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Resurfacing of Federal Ocean Terminal Jetty Berths 1, 2, and 3
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Onne, Rivers State, Nigeria

Submitted by Prestige Concrete Products

Federal Ocean Terminal Berths

Nigerian Ports Authority
Onne, Rivers State, Nigeria

Repair Contractor
Prodeco International Limited
Onne, Rivers State, Nigeria

Material Supplier/

X-Calibur International FZC
Sharjah, UAE

Material Supplier/

Tarmac America, LLC
North Palm Beach, FL 

The Federal Ocean Terminal (FOT) Berths 1, 2, and 3 were constructed in 2001. The berths function as an oil and gas field service jetty for supply and service vessels for the oil and gas platforms in the Niger delta. The 24-hours-a-day, 7-days-a-week unimpeded operation of this jetty is key to the oil and gas industry in Nigeria. 

By 2010, the 2260 ft (690 m) long reinforced concrete jetty was showing early signs of abrasion and corrosion-induced damage on the main slab. A comprehensive condition survey revealed that the structure was in overall good condition with the exception of the jetty deck. The top side of the deck had started to deteriorate from abrasion and corrosion of the top steel due to lack of sufficient cover.

It was decided to remove the upper 2-3/8 in. (60 mm) of the deck and resurface with a high-performance overlay concrete. To minimize cost and provide a repair service life of 20 years, it was decided to design and produce a ready mixed repair concrete with properties similar to a proprietary repair mortar with regard to strength, permeability, and drying shrinkage.

The repair work had to be completed while keeping the jetty fully operational and could not affect port operations. One-hundred sixty-seven (167) 16 x 98 ft (5 x 30 m) panels, for a total area of 270,000 square feet (25,050 square meters), were replaced and recast over a period of 8 months, completed in November 2012. An innovative approach to curing and protecting was implemented using a sand bed over the concrete that enabled port operations to continue with minimal disruption. A lithium silicate hardener was applied to increase abrasion resistance and reduce permeability. 

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