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Condition ManualData Capture of Physical Assets via ConditionAssessmentFremantle Ports and Port of Melbourne Corporation

17 December 2010

Condition ManualC:\Condition Manual - RevC.docx

Condition Manual60156808

Prepared for

Fremantle Ports and Port of Melbourne Corporation

Prepared byMaunsell Australia Pty LtdLevel 9, 8 Exhibition Street, Melbourne VIC 3000, AustraliaT +61 3 9653 1234 F +61 3 9654 7117 www.maunsell.comABN 20 093 846 925

17 December 2010

60156808

© AECOM Australia Pty Ltd 2011

The information contained in this document produced by AECOM Australia Pty Ltd is solely for the use of the Client identified onthe cover sheet for the purpose for which it has been prepared and AECOM Australia Pty Ltd undertakes no duty to or acceptsany responsibility to any third party who may rely upon this document.

All rights reserved. No section or element of this document may be removed from this document, reproduced, electronicallystored or transmitted in any form without the written permission of AECOM Australia Pty Ltd.


Quality InformationDocument Condition Manual

Ref 60156808

Date 06/01/2011

Prepared byRev A (2007): Tahlia GriffinRev C (2010): Eamon Sullivan

Reviewed byRev A (2007): Sandy MuirRev C (2010): Gary Rykers

Revision History

Revision RevisionDate Details

Authorised

Name/Position Signature

A 19/03/2007 Final Condition ManualJames BandtPrincipalConsultant

B 27/07/2010 Stage 1 update, draft forcomment Gary Rykers

C 17/12/2010 Stage 1 update, finalversion for issue to client Gary Rykers


Table of Contents1.0 Background 1

1.1 About this Manual 11.2 Condition Assessment Methodology 11.3 Use of Condition Rating 21.4 Description of Key Definitions 21.5 Relationship with Asset Management System 31.6 Asset Hierarchy 31.7 Condition Assessment Frequency 8

2.0 Buildings 92.1 Structural 92.2 Services 92.3 Sub-Structure 102.4 Fittings 10

3.0 Roads 113.1 Pavement 113.2 Furniture 123.3 Verges 123.4 Kerb and Channel 13

4.0 Sewerage 144.1 Pipes 144.2 Manholes 144.3 Pump Station Structure 144.4 Pump Station Mechanical and Electrical 15

5.0 Drainage 165.1 Pipes 165.2 Pits 165.3 Traps Structural 165.4 Traps Mechanical and Electrical 17

6.0 Water 186.1 Pipes 186.2 Water-main Fittings 18

7.0 Wharves/Jetties 197.1 Piles 207.2 Sub Structures 217.3 Deck 227.4 Furniture 237.5 Fenders 237.6 Cathodic Protection 23

8.0 Structures 248.1 Structural 248.2 Mechanical and Electrical 24

9.0 Navigational Structures 259.1 Lights / Day-marks 259.2 Supporting Structure 25

Condition ManualC:\Condition Manual - RevC.docx Page 4

9.3 Piles 269.4 Footings 26

10.0 Telecommunications 2710.1 Cables 2710.2 Pits 27

11.0 Power 2811.1 Street Lighting 2811.2 HV Cabling 2811.3 LV Cabling 2811.4 Substations 2911.5 Switchboards 29


1.0 Background1.1 About this ManualThis Condition Manual (Manual) provides standard condition rating criteria for Fremantle Ports’ andPort of Melbourne Corporation’s (PoMC) assets. These condition rating criteria have been developedto facilitate consistency and repeatability when assessing a condition grading for assets / assetcomponents.

The first version of the Manual (Rev A) was completed in 2007 by Maunsell (now known as AECOM).In 2010, the Manual was jointly reviewed by Fremantle Ports and PoMC. The 2010 update (Rev C)addressed improvement opportunities common to all asset classes and involved an update of Section1 (Background) only. A second stage update is proposed for 2011, to address further improvementopportunities that are asset class specific and will involve update of all remaining sections.

The condition grading criteria have been developed through workshops with Fremantle Ports andPoMC and are based around industry standards. It is intended that this document will be used byFremantle Ports and PoMC as a guide for conducting condition surveys of their major assets / assetcomponents.

The condition rating criteria provided are intended to cover all major asset groups and components.The major asset groups are:

Buildings Port Interface Structures (e.g. wharf, jetty, pier, landing) Navigational Aids Roads Supplemental Structures (e.g. tower, gantry, gangway, other) Services (e.g. sewerage, drainage, water, telecommunications, power, oil) Railways Cargo Handling Equipment (not included in the scope of this Manual)

1.2 Condition Assessment MethodologyThe assessment of asset condition is an essential part of asset management planning.

The condition data collected is used to support core asset management activities such as, riskmanagement, predictive modelling, planned maintenance and rehabilitation, asset valuation, worksprioritisation and budget forecasting. The process of collecting consistent and repeatable conditiondata forms a core part of the application of asset management, as defined in Figure 1.


