IKGAtl Kenneth Grubb Associates Ltd

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1 IKGAtl Kenneth Grubb Assoiates Ltd BURO HAPPOLD COPPERHOUSE SLUICE GATE DOCUMENT REVISION RECORD Doument Number: Number of Pages: Doument Title: Saved as: C0395/006/DOC 31 REPORT ON THE MECHANICAL SURVEY OF THE COPPERHOUSE SLUICE VERTICAL LIFT GATE K:\Contrats Working\ \C0395B Copper House Sluie\Douments\C0395B_006_DOC Rev A 1.do REV DATE A AUTHOR CHECKED APPROVED C Appleton R Digby K Grubb Refer to the Revision Sheet at the rear of this doument for details of modifiations. Do Ref C0395_006_do Rev A 1 Mehanial Survey of the Vertial

2 :fl!kgali Kenneth Grubb Assoiates Ltd CONTENTS 1. INTRODUCTION SURVEY FINDINGS Review of doumentation SURVEY OF THE GATE STRUCTURE, CIVIL INTERFACES AND LIFTING GEAR Gate Struture Civil Work Interfaes Gate Sealing System Lateral Gate Guiding System Gate Lifting Gear Eletrial Equipment ISSUES AND CONSTRAINTS RECOMMENDATIONS Gate Struture Civil Works Interfaes Gate Sealing System Lateral Gate Guiding System Gate Lifting Gear Eletrial Equipment CONCLUSIONS Do Ref C0395_006_do Rev A 2 Mehanial Survey of the Vertial 1J '0 d G ".l},cj 0: CJ: ; a: le G': II:

3 IKGALI Kenneth Grubb Assoiates Ltd 1. INTRODUCTION At the request of Sura Happold (BH) (the onsultants retained diretly by the Hayle Harbour site developer, lng), Kenneth Grubb Assoiates Ltd (KGAL) has undertaken a mehanial survey of the sited at on Copperhouse Pool and operated by the Environment Ageny Operations Delivery Staff. The survey was of a non-intrusive nature and undertaken during tidal onditions. There is some residual risk that problems relating to the gate were not unovered. Members of the Environment Ageny (EA) staff were on hand to assist the surveyors with information regarding the history of the installation and the site in general. They were also able to provide information with regard to the operation and maintenane of the gates. In addition, Dave Turner of the EA was ontated and provided useful bakground information. The purpose of the survey was to determine the ondition and servieability of the existing gate and drive mehanisms, take measurements of the installation, establish the need for any refurbishment work and ensure that no other problems exist. Also, to onsider the possibility of the gate being apable of being used in a sluiing/souring apaity. As the gate is owned and operated by the Environment Ageny, no attention was given to operational, management or Health and Safety issues, though problems in this regard are obvious on the site. The survey was undertaken between 4th and 6th September Personnel involved: Chris Rose Ken Grubb Chris Appleton (BH) (KGAL) (KGAL) Part- time The purpose of the vertial gate is, primarily, to at as a flood defene mehanism to prevent flooding of the area from tidal water. The seondary purpose of the gate is to regulate the saltwater inundation within the Copperhouse Pool. Note that historially the gate was used as a means of souring sand from the harbour hannels. Sine that time the gate design has been hanged by the EA. There may be some advantage to the potential Hayle harbour development if this funtionality ould be restored. The gate was originally manufatured and installed in 1981 as the diret replaement for a pair of mitre gates. It was originally designed to work as a roller gate. The roller axles are still fitted to the ends of the gate. Do Ref C0395_006_do Rev A 3 Mehanial Survey of the Vertial

4 ' Q IKGALI Kenneth Grubb Assoiates Ltd However, at some time following original installation, the rollers were removed and the gate was modified to run on non-metalli wearing strips mounted on the opposing inner faes of the existing ivil guide setion. Mr. Dave Turner of the Environment Ageny stated that the reason that the gate was onverted to a sliding gate was the high ost of maintenane attributed to the roller bearings whih had ontinually seized. The gate is generally maintained in a position with the lowest edge of the gate approximately 600mm above the ivil sill. No speial problems assoiated with the operation of the equipment had been reported to KGAL prior to the inspetion. Disussions with the EA site staff indiated that the very nature of the gate operation (i.e. either tidal flood defene or undershot gate to relieve upstream flooding) had meant that the gate was very rarely operated. 2. SURVEY FINDINGS 2.1 Review of doumentation There were no drawings of the installation made available to the surveyors. It is understood that drawings are available from the EA. t I f (i; II: e 1:: I Do Ref C0395_006_do Rev A 4 Mehanial Survey of the Vertial & e: e

