Port of Melbourne Condition Manual

Condition Manual
Data Capture of Physical Assets via Condition

Assessment
Fremantle Ports and Port of Melbourne Corporation
17 December 2010
Condition Manual
60156808
Prepared for
Fremantle Ports and Port of Melbourne Corporation
Prepared by
Maunsell Australia Pty Ltd
Level 9, 8 Exhibition Street, Melbourne VIC 3000, Australia
T +61 3 9653 1234 F +61 3 9654 7117 www.maunsell.com
ABN 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 on
the cover sheet for the purpose for which it has been prepared and AECOM Australia Pty Ltd undertakes no duty to or accepts
any 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, electronically
stored or transmitted in any form without the written permission of AECOM Australia Pty Ltd.
Condition Manual
C:\Condition Manual - RevC.docx
Quality Information
Document Condition Manual
Ref 60156808
Date 06/01/2011
Rev A (2007): Tahlia Griffin
Prepared by
Rev C (2010): Eamon Sullivan
Rev A (2007): Sandy Muir
Reviewed by
Rev C (2010): Gary Rykers
Revision History
Authorised
Revision
Revision Details
Date
Name/Position Signature
James Bandt
A 19/03/2007 Final Condition Manual Principal
Consultant
Stage 1 update, draft for

B 27/07/2010 Gary Rykers
comment
Stage 1 update, final
C 17/12/2010 Gary Rykers
version for issue to client
Condition Manual
Table of Contents
1.0 Background 1
1.1 About this Manual 1
1.2 Condition Assessment Methodology 1
1.3 Use of Condition Rating 2
1.4 Description of Key Definitions 2
1.5 Relationship with Asset Management System 3
1.6 Asset Hierarchy 3
1.7 Condition Assessment Frequency 8
2.0 Buildings 9
2.1 Structural 9
2.2 Services 9
2.3 Sub-Structure 10
2.4 Fittings 10
3.0 Roads 11
3.1 Pavement 11
3.2 Furniture 12
3.3 Verges 12
3.4 Kerb and Channel 13
4.0 Sewerage 14
4.1 Pipes 14
4.2 Manholes 14
4.3 Pump Station Structure 14
4.4 Pump Station Mechanical and Electrical 15
5.0 Drainage 16
5.1 Pipes 16
5.2 Pits 16
5.3 Traps Structural 16
5.4 Traps Mechanical and Electrical 17
6.0 Water 18
6.1 Pipes 18
6.2 Water-main Fittings 18
7.0 Wharves/Jetties 19
7.1 Piles 20
7.2 Sub Structures 21
7.3 Deck 22
7.4 Furniture 23
7.5 Fenders 23
7.6 Cathodic Protection 23
8.0 Structures 24
8.1 Structural 24
8.2 Mechanical and Electrical 24
9.0 Navigational Structures 25
9.1 Lights / Day-marks 25
9.2 Supporting Structure 25
Condition Manual
9.3 Piles 26
9.4 Footings 26
10.0 Telecommunications 27
10.1 Cables 27
10.2 Pits 27
11.0 Power 28
11.1 Street Lighting 28
11.2 HV Cabling 28
11.3 LV Cabling 28
11.4 Substations 29
11.5 Switchboards 29
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C:\Condition Manual - RevC.docx Page 4
1.0 Background
1.1 About this Manual
This Condition Manual (Manual) provides standard condition rating criteria for Fremantle Ports’ and
Port of Melbourne Corporation’s (PoMC) assets. These condition rating criteria have been developed
to facilitate consistency and repeatability when assessing a condition grading for assets / asset
components.
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 Section
1 (Background) only. A second stage update is proposed for 2011, to address further improvement
opportunities 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 and
PoMC and are based around industry standards. It is intended that this document will be used by
Fremantle Ports and PoMC as a guide for conducting condition surveys of their major assets / asset
components.
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 Methodology

The 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, risk
management, predictive modelling, planned maintenance and rehabilitation, asset valuation, works
prioritisation and budget forecasting. The process of collecting consistent and repeatable condition
data forms a core part of the application of asset management, as defined in Figure 1.
Condition Manual
DATA COLLECTION /
EXISTING DATA MEASURE PERFORMANCE
•Environmental •Customer
•Strategic LEVEL OF ASSET MANAGEMENT
•Financial
•Legislative SERVICE •Political PLAN
PREDICT ASSESS FINANCIAL