ASSESS RISKSASSESS RISKSOF FAILUREOF FAILURE

EVALUATEEVALUATETREATMENT OPTIONSTREATMENT OPTIONS

••EnvironmentalEnvironmental••StrategicStrategic••LegislativeLegislative

DATA COLLECTION /DATA COLLECTION /MEASURE PERFORMANCEMEASURE PERFORMANCEEXISTING DATAEXISTING DATA

LEVEL OFLEVEL OFSERVICESERVICE

PREDICTPREDICTDEMANDDEMAND

FAILURE MODEFAILURE MODEANALYSISANALYSIS

••CustomerCustomer••FinancialFinancial••PoliticalPolitical

ASSESS FINANCIALASSESS FINANCIALIMPACTS (IMPACTS (CashflowCashflow))

IDENTIFY OPTIMUMIDENTIFY OPTIMUMSOLUTIONSOLUTION

ASSET MANAGEMENTASSET MANAGEMENTPLANPLAN

CONDITIONCONDITIONASSESSMENTASSESSMENT

Figure 1: Asset Management Process

This Manual provides criteria to assess asset condition on a rating scale of 1 - 5 (excellent to verypoor), linked to standard definitions describing physical condition of the assets.

In providing a condition assessment methodology, it is essential that the assessments are reliable andconsistent so asset managers can be confident in the data.

1.3 Use of Condition RatingThe scope of this Manual covers condition rating based on visual assessments of an asset’s physicalcondition (or age where an asset group cannot be visually inspected). As much as is practicable with avisual condition assessment, the condition rating descriptions incorporated into a 1 - 5 rating scale arelinked to expected failure mechanisms, via the objective assessment of visible defects expected foreach asset type.

1.4 Description of Key DefinitionsFor clarity and understanding, Table 1 provides a summary of the key definitions used throughout thisdocument.

Table 1: Key Definitions

Term Description of Key DefinitionsAsset A physical resource controlled by an entity which has value, enables

services to be provided and has an economic life greater than 12 months.An asset may or may not be comprised of components.For example, a wharf is defined as an asset. However, the asset itself - inthis case, the wharf - consists of a number of constituent components suchas piles, beams, fenders, a deck and sheet piles.

Asset Category The type of assets within an asset class. For example, the buildings assetclass contains a number of asset categories including substation, shed,warehouse and workshop among others.

Asset Class A group of assets with a similar functional purpose. Asset class is thehighest level in the asset hierarchy. In the context of ports, asset classesinclude buildings, navigational aids, roads, railways etc.

Asset Component Specific parts of an asset with an independent physical or functional identityand having specific attributes such as different life expectancy,maintenance regimes or risk. For example, piles, beams, fenders, a deckand sheet pile walls would all be considered components of a wharf. Anasset component is a subset of the asset itself.


Term Description of Key DefinitionsAsset Hierarchy An infrastructure framework for segmenting an asset portfolio into

appropriate classifications. The asset hierarchy can be based on assetfunction, asset type or a combination of the two.

Condition Rating Scale The standardised classification system used to identify the current conditionof an asset component (which forms part of a particular asset).

Inspection Frequency The inspection frequency defines how often a condition rating survey will beconducted for each asset group (or potentially each asset category). Theinspection frequency can be different for each inspection type.

Inspection Type Level 1 – Routine inspection performed in accordance with a pre-preparedchecklist, typically conducted by a maintenance technical officer.Level 2 – Periodic visual condition survey performed in accordance with aconsistent and repeatable process (this Manual), typically undertaken by anengineer. Level 2 condition rating results are typically stored in an AssetManagement System and used to drive needs based forward programs.Level 3 – Detailed engineering testing, analysis and assessment, likely toinvolve specialised equipment and/or a high level of technical expertise.

Location Referencing A structured referencing system that identifies the position of individualcomponents or assets. The location referencing system may vary accordingto the asset class. Condition rating survey outputs are recorded inaccordance with the adopted location referencing system. ‘Return to field’activities rely on the location referencing system to re-locate defectsidentified during the condition rating survey and to ensure repeatedinspections are recorded against the same component or asset.

Start Datum The start datum is an integral part of the location referencing system. Thestart datum is a clearly defined location or reference point, used as thestarting point for subsequent location referencing measurements.

1.5 Relationship with Asset Management SystemAsset condition rating data should be stored in an asset management system for use by the assetowner. As such, the methodology adopted for condition rating needs to be aligned with assetmanagement system functionality. While PoMC (Conquest) and Fremantle Ports (FMMS) use differentsystems for managing asset data, it is recognised that each organisation will need to store andanalyse the collected condition data using their respective systems.