NB: For the purpose of this survey, downstream will be defined as the water in the foreground as shown in Photograph 1 below (i.e. that level open to the sea) and upstream will be defined as water on the other side of the gate as shown in Photograph 1 below (i.

5 IKGALI Kenneth Grubb Assoiates Ltd 3. SURVEY OF THE GATE STRUCTURE, CIVIL INTERFACES AND LIFTING GEAR 3.1 Gate Struture The survey foused initially on the gate struture. NB: For the purpose of this survey, downstream will be defined as the water in the foreground as shown in Photograph 1 below (i.e. that level open to the sea) and upstream will be defined as water on the other side of the gate as shown in Photograph 1 below (i.e. the impounded Copperhouse Pool). Photograph 1 General view of the gate, lifting frame superstruture, aess footbridge, plant room and ontrol ubile of the vertial lift gate at Do Ref C0395_006_do Rev A 5 Mehanial Survey of the Vertial

!KGALI Kenneth Grubb Assoiates Ltd The gate is a steel fabriation onsisting of a retangular skinplate stiffened on the

ft Photograph 2 General view of the front or downstream fae of the gate showing the retangular skinplate : : e: The upper

dition with no evidene of degradation of the painting system.

6 !KGALI Kenneth Grubb Assoiates Ltd The gate is a steel fabriation onsisting of a retangular skinplate stiffened on the rear fae by a series of steel astellated beam setions and small vertial web plates. ft Photograph 2 General view of the front or downstream fae of the gate showing the retangular skinplate : : e: The upper setion of the skinplate above the tidal marks appears to be in very good on.dition with no evidene of degradation of the painting system. The lower setion of the skinplate below the tidal marks has large areas where the paint has been removed and widespread surfae orrosion of the exposed substrate is evident (see photograph 3). Do Ref C0395_006_do Rev A 6 Mehanial Survey of the Vertial e e: e e: t= 1:

IKGALI Kenneth Grubb Assoiates Ltd Photograph 3 General view of the bottom right hand orner of the

measurements were taken and established that "pitting" or indentations up to 2mm deep were ommon.

for the front or downstream fae of the gate in that the areas above the nominal tidal marks were

7 IKGALI Kenneth Grubb Assoiates Ltd Photograph 3 General view of the bottom right hand orner of the front or downstream fae of the gate showing the widespread orrosion on the skinplate Loalised measurements were taken and established that "pitting" or indentations up to 2mm deep were ommon. The rear or upstream fae of the gate appeared to be in a very similar ondition to that desribed for the front or downstream fae of the gate in that the areas above the nominal tidal marks were generally in better ondition than those below. Do Ref C0395_006_do Rev A 7 Mehanial Survey of the Vertial

IKGALI Kenneth Grubb Assoiates Ltd -f f ' ( e f;: f; g e:

horizontal astellated beams had aumulated a wide range of

8 IKGALI Kenneth Grubb Assoiates Ltd -f f ' ( e f;: f; g e: Photograph 4. General view of the rear or upstream fae of the gate showing the astellated beam and vertial web plate stiffeners The horizontal astellated beams had aumulated a wide range of debris varying ar from seaweed to timber flotsam. Do Ref C0395 _ 006 _do Rev A 8 Mehanial Survey of the

the gate showing the aumulation of debris on

9 ' " IKGAL,I K_e_nn_e_t_h_G_,.,_u_bb_A_s_so ia_t_es_l-td ; o_p_p_e_rh_o_u_s_e_s_lu_i_e_ Photograph 5 General view of the rear or upstream fae of the gate showing the aumulation of debris on the astellated beams Do Ref C0395_006_do Rev A 9 Mehanial Survey of the Vertial

IKGALI Kenneth Grubb Assoiates Ltd There was some very limited surfae "weepage" of orrosion produts around the ( astellated beams where the paint system had been damaged.

a knife-edge and would be unsuitable to at as a sluiing struture without modifiation. This is beause the urrent design of both the struture and sealing system would be prone to vibration.