DEMAND IMPACTS (Cashflow
(Cashflow))
IDENTIFY OPTIMUM
CONDITION SOLUTION
ASSESSMENT
EVALUATE
TREATMENT OPTIONS
FAILURE MODE ASSESS RISKS

ANALYSIS OF FAILURE
Figure 1: Asset Management Process
This Manual provides criteria to assess asset condition on a rating scale of 1 - 5 (excellent to very
poor), linked to standard definitions describing physical condition of the assets.
In providing a condition assessment methodology, it is essential that the assessments are reliable and
consistent so asset managers can be confident in the data.
1.3 Use of Condition Rating

The scope of this Manual covers condition rating based on visual assessments of an asset’s physical
condition (or age where an asset group cannot be visually inspected). As much as is practicable with a
visual condition assessment, the condition rating descriptions incorporated into a 1 - 5 rating scale are
linked to expected failure mechanisms, via the objective assessment of visible defects expected for
each asset type.
1.4 Description of Key Definitions

For clarity and understanding, Table 1 provides a summary of the key definitions used throughout this
document.
Table 1: Key Definitions
Term Description of Key Definitions

Asset 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 - in
this case, the wharf - consists of a number of constituent components such
as piles, beams, fenders, a deck and sheet piles.
Asset Category The type of assets within an asset class. For example, the buildings asset
class 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 the
highest level in the asset hierarchy. In the context of ports, asset classes
include buildings, navigational aids, roads, railways etc.
Asset Component Specific parts of an asset with an independent physical or functional identity
and having specific attributes such as different life expectancy,
maintenance regimes or risk. For example, piles, beams, fenders, a deck
and sheet pile walls would all be considered components of a wharf. An
asset component is a subset of the asset itself.
Condition Manual
Term Description of Key Definitions
Asset Hierarchy An infrastructure framework for segmenting an asset portfolio into
appropriate classifications. The asset hierarchy can be based on asset
function, asset type or a combination of the two.
Condition Rating Scale The standardised classification system used to identify the current condition
of an asset component (which forms part of a particular asset).
Inspection Frequency The inspection frequency defines how often a condition rating survey will be
conducted for each asset group (or potentially each asset category). The
inspection frequency can be different for each inspection type.
Inspection Type Level 1 – Routine inspection performed in accordance with a pre-prepared
checklist, typically conducted by a maintenance technical officer.
Level 2 – Periodic visual condition survey performed in accordance with a
consistent and repeatable process (this Manual), typically undertaken by an
engineer. Level 2 condition rating results are typically stored in an Asset
Management System and used to drive needs based forward programs.
Level 3 – Detailed engineering testing, analysis and assessment, likely to
involve specialised equipment and/or a high level of technical expertise.
Location Referencing A structured referencing system that identifies the position of individual
components or assets. The location referencing system may vary according
to the asset class. Condition rating survey outputs are recorded in
accordance with the adopted location referencing system. ‘Return to field’
activities rely on the location referencing system to re-locate defects
identified during the condition rating survey and to ensure repeated
inspections are recorded against the same component or asset.
Start Datum The start datum is an integral part of the location referencing system. The
start datum is a clearly defined location or reference point, used as the
starting point for subsequent location referencing measurements.
1.5 Relationship with Asset Management System

Asset condition rating data should be stored in an asset management system for use by the asset
owner. As such, the methodology adopted for condition rating needs to be aligned with asset
management system functionality. While PoMC (Conquest) and Fremantle Ports (FMMS) use different
systems for managing asset data, it is recognised that each organisation will need to store and
analyse the collected condition data using their respective systems.
1.6 Asset Hierarchy