1.6 Asset HierarchyThe asset hierarchy drives consistent organisational reporting for asset operations, maintenance,renewal and upgrade/new works. The hierarchy breaks down complex assets into manageablecomponents and forms the foundation for recording of asset information through corporate businessprocesses and systems (such as the asset management system – see section 1.5).

In general, the asset management system will categorise assets using a number of asset classes,asset categories and asset components. For each asset category, a number of individual assets maybe listed.

Whilst asset hierarchies are often separated by asset class, the hierarchy can also take a spatialapproach whereby asset classes in the same location are grouped together (e.g. “Berth 1” couldcontain not only the structural components but also supporting infrastructure such as electricalservices, water supply etc).


Although each port may structure their hierarchy differently within the asset management system, it isimportant that the hierarchy be setup in such a way as to facilitate essential business functions suchas maintenance management, financial reporting and data management.

The table below outlines the specific asset classes, asset categories and asset components coveredby this Manual. Condition assessment will be consistently undertaken at the component level; withcondition assessment being undertaken only for asset components that are considered materiallysignificant. That is, asset components which have a material value (to be determined by eachorganisation) relative to the total value of the asset should be subject to condition assessment.

It should be noted, however, that some asset components of low value may be critically important tothe ongoing serviceability of the asset as a whole. In this instance, the component should be includedin a condition assessment regime regardless of direct monetary value.

Table 2: Asset Hierarchy for Condition Assessment

Asset Class Asset Category Asset Component Material Type ReferenceBuildings

Amenities buildingStructural 2.1Services 2.2Substructure 2.3Fittings 2.4

GatehouseStructural 2.1Services 2.2Substructure 2.3Fittings 2.4

Historic buildingStructural 2.1Services 2.2Substructure 2.3Fittings 2.4

Maintenance building(e.g. workshop)

Structural 2.1Services 2.2Substructure 2.3Fittings 2.4

Office building (byfloor)


Portable buildingStructural 2.1Services 2.2Substructure 2.3Fittings 2.4

Storage building (e.g.warehouse, shed)


SubstationStructural 2.1


Asset Class Asset Category Asset Component Material Type ReferenceServices 2.2Substructure 2.3Fittings 2.4

Port Interface StructuresWharves / Piers /Jetties / Landings

Deck 7.3Timber

ConcreteDeck overlay 7.3

AsphaltConcrete

Pile 7.1TimberSteel

Concrete filledsteel

ConcreteFender 7.5

Appurtenance 7.4Timber

ConcreteSteel

Revetment and scourprotection TBD Stage 2

RockConcrete

Sheet pile wall TBD Stage 2Concrete

SteelBeams and cross heads 7.2

TimberConcrete

Steel

Bracing TBD Stage 2TimberSteel

ConcreteCathodic protectionsystem 7.6Ro Ro ramp TBD Stage 2Dolphin pile 7.1

TimberSteel

Concrete filledsteel

ConcreteDolphin deck 7.3

TimberConcrete

Dolphin deck overlay 7.3Asphalt

Concrete

Navigational AidsBeacon (water-based)


Asset Class Asset Category Asset Component Material Type ReferenceNavigation light / day mark 9.1Structure 9.2Pile 9.3Footings 9.4

Buoy (water-based)Navigation light / day mark 9.1Buoy TBD Stage 2Directional wave rider TBD Stage 2Coastal monitoring deviceAWAC TBD Stage 2

Tower (land-based)Navigation light / day mark 9.1Structure 9.2Footings 9.4

Lighthouse (land-based)

Navigation light 9.1Structure 9.2Equipment TBD Stage 2Footings 9.4

RoadsPavement

Public road 3.1Asphalt

ConcreteGranular withSprayed Seal

UnsealedStacking area 3.1

AsphaltConcrete

Granular withSprayed Seal

UnsealedParking area 3.1

AsphaltConcrete

Granular withSprayed Seal

UnsealedMinor drainage Kerb and channel 3.4Path Footpath / Bike path TBD Stage 2Environment Medians 3.3

Shoulders 3.3Verge 3.3Linemarking 3.3

FurnitureSigns 3.2Light poles 3.2Bollards 3.2Barriers 3.2Guardrails 3.2

Bridge

As per VicRoads BridgeCondition InspectionManual – Level 2Inspections Not In Scope

Supplemental StructuresLand-based structure


Asset Class Asset Category Asset Component Material Type Reference(e.g. tower, gantry,gangway)

Structure 8.1Mechanical and electrical 8.2

SeawallStructure TBD Stage 2

ServicesSewerage

Gravity main 4.1Rising main 4.1Manhole 4.2Pump station - structure 4.3Pump station - mechanical/ electrical 4.4

DrainagePipe 5.1Pit 5.2Trap 5.3

WaterPipe 6.1Pump station - structure 4.3Pump station - mechanical/ electrical 4.4Valve 6.2Hydrant 6.2

TelecommunicationsCables 10.1Pits 10.2Poles TBD Stage 2

PowerStreet lighting 11.1HV Cabling 11.2LV Cabling 11.3Substations 11.4Switchboards 11.5