10 IKGALI Kenneth Grubb Assoiates Ltd There was some very limited surfae "weepage" of orrosion produts around the ( astellated beams where the paint system had been damaged. ( Photograph 6 Loal view of the rear or upstream fae of the gate showing the loalised limited orrosion present on the astellated beams The bottom edge of the gate fabriation has not been designed as a knife-edge and would be unsuitable to at as a sluiing struture without modifiation. This is beause the urrent design of both the struture and sealing system would be prone to vibration. The gate struture has plates losing off the open gate setions at eah end. This original arbon steel end plate has additionally been lad at some time postommissioning with a bolted stainless steel plate over almost its entire length. The roller wheels originally fitted to the gate had also been removed. The roller gate has effetively been onverted to a sliding gate by this modifiation.. However the axles to mount the wheels onto the gate had all been left in plae. Do RefC0395_006_do Rev A 10 Mehanial Survey of the Vertial ( (:.: (; g g @; @:

itself has irular holes ut out of it to permit the original roller axles to protrude through.

11 IKGALI Kenneth Grubb Assoiates Ltd Photograph 7 View of the end setion of the gate showing additional "all over" plate with loal ut-outs for original roller axles and two folded guide angles ating as front and rear load bearers The stainless steel plate itself has irular holes ut out of it to permit the original roller axles to protrude through. The lowest setion of original end plate that remained unovered by the stainless steel plate had orroded badly. Do Ref C0395_006_do Rev A 11 Mehanial Survey of the Vertial

folded and bolted stainless steel "angles". The purpose of these angles is to at as load bearing guides in the absene of the original roller wheels.

12 /KGALI Kenneth Grubb Assoiates Ltd Copperhol.ise Sluie. Photograph 8 View of the end setion of the gate showing extent of additional "all over" stainless steel plate On top of the stainless steel plate at the extreme upstream and downstream edges are two folded and bolted stainless steel "angles". The purpose of these angles is to at as load bearing guides in the absene of the original roller wheels. However, the design of the modifiation does not lend itself to load transferene beause of the use of slotted holes and tapered washers. The strength of the bolted detail is a onern and may not be fit for purpose. The angles bear upon non-metalli bearing strips bolted into the upstream and downstream internal faes of the ivil work guide. A diffiulty with this detail is that a flat sliding fae is srewed to a rowned rail fae with a flexible sealant taking up the neutral voids. It is believed that this ontributes to the damage found at lower setions (see ivil work interfaes). Do Ref C0395_006_do Rev A 12 Mehanial Survey of the Vertial

2 Civil Work Interfaes The non-metalli bearing strips run the full height of the ivil guide slot on both the

13 IKGALI Kenneth Grubb Assoiates Ltd Photograph 9 View of the end setion of the gate showing folded stainless steel angles and upstream and downstream bolt-on bearing I sealing faes 3.2 Civil Work Interfaes The non-metalli bearing strips run the full height of the ivil guide slot on both the upstream and downstream faes. The upper setions of the bearing strips appear to be intat and in reasonable ondition. Do Ref C0395_006_doRev A 13 Mehanial Survey of the Vertial

. sealing faes However the lower setions of both the upstream and downstream sealing faes

14 ' e: (:.:!KGALI Kenneth Grubb Assoiates Ltd t, t ( ( (: t; Photograph 1 0 General view of the upstream and downstream bolt-on bearing I.. sealing faes However the lower setions of both the upstream and downstream sealing faes are badly damaged and in some ases, missing ompletely. (: f:: (: : f; (: (; = Do Ref C0395_006_do Rev A 14 Mehanial Survey of the Vertial

setion of the downstream bolt-on bearing I sealing

15 .. '!KGALI Kenneth Grubb Assoiates Ltd Photograph 11 Loalised view of the damage apparent on the lower setion of the downstream bolt-on bearing I sealing faes Do Ref C0395_006_do Rev A 15 Mehanial Survey of the Vertial

The very lowest setions of the ivil work guide are the worst affeted, with evidene of extreme souring, loss of material and build up of marine life.