The asset hierarchy drives consistent organisational reporting for asset operations, maintenance,
renewal and upgrade/new works. The hierarchy breaks down complex assets into manageable
components and forms the foundation for recording of asset information through corporate business
processes 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 may
be listed.
Whilst asset hierarchies are often separated by asset class, the hierarchy can also take a spatial
approach whereby asset classes in the same location are grouped together (e.g. “Berth 1” could
contain not only the structural components but also supporting infrastructure such as electrical
services, water supply etc).
Condition Manual
Although each port may structure their hierarchy differently within the asset management system, it is
important that the hierarchy be setup in such a way as to facilitate essential business functions such
as maintenance management, financial reporting and data management.
The table below outlines the specific asset classes, asset categories and asset components covered
by this Manual. Condition assessment will be consistently undertaken at the component level; with
condition assessment being undertaken only for asset components that are considered materially
significant. That is, asset components which have a material value (to be determined by each
organisation) 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 to
the ongoing serviceability of the asset as a whole. In this instance, the component should be included
in a condition assessment regime regardless of direct monetary value.
Table 2: Asset Hierarchy for Condition Assessment
Asset Class Asset Category Asset Component Material Type Reference

Buildings
Amenities building
Structural 2.1
Services 2.2
Substructure 2.3
Fittings 2.4
Gatehouse
Structural 2.1
Services 2.2
Substructure 2.3
Fittings 2.4
Historic building
Structural 2.1
Services 2.2
Substructure 2.3
Fittings 2.4
Maintenance building
(e.g. workshop)
Structural 2.1
Services 2.2
Substructure 2.3
Fittings 2.4
Office building (by
floor)
Structural 2.1
Services 2.2
Substructure 2.3
Fittings 2.4
Portable building
Structural 2.1
Services 2.2
Substructure 2.3
Fittings 2.4
Storage building (e.g.
warehouse, shed)
Structural 2.1
Services 2.2
Substructure 2.3
Fittings 2.4
Substation
Structural 2.1
Condition Manual
Services 2.2
Substructure 2.3
Fittings 2.4
Port Interface Structures

Wharves / Piers /
Jetties / Landings
Deck 7.3
Timber
Concrete
Deck overlay 7.3
Asphalt
Concrete
Pile 7.1
Timber
Steel
Concrete filled
steel
Concrete
Fender 7.5
Appurtenance 7.4
Timber
Concrete
Steel
Revetment and scour
protection TBD Stage 2
Rock
Concrete
Sheet pile wall TBD Stage 2
Concrete
Steel
Beams and cross heads 7.2
Timber
Concrete
Steel
Bracing TBD Stage 2

Timber
Steel
Concrete
Cathodic protection
system 7.6
Ro Ro ramp TBD Stage 2
Dolphin pile 7.1
Timber
Steel
Concrete filled
steel
Concrete
Dolphin deck 7.3
Timber
Concrete
Dolphin deck overlay 7.3
Asphalt
Concrete
Navigational Aids
Beacon (water-based)
Condition Manual
Navigation light / day mark 9.1
Structure 9.2
Pile 9.3
Footings 9.4
Buoy (water-based)
Buoy TBD Stage 2
Directional wave rider TBD Stage 2
Coastal monitoring device
AWAC TBD Stage 2
Tower (land-based)
Structure 9.2
Footings 9.4
Lighthouse (land-
based)
Navigation light 9.1
Structure 9.2
Equipment TBD Stage 2
Footings 9.4
Roads
Pavement
Public road 3.1
Asphalt
Concrete
Granular with
Sprayed Seal
Unsealed
Stacking area 3.1
Asphalt
Concrete
Granular with
Sprayed Seal
Unsealed
Parking area 3.1
Asphalt
Concrete
Granular with
Sprayed Seal
Unsealed
Minor drainage Kerb and channel 3.4
Path Footpath / Bike path TBD Stage 2
Environment Medians 3.3
Shoulders 3.3
Verge 3.3
Linemarking 3.3
Furniture
Signs 3.2
Light poles 3.2
Bollards 3.2
Barriers 3.2
Guardrails 3.2
As per VicRoads Bridge
Condition Inspection
Manual – Level 2
Bridge Inspections Not In Scope
Supplemental Structures
Land-based structure
Condition Manual
(e.g. tower, gantry,
gangway)
Structure 8.1
Mechanical and electrical 8.2
Seawall
Structure TBD Stage 2
Services
Sewerage
Gravity main 4.1
Rising main 4.1
Manhole 4.2
Pump station - structure 4.3
Pump station - mechanical
/ electrical 4.4
Drainage
Pipe 5.1
Pit 5.2
Trap 5.3
Water
Pipe 6.1
Pump station - structure 4.3
Pump station - mechanical
/ electrical 4.4
Valve 6.2
Hydrant 6.2
Telecommunications
Cables 10.1
Pits 10.2
Poles TBD Stage 2
Power
Street lighting 11.1
HV Cabling 11.2
LV Cabling 11.3
Substations 11.4
Switchboards 11.5
Oil
Equipment TBD Stage 2
Railways
Railway
Track TBD Stage 2
Sleepers TBD Stage 2
Ballast TBD Stage 2
Signalling equipment TBD Stage 2
Cargo Handling Equipment