OilEquipment TBD Stage 2

RailwaysRailway

Track TBD Stage 2Sleepers TBD Stage 2Ballast TBD Stage 2Signalling equipment TBD Stage 2

Cargo Handling EquipmentShip unloader Not in scopeStacker reclaimer Not in scopeMachinery House Not in scopeLoading boom Not in scopeMain columns, mastsand beams Not in scopeControl cabin Not in scopeBoom luff Not in scopeSuper structure Not in scopeTripper trailer Not in scopeConveyor tower Not in scope


Asset Class Asset Category Asset Component Material Type ReferenceReceival hopper Not in scopeUnloading hopper Not in scopeLoading chutes Not in scopeCrane rail Not in scopeCrane rail beam Not in scope

1.7 Condition Assessment FrequencyInfrastructure assets deteriorate over time. The collection of consistent and repeatable condition dataallows time-series deterioration trends to be identified and modelled. These can be used to feedrenewal models and other sophisticated asset management tools and analyses. There is an inherentrisk in making business decisions regarding significant capital renewal investment based on out-datedcondition data. As such, up-to-date condition data is of significant importance when an organisation isactively undertaking an asset remediation / renewal program.

These objectives can best be met where there is a defined frequency of condition data survey, foreach asset class. As a supporting document to this Manual, it is proposed that a separate guideline bedeveloped to define the recommended survey types and frequency for each asset class. The guidelinewill undergo detailed review by Australian port authorities to ensure that appropriate practices areadopted and to optimise the return on investment with respect to condition assessment.


2.0 Buildings2.1 StructuralThis component includes roof, walls and flooring.

Rating Definition Description

1 Excellent Sound physical condition. No work required.

2 Good Acceptable physical condition. Minor wear and tear. Maintenance required.

3 Average Deterioration evident. Failure unlikely in the near future but furtherdeterioration likely. Work required in next 3 years but asset is stilloperating.

4 Poor Failure likely in the next 5 years. Substantial work required in short-term.

5 Very Poor Asset failed or failure imminent. Asset represents a risk. Major work orreplacement required urgently.

Table 3: Buildings Structural Criteria

2.2 ServicesThis component includes mechanical, electrical and plumbing services.


1 Excellent Sound modern components. All operable and well maintained.

2 Good Minor wear and tear. Minor oil leaks and gland wear evident. Efficiencyunaffected. Maintenance required.

3 Average All components functioning acceptably. Some deterioration evident.Efficiency diminished. Bearing and gland wear becoming more evident.Corrosion of metal components becoming evident.

4 Poor Function and/or running costs affected significantly by failures ormaintenance needs. Whole of life costs excessive compared toreplacement cost. Requires major overhaul in 1 to 2 years.

5 Very Poor Electrically or mechanically unsafe or in disrepair. Unsafe to use, toounreliable or costly to operate. Requires immediate action.

Table 4: Buildings Services Criteria


2.3 Sub-StructureThis component includes floor slabs and footings and any part of the structure ground level and below.




3 Average Deterioration evident. Failure unlikely in the near future but furtherdeterioration likely. Work required in next 3 years but asset is still operating.



Table 5: Buildings Sub-Structure Criteria

2.4 FittingsThis component includes all interior fittings and furnishings.







Table 6: Buildings Fittings Criteria


3.0 Roads3.1 Pavement

Rating

Distress Mode Failure Type 1 2 3 4 5

Cracking

Longitudinal /Transverse

No visible signs ofcracking

Maximum crackwidth < 5 mm

Maximum crackwidth 6 - 10 mm

Maximum crackwidth 11 - 15 mm

Maximum crack width> 15 mm

Pattern No visible signs ofcracking

Crack Pattern < 4%of pavement area

Crack Pattern5 - 10% of

pavement area

Crack Pattern11 - 25% of

pavement area

Crack Pattern> 25% of pavement

area

Disintegration PotholesNo visible signs of

pavementdisintegration

< 3 potholesevery 100 m

3 potholesevery 100 m

3 - 5 potholesevery 100 m

> 5 potholesevery 100 m

Distortion Rutting, HeavingNo visible signs of

pavementdistortion

< 20 mm deep 20 – 30 mm deep 31 - 50 mm deep > 50 mm deep

Edge Breaks Edge breaks No visible signs ofedge breaking < 50 mm deep 51 – 100 mm deep 101 - 200 mm deep > 200 mm deep