16 The very lowest setions of the ivil work guide are the worst affeted, with evidene of extreme souring, loss of material and build up of marine life. t t f ' ( ' (: (: Photograph 12 Loalised view of the erosion damage and build up of marine life on the lowest setion of the ivil work guide slot At the sill, there is a ast in sill beam that ats as the sealing surfae for the seal along the bottom edge of the gate. The surfae of the beam suggests that it is made from stainless steel, although this is unertain, and it appears to be in reasonable ondition. There is loal damage to the harbour walls in the viinity of the gate. No attempt has been made to evaluate this or assess the impat of potential sluiing operations. This should be onsidered by a qualified ivil engineer. Do Ref C0395_006_do Rev A 16 Mehanial Survey of the Vertial {:.: e:.= (: = : : ;

17 /KGAJJ/ Kenneth Grubb Assoiates Ltd Photograph 12 General view of the ast in sill beam Do Ref C0395_006_do Rev A 17 Mehanial Survey of the Vertial

w Kenneth Grubb Assoiates Ltd --------------------------------------------------- 3.3 Gate Sealing System The gate sealing system is intended to seal in both diretions.

the ast-in sill beam and up the opposite side of the gate. The L or "Hokey Stik" seal is an ative seal in that it is "ativated" by hydrostati pressure impinging on the leg of the seal.

Photograph 13 View of the end setion of the gate showing the bak to bak L shaped or "Hokey Stik" seals and metalli lamp strip The only problem with this is that higher up on the gate (i.e. near to the free surfae of the water when the gate is lowered), there is almost no hydrostati loading on the seal.

18 w Kenneth Grubb Assoiates Ltd Gate Sealing System The gate sealing system is intended to seal in both diretions. The system onsists of two L shaped or "Hokey Stik" seals bak to bak that at full length down one end of the gate (against a plate mou11ted on the downstream lip of the ivil work guide) aross the ast-in sill beam and up the opposite side of the gate. The L or "Hokey Stik" seal is an ative seal in that it is "ativated" by hydrostati pressure impinging on the leg of the seal. The higher the load, the more the seal is pressed into the mating surfae and in theory, the more effetive the sealing. However, there are gaps between the side seals and their sealing faes. Photograph 13 View of the end setion of the gate showing the bak to bak L shaped or "Hokey Stik" seals and metalli lamp strip The only problem with this is that higher up on the gate (i.e. near to the free surfae of the water when the gate is lowered), there is almost no hydrostati loading on the seal. In these positions, the seal will probably leak slightly. Do Ref C do Rev A 18 Mehanial Survey of the Vertial

Photograph 14 View of the bottom orner setion of the gate showing the interfae between the side and bottom bak to bak L shaped.

19 JKGAI,:_!J --K-en_n_e G_r_ub_b_A ss_o m_re_s Lt_d o_p_p_e_rh_o_u_s_e_s_lu_i_e_ Looking at the lowest orners of the gate, the bak to bak seal turns through goo and travels along the bottom edge of the gate. Photograph 14 View of the bottom orner setion of the gate showing the interfae between the side and bottom bak to bak L shaped. or "Hokey Stik" seals and metalli lamp strips The orner setions between the side and bottom seals have large gaps visible. This means that the seal is not effetive in this position and given the head ating at this point, that water will tend to jet through the gap and impat on the ivil works behind. Over the ourse of time, this ould lead to erosion of the ivil works. 3.4 Lateral Gate Guiding System _ The gate struture is guided laterally by two pairs of guide rollers on eah end of the gate. The rollers at against a plate mounted on the upstream lip of the ivil work guide. Do Ref C0395_006_do Rev A 19 Mehanial Survey of the Vertial

IKGALI Kenneth Grubb Assoiates Ltd Photograph 15 View of the end setion of the gate showing one pair of lateral guide rollers and the lateral guide plate that they at against The rollers are thought

