Construction of Terminal Berth in East Port Said

Construction of Terminal Berth in East Port Said

Port Said – Egypt

 Construction of Terminal Berth in East Port Said

CONTENTS
1.0 INTRODUCTION ...........................................................................................................3
1.1 BRIEF DESCRIPTION OF PROJECT AND ITS OBJECTIVES.................................................3
2.0 SCOPE OF WORKS .........................................................................................................
2.1 PROJECT DETAILS ..........................................................................................................3
2.2 PROJECT CATEGORY BY QUANTITIES............................................................................4
3.0 EXECUETION SUMMARY ..........................................................................................4
3.1 MOBILIZATION...............................................................................................................4
3.2 BORED PILES .................................................................................................................. 4
3.3 CFA PILES ....................................................................................................................4
3.4 DRIVEN PILES ............................................................................................................5
3.5 DECK BEAMS..............................................................................................................5
3.6 DECKSLAB ..................................................................................................................6
3.7 BOLLARDS & FENDERS SYSTEM ...........................................................................6
4.0 RESOURCES AND PLANNING TECHNIQUE ..........................................................7
4.1 RESOURCES....................................................................................................................7
4.2 PROJECT DURATION AND CRITICAL PATH. ....................................................................9
5.0 ALLOCATING RESOURCES AND LEVELLING .................................................. 10
6.0 1ST CHECK FOR CRASHING AND OPTIMUM DURATION .......................... 11
 Construction of Terminal Berth in East Port Said
1.0 INTRODUCTION

1.1 Brief Description of Project

The project is a construction of a quay length 100 meters. The project consists of:

A- Deep foundation:
A.1- Front Piles (Steel pipes).
A.2- Sheet Piles.
A.3- Intermediate Piles: Two rows of bored piles, every row consists of 143 pile
A.4- Rear Piles:
A.4-1: Bored piles.
A.4-2: CFA.
B- Deck of Berth:
B.1- Main Beams: there are two main beams one of them above the front piles and the other
is above the rear piles.

B.2- Main slab

C- Berth Accessories:
C-1: Fenders
C-2: Bollard

2.2 Project Category

Project Category Quantity

Project duration 12 months.
Marine Offshore and Onshore
Offshore
Construction of the main quay wall
- Driven Piles (Steel Pipe) - 4823Ton
- Driven piles Piles (RC) - 4762 M3
- Sheet Piles - 310 Ton
- Bored Piles - 15659.5lm
- CFA - 1835lm
Onshore
R.C Platform on the Piles Works 10600 m3
 Construction of Terminal Berth in East Port Said

3.0 Executive Summary

3.1 Mobilization

1- Excavation for construction area ( 32 m x 100 m ) with 1.5 m depth making total
excavation volume 4800 m3 to be done in 30 days.
2- Soil replacement using base coarse for the excavated area to increase the bearing capacity
for soil to bear heavy drilling machines and cranes to be done in 30 days.
3- Considering( 2 excavator,2 loaders, 4 trucks ) for excavation and base coarse material
delivery and execution, resources estimated for this activity is 111,000 LE / day over 45 days
total period for mobilization.

3.2 Bored Piles

1- The 100 m berth divided into 2 areas 50 m for each, each area contains 120 bored piles, the
pile parameters is 1.2 m diameter & 70 m length, to be done in 80 days, 3 piles/day using 3
drilling machines and two cranes for installing RFT and pouring concrete.

3.3 CFA piles

1-The berth contains 60 CFA pile (0.6 m Diameter and 11 m length) to be executed between
the back line of bored piles as underground water barrier.
2- The estimated rate is executing 4 piles / day to be done in 15 days. Using one drilling
machine.
 Construction of Terminal Berth in East Port Said

3.4 Driven piles

The front steel Driven piles is a front steel wall towards water, it’s a 2 m diameter steel pipes,
each pile consists of two steel parts, lower and upper pipe, these parts are driven into ground
by a vibrator or a hydraulic hummer if needed, the a 30 m length Z-type sheet piles installed
between these piles to form a front line against water.