Ship unloader Not in scope
Stacker reclaimer Not in scope
Machinery House Not in scope
Loading boom Not in scope
Main columns, masts
and beams Not in scope
Control cabin Not in scope
Boom luff Not in scope
Super structure Not in scope
Tripper trailer Not in scope
Conveyor tower Not in scope
Condition Manual
Receival hopper Not in scope
Unloading hopper Not in scope
Loading chutes Not in scope
Crane rail Not in scope
Crane rail beam Not in scope
1.7 Condition Assessment Frequency

Infrastructure assets deteriorate over time. The collection of consistent and repeatable condition data
allows time-series deterioration trends to be identified and modelled. These can be used to feed
renewal models and other sophisticated asset management tools and analyses. There is an inherent
risk in making business decisions regarding significant capital renewal investment based on out-dated
condition data. As such, up-to-date condition data is of significant importance when an organisation is
actively undertaking an asset remediation / renewal program.
These objectives can best be met where there is a defined frequency of condition data survey, for
each asset class. As a supporting document to this Manual, it is proposed that a separate guideline be
developed to define the recommended survey types and frequency for each asset class. The guideline
will undergo detailed review by Australian port authorities to ensure that appropriate practices are
adopted and to optimise the return on investment with respect to condition assessment.
Condition Manual
2.0 Buildings
2.1 Structural
This 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 further
deterioration likely. Work required in next 3 years but asset is still
operating.
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 or
replacement required urgently.
Table 3: Buildings Structural Criteria
2.2 Services
This 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. Efficiency
unaffected. 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 or
maintenance needs. Whole of life costs excessive compared to
replacement cost. Requires major overhaul in 1 to 2 years.
5 Very Poor Electrically or mechanically unsafe or in disrepair. Unsafe to use, too
unreliable or costly to operate. Requires immediate action.
Table 4: Buildings Services Criteria
Condition Manual
2.3 Sub-Structure
This component includes floor slabs and footings and any part of the structure ground level and below.

deterioration likely. Work required in next 3 years but asset is still operating.
Table 5: Buildings Sub-Structure Criteria
2.4 Fittings
This component includes all interior fittings and furnishings.

Table 6: Buildings Fittings Criteria
Condition Manual
3.0 Roads
3.1 Pavement
Rating
Distress Mode Failure Type 1 2 3 4 5
Longitudinal / No visible signs of Maximum crack Maximum crack Maximum crack Maximum crack width
Transverse cracking width < 5 mm width 6 - 10 mm width 11 - 15 mm > 15 mm
Cracking
Crack Pattern Crack Pattern Crack Pattern
No visible signs of Crack Pattern < 4%
Pattern 5 - 10% of 11 - 25% of > 25% of pavement
cracking of pavement area
pavement area pavement area area
No visible signs of < 3 potholes 3 potholes 3 - 5 potholes > 5 potholes
Disintegration Potholes pavement
disintegration every 100 m every 100 m every 100 m every 100 m
No visible signs of
Distortion Rutting, Heaving pavement < 20 mm deep 20 – 30 mm deep 31 - 50 mm deep > 50 mm deep
distortion
No visible signs of
Edge Breaks Edge breaks < 50 mm deep 51 – 100 mm deep 101 - 200 mm deep > 200 mm deep
edge breaking
Material Loss, Texture loss Texture loss Texture loss Texture loss extends
Surface Texture No visible signs of
Scabbling, extends up to 5% of extends 6 – 10 % of extends 10 - 20% of > 20% of pavement
Loss texture loss
Peeling pavement area pavement area pavement area area
Pavement shows Pavement shows
Pavement shows Appearance of the
Pavement looks in some signs of numerous signs of
Appearance signs of significant road is unpalatable to
‘as new’ condition patching on road patching on road
patching the community
surface surface
Table 7: Roads Pavement Criteria
Condition Manual
3.2 Furniture
This component includes signs, light poles, bollards, barriers and guard rails.

operating.
Table 8: Roads Furniture Criteria
3.3 Verges
This component includes nature strips, grassed areas trees and footpaths.