5 Gate Lifting Gear The gate struture is lifted and lowered using a motor-driven, steel-wire, rope-winh system.

20 IKGALI Kenneth Grubb Assoiates Ltd Photograph 15 View of the end setion of the gate showing one pair of lateral guide rollers and the lateral guide plate that they at against The rollers are thought to be manufatured by Brauer. They are approximately 200mm diameter and 50mm tread width. 3.5 Gate Lifting Gear The gate struture is lifted and lowered using a motor-driven, steel-wire, rope-winh system. The motor drives a grooved drum on whih a stainless steel wire rope (of approx of an inh diameter) is wound. The steel wire rope passes over a series of sheaves and pulleys at both ends of the gate and is terminated at a fixed point on the gate support superstruture at the motor drive end. Thus as the drum turns, the steel wire rope is either paid out or wound onto the drum depending on the diretion of drum rotation. This in tum therefore ats to either lower or raise the gate. Do Ref C0395_006_do Rev A 20 Mehanial Survey of the Vertial e : -: : = = : : : :.-: a: : : a:

IKGALI Kenneth Grubb Assoiates Ltd The pulley I sheave onfiguration basially means that the gate is raised or lowered at 25% of the amount of steel

Photograph 16 View of the gate atuation mehanism onsisting of an eletri drive motor, drum, steel wire rope and Slak Rope mehanism I swith The steel

This devie is fitted to prevent the steel wire rope beoming loose on the drum in the event that the gate was being lowered, beame jammed in its

21 IKGALI Kenneth Grubb Assoiates Ltd The pulley I sheave onfiguration basially means that the gate is raised or lowered at 25% of the amount of steel wire rope paid out from the drum. Photograph 16 View of the gate atuation mehanism onsisting of an eletri drive motor, drum, steel wire rope and Slak Rope mehanism I swith The steel wire rope leaving the drum is fitted with a Slak Rope mehanism onsisting of a guide pulley and lever frame together with a swith. This devie is fitted to prevent the steel wire rope beoming loose on the drum in the event that the gate was being lowered, beame jammed in its guides and ould not be physially lowered further. The steel wire rope exits through a slot in the roof of the protetive enlosure. The slot is proteted by a moveable guard whih moves as the steel-wire rope pays out from the drum. Do Ref C0395_006_do Rev A 21 Mehanial Survey of the Vertial

lkgali Kenneth Grubb Assoiates Ltd Photograph 17 View of the two pulley wheels on one side of the gate Copperhouse Sluie Photograph 17 shows the steel wire rope passing under one

the gate. The motor and gearbox appeared to be in satisfatory ondition and the operator did not report any problems with the operation or availability of the drive mehanism.

There does not appear to be any mehanism for preventing the wire ropes from beoming detahed from the gate pulleys in a slak-rope situation.

22 lkgali Kenneth Grubb Assoiates Ltd Photograph 17 View of the two pulley wheels on one side of the gate Copperhouse Sluie Photograph 17 shows the steel wire rope passing under one pulley, up and over the pulley at the top of the gate support superstruture (not shown), bak down under the other pulley and aross to the orresponding pulley on the opposite side of the gate. The motor and gearbox appeared to be in satisfatory ondition and the operator did not report any problems with the operation or availability of the drive mehanism. The steel wire rope appears to be servieable and generally in good ondition. The pulleys and sheaves have been greased and were all found to rotate without slippage or stiking. There does not appear to be any mehanism for preventing the wire ropes from beoming detahed from the gate pulleys in a slak-rope situation. There is not an obvious method for renewing the wire rope without exposing persons to Health and Safety hazards of working at height. Do Ref C0395_006_do Rev A 22 Mehanial Survey of the Vertial t e.(; e e: g : It e: e: e: e:

w Kenneth Grubb Assoiates Ltd ----------------------------------,---------------------- 3.

Aess to the ontrol panel was not available and no reasonable opinion ould be made as to its ondition.

equipment is housed within the eletrial enlosure. The interior of the housing appeared to be dry and lean, with no obvious signs of moisture ingress.