The method of statement of this activity:

1- Lifting the 1st lower pipe and installing it into ground using vibrator, the pipi is installed
by a steel form to prevent miss co-ordinations, then the 2nd upper pipe lifted and welded
into the lower one then installed till cut off level.
2- After installing the 2nd pipe, the sheet piles is driven between each pile.
3- Then the excavation process, installing RFT then pouring concrete.

3.5 Deck Beams

1-After executing piles, the 2nd main part of the berth is the Deck of berth (beams and slab), the
area between piles is excavated till cutoff level to show pile caps, to demolish the piles caps to
show the RFT splice connection with the beams, after excavation and soil replacement, A plain
concrete is casted over the excavated area with top level of the cut off, then a concrete spacers
is casted over the plain concrete to fix the beam RFT over and make the concrete cover of the
beams.

2- After fixing the beam RFT, beam formwork is fixed preparing for pouring concrete.
 Construction of Terminal Berth in East Port Said

4.0 RESOURCES AND PLANNING TECHNIQUE

4.1 Resources

For Resources allocating, levelling and planning technique I used MS project 2016.
As shown above the available resources for each main activity mentioning below the
resources estimations criteria:
1- Indirect cost
Considering indirect monthly salaries for Managers, Engineers, Document Control ,
QC/QA, Office Stuff, House-keeping , Housing For manpower, transportation for
manpower ..etc.
Estimated by: 250,000 LE/month

2- Bored Piles
Based on planned progress rate 3 piles/day, that would be achieved by 3 drilling
machines, loader, 2 cranes for concrete pouring and installing RFT, Considering the
hire cost for these equipment and wages of skilled labor and drivers.
Estimated by: 200,000 LE/day
 Construction of Terminal Berth in East Port Said

4.2 Planning technique

Activity Duration
Portsaid Terminal berth 355 days
Mobilization 45 days
Excavation 30 days
Soil Replacement 30 days
Piles 181 days
Bored Piles 80 days
CFA Piles 15 days
Driven Steel Piles 136 days
Lower Pipes 60 days
Upper Pipes 90 days
Sheet Piles 60 days
Plain Concrete 37 days
Excavation Between Piles 30 days
Soil Replacement between piles 30 days
Formwork & Casting PC 30 days
Deck 218 days
Beams 185 days
Demolishing Piles caps 70 days
Concrete Spacers 20 days
Area 1 85 days
Fixing RFT Area 1 60 days
Formworks Area 1 44 days
Casting Beams Area 1 4 days
Area 2 70 days
Fixing RFT Area 2 60 days
Formworks Area 2 45 days
Casting Beams Area 2 4 days
Slab 78 days
Area 1 32 days
Slab Formworks Area 1 15 days
Slab RFT Area 1 20 days
Slab Casting Area 1 6 days
Area 2 33 days
Slab Formworks Area 2 15 days
Slab RFT Area 2 20 days
Slab Casting Area 2 6 days
Installing Bollards & Fenders system 20 days
 Construction of Terminal Berth in East Port Said

The Project duration is 355 days

Critical Path Activities Shown in Red, I Used MS Project 2016, attached the project
file.
 Construction of Terminal Berth in East Port Said
5.0 Allocating Resources and Levelling

1- Indirect Costs Resources usage graph over time

2- Mobilization Resources usage graph over time

According to schedule most of mobilization process activities (Excavation and Soil

replacement) take action in jan-2016 the decreases in February as shown.
Construction of Terminal Berth in East Port Said
3- Bored Piles Resources Usage over time

4- CFA Piles Resources Usage over time

Construction of Terminal Berth in East Port Said
5- Deck Activity Resources usage graph over time

6- Bollards & fenders system Resources usage graph over time

 Construction of Terminal Berth in East Port Said
From the previous resources graphs according to the schedule, the resources loading draph for
all activities can be shown as the following:

As shown in the above table and graph, the maximum resources required is in April, 2016. By
17,613,715.00 LE then March, 2016 by 13,228,750.00 LE with undesirable variance with
other months values.
So the corrective action is to reschedule the Non-critical activities with float in these March,
April and May, 2016 like lower pipes, upper pipes and sheet piles activities with the leveling
delay indicated over non critical activities in light brown as following:
 Construction of Terminal Berth in East Port Said

As shown Above, The Driven piles activity was levelled as it was non-critical activity in and
over allocation months, now the variance decreased to be (+/-) 500,000 LE instead of 7
million before between Feb-2016 and March 2016, and 2,500,000 LE between April and may
instead of 7,500,000 LE.