Surface TextureLoss

Material Loss,Scabbling,

Peeling

No visible signs oftexture loss

Texture lossextends up to 5% of

pavement area

Texture lossextends 6 – 10 % of

pavement area

Texture lossextends 10 - 20% of

pavement area

Texture loss extends> 20% of pavement

area

Appearance Pavement looks in‘as new’ condition

Pavement showssome signs of

patching on roadsurface

Pavement showsnumerous signs ofpatching on road

surface

Pavement showssigns of significant

patching

Appearance of theroad is unpalatable to

the community

Table 7: Roads Pavement Criteria


3.2 FurnitureThis component includes signs, light poles, bollards, barriers and guard rails.







Table 8: Roads Furniture Criteria

3.3 VergesThis component includes nature strips, grassed areas trees and footpaths.


1 Excellent Clean and neat surroundings, no rubbish evident and well groomedvegetation/grass. No work required.

2 Good Clean surroundings however vegetation/grass is growing outside definedarea. Regular pruning/mowing required.

3 Average Vegetation/grass requires cutting back or slashing within it boundaries.Supplemented by regular pruning/mowing. Some rubbish evident.

4 Poor Area over grown or vegetation dying. Dirty appearance. Major clean-up andreplanting required.

5 Very Poor Area over grown or vegetation dead. Dirty appearance. Major clean-up andreplanting required.

Table 9: Roads Verges Criteria


3.4 Kerb and Channel

Rating

Distress Mode 1 2 3 4 5

LongitudinalProfile(Vertical jointdisplacement,sagging, ponding)

No visible signs ofjoint displacement

and ponding

Some jointdisplacement

over < 10% oflength of kerb andchannel segment

JointDisplacement

< 20% of length ofkerb and channel

segment

JointDisplacement

between 20 - 40%of length of kerb

and channelsegment

Extensive jointdisplacement

(>40%) of lengthof kerb and

channel segmentresulting in manyindividual failures

Horizontal Profile(Horizontal jointdisplacement,heaving)

No visible signs ofjoint displacement

and heaving

Some jointdisplacement

over < 10% ofkerb and channel

segment

JointDisplacement

< 20% along kerband channel

segment

JointDisplacement

between 20 - 40%along kerb and

channel segment

Extensive jointdisplacement(>40%) along

kerb and channelsegment resultingin many individual

failures

Blockages andobstructions e.g.weed growth

No sign ofblockages andobstructions

Minor blockagesand obstructions<10% of kerb and

channel joint

Moderateblockages andobstructions<

20% along kerband channel joints

Blockages andobstructions

between 20 - 40%along kerb andchannel joints

Extensiveblockages andobstructions

(>40%) alongkerb and channel

joints

Table 10: Roads Kerb and Channel Criteria


4.0 Sewerage4.1 PipesAsset Life: 80 years

Rating Definition % Effective Life Life Remaining

1 Excellent 91 - 100 73 - 80 years

2 Good 71 - 90 57 – 72 years

3 Average 41 - 70 33 – 56 years

4 Poor 11 - 40 9 – 32 years

5 Very Poor 0 - 10 0 – 8 years

Table 11: Sewerage Pipes Criteria

4.2 Manholes



2 Good Acceptable physical condition. Minor wear and tear. Minor infiltration inbenching and joints around pipes. Maintenance required.

3 Average Deterioration evident. Some loose step irons. Infiltration into benching andconcrete breaking away from pipe joints. Minor repairs required.

4 Poor Step irons missing or can be pulled from wall. Concrete in benchingbreaking away. Concrete around pipe joints missing. Major repairs required.

5 Very Poor Step irons missing. Manholes/pits represent a significant safety risk.Benching disintegrated i.e. cannot function and concrete missing. Majorleaks around pipe joints or pipes separating from manhole / pit. Structure ofmanhole or pit requires replacing.

Table 12: Sewerage Manholes Criteria

4.3 Pump Station Structure







Table 13: Sewerage Pump Station Structure Criteria


4.4 Pump Station Mechanical and Electrical







Table 14: Sewerage Pump Station Mechanical and Electrical Criteria


5.0 Drainage5.1 PipesAsset Life: 80 years



2 Good 71 - 90 57 – 72 years

3 Average 41 - 70 33 – 56 years

4 Poor 11 - 40 9 – 32 years


Table 15: Drainage Pipes Criteria

5.2 PitsThis component includes outfalls and end walls.



2 Good Acceptable physical condition. Minor wear and tear. Minor infiltration inbenching and joints around pipes. Maintenance required.

3 Average Deterioration evident. Some loose step irons. Infiltration into benching andconcrete breaking away from pipe joints. Minor repairs required.

4 Poor Step irons missing or can be pulled from wall. Concrete in benchingbreaking away. Concrete around pipe joints missing. Major repairs required.

5 Very Poor Step irons missing. Manholes/pits represent a significant safety risk.Benching disintegrated i.e. cannot function and concrete missing. Majorleaks around pipe joints or pipes separating from manhole / pit. Structure ofmanhole or pit requires replacing.