1 Excellent Clean and neat surroundings, no rubbish evident and well groomed
vegetation/grass. No work required.
2 Good Clean surroundings however vegetation/grass is growing outside defined
area. 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 and
replanting required.
5 Very Poor Area over grown or vegetation dead. Dirty appearance. Major clean-up and
replanting required.
Table 9: Roads Verges Criteria
Condition Manual
3.4 Kerb and Channel
Rating
Distress Mode 1 2 3 4 5
Joint Extensive joint
Joint
Longitudinal Some joint Displacement displacement
Displacement
Profile No visible signs of displacement between 20 - 40% (>40%) of length
< 20% of length of
(Vertical joint joint displacement over < 10% of of length of kerb of kerb and
kerb and channel
displacement, and ponding length of kerb and and channel channel segment
segment
sagging, ponding) channel segment segment resulting in many
individual failures
Joint Joint Extensive joint

Horizontal Profile Some joint Displacement Displacement displacement
No visible signs of displacement < 20% along kerb between 20 - 40% (>40%) along
(Horizontal joint joint displacement over < 10% of kerb and channel
displacement, and channel along kerb and
and heaving kerb and channel segment channel segment segment resulting
heaving) segment in many individual
failures
Extensive
Moderate Blockages and
Minor blockages blockages and
Blockages and No sign of blockages and obstructions
and obstructions obstructions
obstructions e.g. blockages and obstructions< between 20 - 40%
<10% of kerb and (>40%) along
weed growth obstructions 20% along kerb along kerb and
channel joint kerb and channel
and channel joints channel joints
joints
Table 10: Roads Kerb and Channel Criteria
Condition Manual
4.0 Sewerage
4.1 Pipes
Asset 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 in
benching and joints around pipes. Maintenance required.
3 Average Deterioration evident. Some loose step irons. Infiltration into benching and
concrete breaking away from pipe joints. Minor repairs required.
4 Poor Step irons missing or can be pulled from wall. Concrete in benching
breaking 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. Major
leaks around pipe joints or pipes separating from manhole / pit. Structure of
manhole or pit requires replacing.
Table 12: Sewerage Manholes Criteria
4.3 Pump Station Structure

operating.
Table 13: Sewerage Pump Station Structure Criteria
Condition Manual
4.4 Pump Station Mechanical and Electrical

Table 14: Sewerage Pump Station Mechanical and Electrical Criteria
Condition Manual
5.0 Drainage
5.1 Pipes

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 Pits
This component includes outfalls and end walls.

2 Good Acceptable physical condition. Minor wear and tear. Minor infiltration in
benching and joints around pipes. Maintenance required.
3 Average Deterioration evident. Some loose step irons. Infiltration into benching and
concrete breaking away from pipe joints. Minor repairs required.
4 Poor Step irons missing or can be pulled from wall. Concrete in benching
breaking 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. Major
leaks around pipe joints or pipes separating from manhole / pit. Structure of
manhole or pit requires replacing.
Table 16: Drainage Pits Criteria
5.3 Traps Structural

This component includes isolation pits and litter traps.

operating.
Table 17: Drainage Traps Structural Criteria
Condition Manual
5.4 Traps Mechanical and Electrical

Table 18: Drainage Traps Mechanical and Electrical Criteria
Condition Manual
6.0 Water
6.1 Pipes

1 Excellent As new.
2 Good Showing minor signs of wear on tear on pipe coating. No damage evident. No
sign of leaking from joints.
3 Average Damage to the pipe coating and minor corrosion evident. Joints showing
some wear and tear. Moisture apparent. Corrosion to be removed and
coating replaced.
4 Poor Major corrosion evident along the pipe length. Joints leaking. Replacement
required 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 Fittings