6.0 Check for crashing feasibility before start

Normal Crashed
Activity Duration Duration Slope
Cost (LE) Cost (LE)
(Day) (Day)

Mobilization 45
5,000,000.00 35 5,010,000.00 1,000.00
Bored Piles 80
20,000,000.00 60 20,050,000.00 2,500.00
CFA Piles 15
1,500,000.00 10 1,520,000.00 6,666.67
Driven Steel Piles 136
30,000,000.00 120 30,200,000.00 12,500.00
Deck 218
25,000,000.00 200 25,200,000.00 5,555.56
Installing Bollards & Fenders system 20
5,000,000.00 15 5,015,000.00 3,000.00
 Construction of Terminal Berth in East Port Said

Crashing based on:

1- Mobilization: was based on 2.5 hrs overtime per day, 2.5 hrs over 35 days makes
87 man hour work which makes the crashed time variance (45 days before crashing)
Working day = 8 hours

2- Bored Piles: Total bored piles No. = 240 pile, the initial estimation was based on a
progress of 3 piles/day with 3 drilling machines on 8 hour work day, and 20 steel
fabricators and welders to fabricate the required amount, and 4 trucks to deliver ready
concrete mix to site, by increasing the trucks number by one and ten welders and steel
fabricators the progress should reach 4 piles / day. Which gives the available crash
duration (60 days)

3- CFA piles: Total CFA No. is 60 piles, and the initial estimation was based on the
progress of 5 piles/day with gives 15 day duration for the activity, considering the
relatively small parameters for CFA piles (0.6 m Diameter, 10 m length) with
additional bonus for productivity a rate of 6 piles/day which makes total duration 10
days.

4- Deck: Based on increasing Steel fabricators as the Steel RFT quantity for each area
is 1500 ton, estimating manpower is 100 steel fabricator and fixer, with 0.25 ton
productivity per day for each then every area should be finalized by 60 days. To crash
this item by doubling the manpower number should be finished by 30 days making
the whole activity be done within 200 days
 Construction of Terminal Berth in East Port Said
Crashing calculations:

Normal Crashed
Activity Duration Duration Slope
Cost (LE) Cost (LE)
(Day) (Day)

Mobilization 45
5,000,000.00 35 5,010,000.00 1,000.00
Bored Piles 80
20,000,000.00 60 20,050,000.00 2,500.00
CFA Piles 15
1,500,000.00 10 1,520,000.00 6,666.67
Driven Steel Piles 136
30,000,000.00 120 30,200,000.00 12,500.00
Deck 218
25,000,000.00 200 25,200,000.00 5,555.56
Installing Bollards & Fenders system 20
5,000,000.00 15 5,015,000.00 3,000.00

Duration (days) 278 283 298 335 355

Indirect cost
2,316,666.66 2,358,333.30 2,408,333.33 2,791,666.66 2,958,333.33
Direct Cost
90,000,000.00 88,000,000.00 87,000,000.00 86,780,000.00 86,500,000.00
Total Project
Cost 92,316,666.66 90,358,333.30 89,408,333.33 89,571,666.66 89,458,333.33
Construction of Terminal Berth in East Port Said

Optimum project duration

92,316,666.66
90,358,333.30 89,408,333.33 89,571,666.66 89,458,333.33
90,000,000.00
88,000,000.00 87,000,000.00 86,780,000.00 86,500,000.00

2,316,666.66 2,358,333.30 2,408,333.33 2,791,666.66 2,958,333.33

278 283 298 335 355

Duration (days) Indirect cost

Direct Cost Total Project Cost