Table 16: Drainage Pits Criteria

5.3 Traps StructuralThis component includes isolation pits and litter traps.







Table 17: Drainage Traps Structural Criteria


5.4 Traps Mechanical and Electrical







Table 18: Drainage Traps Mechanical and Electrical Criteria


6.0 Water6.1 Pipes


1 Excellent As new.

2 Good Showing minor signs of wear on tear on pipe coating. No damage evident. Nosign of leaking from joints.

3 Average Damage to the pipe coating and minor corrosion evident. Joints showingsome wear and tear. Moisture apparent. Corrosion to be removed andcoating replaced.

4 Poor Major corrosion evident along the pipe length. Joints leaking. Replacementrequired in the next 5 years.

5 Very Poor Severe corrosion evident along the pipe length. Joints leaking and corroded.Replacement required.

Table 19: Water pipes Criteria

6.2 Water-main FittingsThis component includes valves, hydrants, meters, backflow devices, electrolysis pits and markers.



2 Good Minor wear and tear evident.

3 Average All components functioning acceptably. Some deterioration evident. Wearand tear becoming more evident. Corrosion of metal components becomingevident.

4 Poor Function affected, difficult to open or close. Heavy corrosion on valve bodyand seating.

5 Very Poor Fails to function.

Table 20: Water-main Fittings Criteria


7.0 Wharves/JettiesIntroductionGiven the number of asset items and sub items it is envisaged that a sample area of each wharf willbe selected for assessment. The assessment criteria will take into consideration two factors being theseverity of the defect and the extent of the defect (area affected). When assessed the asset will beassigned a percentage against each of the ratings of 1 – 5, an example output is given below:

Condition Rating % Area Affected1 102 303 204 355 5

Table 21: Sample Condition Assessment for a Deck

The table displays the results of a sample assessment of a deck. In this example the results identifythat 10% of the decking has been rated as a condition 1, 30% as a condition 2 etc. It is intended thatthis information be mapped onto the table below to identify the works required. The colours belowindicate the type of work to be undertaken when the condition and percentage area affected coincidewith a colour. For example a condition 3 with a percentage area affected of 31-40% would requirefurther investigation. However should a condition 5 with a percentage area affected of 11-20% alsooccur on the same asset, then the replacement would be required and this would take precedent overthe investigative work.

% Area AffectedCondition 0 - 10 11 - 20 21 - 30 31 - 40 > 40

12345

Table 22: Works Required mapped against Condition by Affected Area

Example of outcomes:

No Works Required ReinspectDetailed

Investigation

Repairwithin 5years

ReplaceImmediately

This process will apply for the following asset components: Piles Deck Sub Structure Fenders

This table is a sample only, the ratings and actions are suggestions and they will need to beformulated following a non detailed assessment of the Levels of Service and Business Risk associatedwith the wharf structures.


7.1 PilesAsset Life: 50 years

Rating Definition % EstimatedRemaining Life

Steel Timber Concrete (Steel Cased)

1 Excellent 61 - 100 As new. As new. As new, some minor surface corrosion present.

2 Good 31 - 60 Acceptable physical condition. Minorwear and tear. Slight rusting(corrosion), loss of paint above water.No work required.

Acceptable physical condition. Minor wear andtear. Little or no rot or decay, though there maybe minor cracks, splits or checks having noaffect on the strength of the component. Noworks required.

Acceptable physical condition. Minor wear and tear. Generalcorrosion and loss of paint above water. No work required.

3 Average 21 - 30 Some heavy corrosion present withrust scale build-up. Estimatedremaining life 10-15 yrs howeverconduct a more detailed assessment todefine this more accurately.

Minor signs of rot or decay. Moderate neckingevident, 350mm diameter remaining, crackingextends beyond connections and splitting is<10mm wide.

Some heavy corrosion present. Estimated remaining life 10-15 yrs however conduct a more detailed assessment todefine this more accurately.

4 Poor 11 - 20 Deterioration evident. Heavy corrosionabove and / or below water. Failureunlikely in the near future but furtherdeterioration likely. Remedial worklikely to be required in the next 5 yrscould include - replacing anode belowwater or wrapping pile above water.

Deterioration evident. Extensive decay, checkingor splitting (<20mm wide). Heavy necking,300mm of diameter remaining along with heavycracking that extends along the member. Failureunlikely in the near future but furtherdeterioration likely. Remedial work required innext 5 years.

Significant deterioration evident in the form of corrosionrelated holing of steel casing and exposure of concreteabove and / or below water Failure unlikely in the nearfuture but further deterioration likely. Remedial workrequired in next 5 years, could include – patch repairs and /or the need for cathodic protection or in the case of existingcathodic protection, a check to see if it is still functioning,replacing anode below water or wrapping pile above water.

5 Very Poor 0 - 10 Failure likely in the next 3 years.Significant loss of steel section throughcorrosion either surface or pitting.Fatigue failure of steel or welds.Substantial work required short term orAsset failed or failure imminent. Assetrepresents a risk. Major work orreplacement required urgently.