This 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. Wear
and tear becoming more evident. Corrosion of metal components becoming
evident.
4 Poor Function affected, difficult to open or close. Heavy corrosion on valve body
and seating.
5 Very Poor Fails to function.
Table 20: Water-main Fittings Criteria
Condition Manual
7.0 Wharves/Jetties
Introduction
Given the number of asset items and sub items it is envisaged that a sample area of each wharf will
be selected for assessment. The assessment criteria will take into consideration two factors being the
severity of the defect and the extent of the defect (area affected). When assessed the asset will be
assigned a percentage against each of the ratings of 1 – 5, an example output is given below:
Condition Rating % Area Affected

1 10
2 30
3 20
4 35
5 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 identify
that 10% of the decking has been rated as a condition 1, 30% as a condition 2 etc. It is intended that
this information be mapped onto the table below to identify the works required. The colours below
indicate the type of work to be undertaken when the condition and percentage area affected coincide
with a colour. For example a condition 3 with a percentage area affected of 31-40% would require
further investigation. However should a condition 5 with a percentage area affected of 11-20% also
occur on the same asset, then the replacement would be required and this would take precedent over
the investigative work.
% Area Affected
Condition 0 - 10 11 - 20 21 - 30 31 - 40 > 40
1
2
3
4
5
Table 22: Works Required mapped against Condition by Affected Area
Example of outcomes:
Repair
Detailed Replace
No Works Required Reinspect within 5
Investigation Immediately
years
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 be
formulated following a non detailed assessment of the Levels of Service and Business Risk associated
with the wharf structures.
Condition Manual
7.1 Piles
Rating Definition % Estimated Steel Timber Concrete (Steel Cased)
Remaining Life
1 Excellent 61 - 100 As new. As new. As new, some minor surface corrosion present.
2 Good 31 - 60 Acceptable physical condition. Minor Acceptable physical condition. Minor wear and Acceptable physical condition. Minor wear and tear. General
wear and tear. Slight rusting tear. Little or no rot or decay, though there may corrosion and loss of paint above water. No work required.
(corrosion), loss of paint above water. be minor cracks, splits or checks having no
No work required. affect on the strength of the component. No
works required.
3 Average 21 - 30 Some heavy corrosion present with Minor signs of rot or decay. Moderate necking Some heavy corrosion present. Estimated remaining life 10-
rust scale build-up. Estimated evident, 350mm diameter remaining, cracking 15 yrs however conduct a more detailed assessment to
remaining life 10-15 yrs however extends beyond connections and splitting is define this more accurately.
conduct a more detailed assessment to <10mm wide.
define this more accurately.
4 Poor 11 - 20 Deterioration evident. Heavy corrosion Deterioration evident. Extensive decay, checking Significant deterioration evident in the form of corrosion
above and / or below water. Failure or splitting (<20mm wide). Heavy necking, related holing of steel casing and exposure of concrete
unlikely in the near future but further 300mm of diameter remaining along with heavy above and / or below water Failure unlikely in the near
deterioration likely. Remedial work cracking that extends along the member. Failure future but further deterioration likely. Remedial work
likely to be required in the next 5 yrs unlikely in the near future but further required in next 5 years, could include – patch repairs and /
could include - replacing anode below deterioration likely. Remedial work required in or the need for cathodic protection or in the case of existing
water or wrapping pile above water. next 5 years. cathodic 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. Asset failed or failure imminent. Asset represents Asset failed or failure imminent. Asset represents a risk.
Significant loss of steel section through a risk. Major work or replacement required Major work or replacement required urgently or Failure likely
corrosion either surface or pitting. urgently or Significant necking of piles down to in the next 3 years. Significant holes in steel section to an
Fatigue failure of steel or welds. 200mm diameter. They may also have large extent that the concrete is exposed and showing signs of
Substantial work required short term or splits, especially under load bearing areas, deterioration. Substantial work required short term.
Asset failed or failure imminent. Asset heavy decay or checks which may have a
represents a risk. Major work or reduction in strength of the member. Substantial
replacement required urgently. work required in very short term.
Table 23: Wharves/Jetties Steel Pile Criteria
Condition Manual
7.2 Sub Structures
This 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 checks The deck soffit shows little or no deterioration through there may
having no effect on strength. be some dampness and efflorescence. Minor vertical or
All bolted connections are tight and in good condition. horizontal cracking may be present with no signs of horizontal
cracking along the beam side within the soffit region.
3 Average The timber shows signs of minor decay, splitting and checks but Minor cracking with rust staining may be present and some
does not affect the strength of the members. initial drummy areas. Minor vertical or horizontal cracking may
The tops of the member may have some moisture ingress and be be present with signs of horizontal cracking along the beam side
wet and slightly spongy. Estimated remaining life 10-15 yrs within the soffit region. Conduct a more detailed assessment.
however conduct a more detailed investigation.
4 Poor Medium decay distributed over beams, or heavy localized decay. Major cracking and spalling may be present with corroding
Splitting and checking may be present. Moisture ingress into the reinforcement visible. Significant signs of horizontal cracking
top of the member has caused softness with indentations and along the beam side within the soffit region. Dampness patches
slight bulging from the deck planks. The strength of the member and efflorescence powder may be more prominent.
has been affected to a minor extent.
Bolted connections may be loose allowing the member to move
excessively when loaded.
The member may have cracked due to overloading, ineffective
support, or supports being too far apart or crossbeams being non-
continuous, i.e. only two supports.
5 Very Poor The member is heavily decayed, split or rotted, with large Heavy cracking and spalling may be present with advanced
indentations at the top along with excessive bulging due to the top corrosion of the reinforcement over large areas. Excessive
being very wet and spongy. moisture penetration and heavy staining around the cracks or
Bolted connections are very loose and the member is moving evidence of excessive deflection or localised structural failure.
excessively when loaded musing deterioration of the member.
The member may be cracked through due to overloading,
ineffective support or crossbeams being non-continuous.
Table 24: Wharves/Jetties Sub-Structures Timber Criteria
Condition Manual
7.3 Deck
Rating Definition % Estimated Timber Concrete