23 w Kenneth Grubb Assoiates Ltd , Eletrial Equipment The majority of the eletrial equipment is housed in a.ontrol panel in an adjaent plant room. Aess to the ontrol panel was not available and no reasonable opinion ould be made as to its ondition. Photograph 18 General view within the motorised winh housing showing the eletrial inoming supply and distribution enlosures Additional eletrial equipment is housed within the eletrial enlosure. The interior of the housing appeared to be dry and lean, with no obvious signs of moisture ingress. Eletrial enlosures are mounted diretly on the internal wall of the housing. They were found to be lean and appeared in good order. The enlosures themselves were not opened, so no opinion an be offered regarding the internal ondition of the equipment Do Ref C0395_006_do Rev A 23 Mehanial Survey of the Vertial

IKGALI Kenneth Grubb Assoiates Ltd ' The housing was fitted with an Emergeny Stop swith to isolate the inoming power ( supply from the rest of the equipment.

Photograph 1 9 General view within the motorised winh housing showing the interloking door power isolation swith The gate has a movement limit swith fitted to the front of the gate.

24 IKGALI Kenneth Grubb Assoiates Ltd ' The housing was fitted with an Emergeny Stop swith to isolate the inoming power ( supply from the rest of the equipment. ' The housing was fitted with an interloking isolation swith mounted on the door aperture. This ats to isolate power to the equipment within the housing when the door is opened. Photograph 1 9 General view within the motorised winh housing showing the interloking door power isolation swith The gate has a movement limit swith fitted to the front of the gate. Photograph 20 General view of the gate movement limit swith This swith is operated by a striker plate also mounted on the front fae of the gate. Do Ref C0395_006_dei Rev A 24 Mehanial Survey of the Vertial., - ( t (: tt : tt : : ft e: e: fc 11:,-;_

ISSUES AND CONSTRAINTS There were no issues raised by the EA staff whilst on site with regard to the operation of the gate.

25 /KGALI Kenneth Grubb Assoiates Ltd The position of many of the limit swithes make them diffiult to maintain safely.. I Photograph 21 General view showing the limit swith striker plate with the gate in fully raised position. 4. ISSUES AND CONSTRAINTS There were no issues raised by the EA staff whilst on site with regard to the operation of the gate. It is understood that the EA has some reservations of the use of the gate as a sluie from a number of viewpoints, inluding: 1. The gate is not urrently suitable for sluiing 2. Using the gate as a sluie might ause damage to the adjaent ivil works, whih are listed strutures 3. There may be Health and Safety impliations for the publi Item 1 has been borne out by the survey, but ould be made aeptable by modifiation. Do Ref C0395_006_do Rev A 25 Mehanial Survey of the Vertial

The effet of previously onverting the gate to sliding operation will be to inrease the loads in the winhing system. It is unknown if this was taken into aount.

26 .t w Kenneth Grubb Assoiates Ltd Item 2 is a ivil issue and is left to others. Item 3 ould be addressed by management and ontrol modifiations. As it was not possible to obtain opies of the original gate installation drawings prior to the survey, the safety margin for the gate struture against the loads urrently seen is indeterminate. The effet of previously onverting the gate to sliding operation will be to inrease the loads in the winhing system. It is unknown if this was taken into aount. It is aknowledged that in general the gate is only operated under balaned head onditions. Aess to the original drawings would permit alulations to take plae to substantiate the design load ase for the original struture. If no suh drawings are available, it would still be possible to determine the approximate apaity of the existing gate by alulation based on the dimensions reorded during this survey. This work ould be arried out, by agreement, if required. Aspets of the previous gate modifiation to sliding operation are doubtful, however the risks assoiated with this appear to belong to the EA and surrounding properties whih may be at inreased flood risk. It is not lear whether stop logs or other means of establishing dry working onditions around the gate are urrently available. It is thought that there is no suh existing provision. The elapsed time.to remove and modify the gate would take it through at least one monthly tidal-yle, this would expose Copperhouse Pool to some flood risk and would have to be arefully timed and oordinated. The EA may require temporary works to be put in plae during this time. No ost allowane has been inluded in urrent estimates for suh temporary works as they are unknown. Should removal of the gate be required as part of any neessary remedial works, very areful planning will be needed as there are various site onstraints suh as the limited hard standing available within the existing EA site ompound and also the lose proximity of overhead ables. These issues would need to be addressed prior to any plan being made. The gate is too large to be easily removed to another plae for modifiation. It may be possible to plae it diretly onto a barge for removal via the harbour. Alternatively there is suffiient spae in the adjaent ar park to make modifiations diretly. All of the work envisaged to enable the gate to be apable of performing as a sluie ould be undertaken under these onditions. Note that a tented, saffold struture would be required, to ontain painting ontaminants. Do Ref C0395_006_do Rev A 26 Mehanial Survey of the Vertial - t t t G e : g g : : : : = : e: tt : I=