Asset failed or failure imminent. Asset representsa risk. Major work or replacement requiredurgently or Significant necking of piles down to200mm diameter. They may also have largesplits, especially under load bearing areas,heavy decay or checks which may have areduction in strength of the member. Substantialwork required in very short term.

Asset failed or failure imminent. Asset represents a risk.Major work or replacement required urgently or Failure likelyin the next 3 years. Significant holes in steel section to anextent that the concrete is exposed and showing signs ofdeterioration. Substantial work required short term.

Table 23: Wharves/Jetties Steel Pile Criteria


7.2 Sub StructuresThis component includes beams and crossheads.

Rating Definition Timber Concrete

1 Excellent As new. As new.

2 Good The timber is in good condition with only minor splits or checkshaving no effect on strength.All bolted connections are tight and in good condition.

The deck soffit shows little or no deterioration through there maybe some dampness and efflorescence. Minor vertical orhorizontal cracking may be present with no signs of horizontalcracking along the beam side within the soffit region.

3 Average The timber shows signs of minor decay, splitting and checks butdoes not affect the strength of the members.The tops of the member may have some moisture ingress and bewet and slightly spongy. Estimated remaining life 10-15 yrshowever conduct a more detailed investigation.

Minor cracking with rust staining may be present and someinitial drummy areas. Minor vertical or horizontal cracking maybe present with signs of horizontal cracking along the beam sidewithin the soffit region. Conduct a more detailed assessment.

4 Poor Medium decay distributed over beams, or heavy localized decay.Splitting and checking may be present. Moisture ingress into thetop of the member has caused softness with indentations andslight bulging from the deck planks. The strength of the memberhas been affected to a minor extent.Bolted connections may be loose allowing the member to moveexcessively when loaded.The member may have cracked due to overloading, ineffectivesupport, or supports being too far apart or crossbeams being non-continuous, i.e. only two supports.

Major cracking and spalling may be present with corrodingreinforcement visible. Significant signs of horizontal crackingalong the beam side within the soffit region. Dampness patchesand efflorescence powder may be more prominent.

5 Very Poor The member is heavily decayed, split or rotted, with largeindentations at the top along with excessive bulging due to the topbeing very wet and spongy.Bolted connections are very loose and the member is movingexcessively when loaded musing deterioration of the member.The member may be cracked through due to overloading,ineffective support or crossbeams being non-continuous.

Heavy cracking and spalling may be present with advancedcorrosion of the reinforcement over large areas. Excessivemoisture penetration and heavy staining around the cracks orevidence of excessive deflection or localised structural failure.

Table 24: Wharves/Jetties Sub-Structures Timber Criteria


7.3 DeckAsset Life: 50 years

Rating Definition % EstimatedRemaining Life

Timber Concrete

1 Excellent 61 - 100 As new. As new.

2 Good 31 - 60 The timber may have minor cracks, splits or checks but is fullyprotected by the preservatives, with no untreated heartwood. Thedecks are well bolted to the supports. Tensioning rods have adequatestressing and there is no damage to the timber at the stressing plates.

The deck soffit shows little or no deterioration throughthere may be some dampness and efflorescence.Minor cracking may be present but has rust stains.

3 Average 21 - 30 Preservative protection may be beginning to dissipate with minorleaching of preservative salts (white powder on underside of deck) andwith minor weathering and rot of timber. Bolting of the deck may beslightly loose with fine reflective cracks through the asphalt on top.Tensioning rods should still have adequate stressing and there shouldbe no damage to the timber at the stressing plates. Detailedassessment to check likely remaining life.

Minor cracking with rust staining may be present andsome initial drummy areas. Some patches andefflorescence may be present. Conduct a moredetailed assessment to evaluate extent of hiddendamage.

4 Poor 11 - 20 Further leaching of the preservative is occurring with the timber lookingwell weathered and rot pockets forming. Bolting of the decks may beloose with medium reflective cracking through the asphalt on top. Withtransverse sheeting, reflective cracking may also be occurring due todifferential movement between the slabs under loading, or due toinadequate bolting. Tensioning rods may be loosing stress with minormovement or separation of the laminations beginning to occur.

Major cracking and spalling may be present withcorroding reinforcement visible. But loss of section orrebar less than 10% e.g. deformed ribs on bars stillvisible. Dampness patches and efflorescence heavyin places.

5 Very Poor 0 - 10 Deterioration of the timber may be well advanced with substantial lossof the preservative protection. Weathering and rot of the timber issevere with some laminations almost rotted out.

Heavy cracking and spalling present with advancedcorrosion of the reinforcement over large areas.Excessive steel section loss greater then 10% andsome bars more heavily corroded. Excessivemoisture penetration and heavy staining around thecracks or evidence of excessive deflection orlocalised structural failure.