Remaining Life
1 Excellent 61 - 100 As new. As new.
2 Good 31 - 60 The timber may have minor cracks, splits or checks but is fully The deck soffit shows little or no deterioration through
protected by the preservatives, with no untreated heartwood. The there may be some dampness and efflorescence.
decks are well bolted to the supports. Tensioning rods have adequate Minor cracking may be present but has rust stains.
stressing and there is no damage to the timber at the stressing plates.
3 Average 21 - 30 Preservative protection may be beginning to dissipate with minor Minor cracking with rust staining may be present and
leaching of preservative salts (white powder on underside of deck) and some initial drummy areas. Some patches and
with minor weathering and rot of timber. Bolting of the deck may be efflorescence may be present. Conduct a more
slightly loose with fine reflective cracks through the asphalt on top. detailed assessment to evaluate extent of hidden
Tensioning rods should still have adequate stressing and there should damage.
be no damage to the timber at the stressing plates. Detailed
assessment to check likely remaining life.
4 Poor 11 - 20 Further leaching of the preservative is occurring with the timber looking Major cracking and spalling may be present with
well weathered and rot pockets forming. Bolting of the decks may be corroding reinforcement visible. But loss of section or
loose with medium reflective cracking through the asphalt on top. With rebar less than 10% e.g. deformed ribs on bars still
transverse sheeting, reflective cracking may also be occurring due to visible. Dampness patches and efflorescence heavy
differential movement between the slabs under loading, or due to in places.
inadequate bolting. Tensioning rods may be loosing stress with minor
movement or separation of the laminations beginning to occur.
5 Very Poor 0 - 10 Deterioration of the timber may be well advanced with substantial loss Heavy cracking and spalling present with advanced
of the preservative protection. Weathering and rot of the timber is corrosion of the reinforcement over large areas.
severe with some laminations almost rotted out. Excessive steel section loss greater then 10% and
some bars more heavily corroded. Excessive
moisture penetration and heavy staining around the
cracks or evidence of excessive deflection or
localised structural failure.
Table 25: Wharves/Jetties Timer Deck Criteria
Condition Manual
7.4 Furniture
This component includes bollards, ladders and the like.

operating.
Table 26: Wharves/Jetties Furniture Criteria
7.5 Fenders

operating.
Table 27: Wharves/Jetties Fenders Criteria
7.6 Cathodic Protection


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
Condition Manual
8.0 Structures
8.1 Structural
The Structures asset group includes gantry, gangways and towers. The structural component includes
a 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. Failure
unlikely 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
Condition Manual
9.0 Navigational Structures
9.1 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 Structure

This component includes other structures such as warning signs.

