on were underneath the new pier being constructed. To access the underside of the pier caps, crew members worked from wooden work floats in the water. SPS vigilantly monitored temperatures, tide, and wind direction and speed to keep workers safe on the floats.
Carbon-fiber reinforcement provided the innovative solution for this project because of its ability to fit in small spaces and its relative ease of installation compared to other strengthening techniques. In addition, another inventive solution was a termination detail that SPS developed using carbon-fiber rods. Because of the beams' layout, SPS was not able to get full development lengths by wrapping around the tops of the beams. Therefore, the termination detail was necessary to develop the carbon fiber reinforcement fully in a limited length.
SPS considers safety among its highest values, and working on the water required special precautions. A cable barrier marking the leading edge of the work site also indicated the area where life preservers were a necessity. SPS constantly monitored the water's level to ensure safe working conditions. If the water level receded too low, safety harnesses were required for getting on and off the floats. If the water level climbed too high, work underneath the pier caps would not be safe. Other standard procedures for working over water included a rescue boat and life rings at specific intervals.
In spite of extreme weather challenges and working within an aggressive schedule, the project was completed in time for the owner to receive its ship on the scheduled date. The owner met its goal of increasing its ability to receive additional ships and cargo.