Table 25: Wharves/Jetties Timer Deck Criteria


7.4 FurnitureThis component includes bollards, ladders and the like.







Table 26: Wharves/Jetties Furniture Criteria

7.5 Fenders







Table 27: Wharves/Jetties Fenders Criteria

7.6 Cathodic ProtectionAsset Life: 30 years



2 Good 71 - 90 22 – 27 years

3 Average 41 - 70 13 – 21 years

4 Poor 11 - 40 4 – 12 years


Table 28: Wharves/Jetties Cathodic Protection


8.0 Structures8.1 StructuralThe Structures asset group includes gantry, gangways and towers. The structural component includesa focus on steel, capturing lattice towers, bolts, coatings and the like.


1 Excellent As new.

2 Good Acceptable physical condition. Minor wear and tear.Slight discolouring of galvanizing - no rust.No work required.

3 Average Deterioration evident. Loss of galvanizing, rust or rust stains evident. Failureunlikely in the near future but further deterioration likely.Work required in next 5 years but asset is still operating.

4 Poor Failure likely in the next 3 years. Rusted areas obvious, some loss of steel.Substantial work required in short-term.


Table 29: Structures Structural Criteria

8.2 Mechanical and Electrical







Table 30: Structures Mechanical and Electrical Criteria


9.0 Navigational Structures9.1 Lights / Day-marks


1 Excellent As new.

2 Good Acceptable physical condition.Aid is not new but performs as intended.No work required.

3 Average Deterioration evident.Aid is less visible than intended, technology is old and repairs problematic.Upgrade required in next five years.

4 Poor Below acceptable standard.Aid is reported faulty by users.Technology is old and no longer used in industry.Substantial work required with in 1 year.


Table 31: Navigational Structures Lights/Day-marks Criteria

9.2 Supporting StructureThis component includes other structures such as warning signs.


1 Excellent As new.

2 Good Acceptable physical condition. Minor wear and tear.Slight discolouring of galvanizing - no rust.No work required.

3 Average Deterioration evident. Loss of galvanizing, rust or rust stains evident. Failureunlikely in the near future but further deterioration likely.Work required in next 5 years but asset is still operating.

4 Poor Failure likely in the next 3 years. Rusted areas obvious, some loss of steel.Substantial work required in short-term.


Table 32: Navigational Structures Supporting Structure Criteria


9.3 Piles


1 Excellent As new.

2 Good Acceptable physical condition. Minor wear and tear.Slight rusting, loss of paint above water.No work required.

3 Average Deterioration evident. Corrosion above and / or below water Failureunlikely in the near future but further deterioration likely. Remedial workrequired in next 5 years, could include - replacing anode below water orwrapping pile above water.

4 Poor Failure likely in the next 3 years. Significant loss of steel section throughcorrosion either surface or pitting. Fatigue failure of steel or welds.Substantial work required short term.


Table 33: Navigational Structures Piles Criteria

9.4 Footings


1 Excellent As New

2 Good The steel plate has only minor rusting. The paint coating has no visibleevidence of imperfections The structure is well bolted to the support, and firmand tight. No sign of imperfections in the welds.

3 Average There is rusting and minor corrosion at the joints but all bolts, welds or rivetsare firm and tight.

4 Poor Medium corrosion is occurring at the joints. The holding down bolts may beslightly loose allowing too much movement of the sections.

5 Very Poor Heavy corrosion is occurring with holes appearing in the plates and welds.Many of the bolts are corroded.

Table 34: Navigational Structures Footings Criteria


10.0 Telecommunications10.1 CablesThis component includes conduits.

Asset Life: 60 years



2 Good 71 - 90 43 – 54 years

3 Average 41 - 70 25 – 42 years

4 Poor 11 - 40 7 – 24 years


Table 35: Telecommunications Cables Criteria

10.2 Pits




2 Good 71 - 90 43 – 54 years

3 Average 41 - 70 25 – 42 years

4 Poor 11 - 40 7 – 24 years


Table 36: Telecommunications Pits Criteria


11.0 Power11.1 Street LightingThis component includes steel poles and wiring, footing corrosion, cabling wear and tear and stability.



2 Good Acceptable physical condition. Minor wear and tear. Maintenance required




Table 37: Power Street Lighting Criteria

11.2 HV CablingThis component includes power poles.




2 Good 71 - 90 43 – 54 years

3 Average 41 - 70 25 – 42 years

4 Poor 11 - 40 7 – 24 years


Table 38: Power HV Cabling Criteria

11.3 LV Cabling




2 Good 71 - 90 43 – 54 years

3 Average 41 - 70 25 – 42 years

4 Poor 11 - 40 7 – 24 years


Table 39: Power LV Cabling Criteria


11.4 Substations

PoMC to Supply

11.5 Switchboards

PoMC to Supply

Documents

Condition Manual - RDwebaapa.files.cms-plus.com/PDFs/Port of Melbourne Condition... · 2013-02-15 · Condition Manual C:\Condition Manual - RevC.docx Condition Manual 60156808 Prepared