1 Excellent As new.
Slight discolouring of galvanizing - no rust.
No work required.
3 Average Deterioration evident. Loss of galvanizing, rust or rust stains evident. Failure
unlikely 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
Condition Manual
9.3 Piles

1 Excellent As new.
Slight rusting, loss of paint above water.
No work required.
3 Average Deterioration evident. Corrosion above and / or below water Failure
unlikely in the near future but further deterioration likely. Remedial work
required in next 5 years, could include - replacing anode below water or
wrapping pile above water.
4 Poor Failure likely in the next 3 years. Significant loss of steel section through
corrosion 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 visible
evidence of imperfections The structure is well bolted to the support, and firm
and tight. No sign of imperfections in the welds.
3 Average There is rusting and minor corrosion at the joints but all bolts, welds or rivets
are firm and tight.
4 Poor Medium corrosion is occurring at the joints. The holding down bolts may be
slightly 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
Condition Manual
10.0 Telecommunications
10.1 Cables
This component includes conduits.

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
Condition Manual
11.0 Power
11.1 Street Lighting
This 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
operating.
Table 37: Power Street Lighting Criteria
11.2 HV Cabling
This 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
Condition Manual
11.4 Substations
PoMC to Supply
11.5 Switchboards
PoMC to Supply
Condition Manual

Port of Melbourne Condition Manual

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Condition Manual

Data Capture of Physical Assets via Condition

© AECOM Australia Pty Ltd 2011

Stage 1 update, draft for

1.2 Condition Assessment Methodology

PREDICT ASSESS FINANCIAL

FAILURE MODE ASSESS RISKS

Figure 1: Asset Management Process

1.3 Use of Condition Rating

1.4 Description of Key Definitions

Term Description of Key Definitions

1.5 Relationship with Asset Management System

1.6 Asset Hierarchy

Table 2: Asset Hierarchy for Condition Assessment

Asset Class Asset Category Asset Component Material Type Reference

Port Interface Structures

Bracing TBD Stage 2

Cargo Handling Equipment

1.7 Condition Assessment Frequency

Rating Definition Description

Table 3: Buildings Structural Criteria

Rating Definition Description

Table 4: Buildings Services Criteria

Rating Definition Description

Table 5: Buildings Sub-Structure Criteria

Rating Definition Description

Table 6: Buildings Fittings Criteria

Distress Mode Failure Type 1 2 3 4 5

Table 7: Roads Pavement Criteria

Rating Definition Description

Table 8: Roads Furniture Criteria

Rating Definition Description

Table 9: Roads Verges Criteria

Joint Joint Extensive joint

Table 10: Roads Kerb and Channel Criteria

Rating Definition % Effective Life Life Remaining

Table 11: Sewerage Pipes Criteria

Rating Definition Description

Table 12: Sewerage Manholes Criteria

4.3 Pump Station Structure

Rating Definition Description

Table 13: Sewerage Pump Station Structure Criteria

Rating Definition Description

Table 14: Sewerage Pump Station Mechanical and Electrical Criteria

Rating Definition % Effective Life Life Remaining

Table 15: Drainage Pipes Criteria

Rating Definition Description

Table 16: Drainage Pits Criteria

5.3 Traps Structural

Rating Definition Description

Table 17: Drainage Traps Structural Criteria

Rating Definition Description

Table 18: Drainage Traps Mechanical and Electrical Criteria

Rating Definition Description

Table 19: Water pipes Criteria

6.2 Water-main Fittings

Rating Definition Description

Table 20: Water-main Fittings Criteria

Condition Rating % Area Affected

Table 21: Sample Condition Assessment for a Deck

Table 22: Works Required mapped against Condition by Affected Area

This process will apply for the following asset components:

Table 23: Wharves/Jetties Steel Pile Criteria

Rating Definition Timber Concrete