27 IKG.L/ Kenneth Grubb Assoiates Ltd ; 5. RECOMMENDATIONS 5.1 Gate Struture The existing gate struture itself appears to be in reasonable ondition. In order to ontinue to work effetively, some remedial work should be undertaken to urtail the spread of orrosion on the gate struture. This would involve grit - blasting the gate in the areas affeted by orrosion (namely below the tidal line) and re-oating the gate in aordane with the paint manufaturers instrutions. It may be possible to arry out painting works "in-situ", but it would be preferable to lift the gate out of its slot, lay it down somewhere lose at hand and repair as required. By removing the gate and onduting the repairs off site it will aid the prevention of environmental pollution reated by blasting and painting the gate. The gate is not suitable for sluiing in its urrent form and strutural modifiations would be required along the bottom edge. Suh modifiations would require gate removal. 5.2 Civil Works Interlaes The ivil works interfaes generally appear to be in reasonable ondition. The exeption is the two side gate guide slots. In this area, there is signifiant Joss of non-metalli gate bearing strips from both upstream and downstream faes of the side guides on both sides of the gate. This is probably due to the high frition fores developed when trying to move the gate when subjet to hydrostati loading. And, the poor mounting detail. The onventional design for hydrostatially loaded vertial lift gates utilises rollers to allow the gate to move whilst under load without the detrimental effets of high rubbing frition. This obviously results in lower lifting fores, whih will assist in keeping the operating loads applied to the lifting gear to a minimum. This in turn means that the equipment will probably operate reliably for longer as it is not overstressed. It is not lear why the original design aused the rollers to seize, but for long term reliable operation of this gate the reommendation would be to return to the roller system. In the light of the previous problems the axle, bearing and roller design should be onsidered in more detail prior to reinstatement. Do Ref C0395_006_do Rev A 27 Mehanial Survey of the Vertial

28 !KG.L/ Kenneth Grubb Assoiates Ltd In addition to the above, the bottom setion of eah of the side gate guide slots is suffering from exessive erosion of the onrete and also loss of setion of the ast in steel guide. This would need to be repaired in any event. Should the deision be taken to return to a roller design, it would be desirable to hek the ondition of the existing trak faes within the side gate guide slots and make additional repairs (over and above those identified in the previous paragraph) if neessary to ensure a" smooth and ontinuous running fae for the rollers. The real argument for returning to a roller design would be if the future use of the gate involved signifiant amounts of time ating as a sluie gate where the gate was moved regularly against a head differential. The area of ivil works immediately upstream of the ill ould not be safely aessed. Whilst no obvious ivil issue ould be seen there is some element of unknown here. 5.3 Gate Sealing System The gate sealing system appears to be intat with little damage evident. There is, however, a gap within the seals at both bottom orners of the gate (probably exatly as originally installed) whih is obviously a onern as these points are oinident with water at the maximum head. Water spurting through these gaps will therefore travel at relatively high loal veloities and will ause further damage to the built in parts and onrete surround over a period of time. For these reasons, it is reommended that this gap be filled or repaired as required to effet a ontinuous seal. Vulanised orner seals are desirable. The bottom seal detail requires modifiation if the gate is to at as a sluie. 5.4 Lateral Gate Guiding System The lateral gate guide system appears to be working satisfatorily with no operational problems reported by the EA. The rollers and mounting brakets were found to be in very good ondition and do not require any remedial ation. 5.5 Gate Lifting Gear The gate lifting gear appears to be working satisfatorily with no operational problems reported by the EA. The steel wire ropes appeared to have been hanged reently and were in good order. Do Ref C0395_006_do Rev A 28 Mehanial Survey of the Vertial

29 IKGAL/ Kenneth Grubb Assoiates Ltd The motor and gearbox should, as a m1nrmum, be inspeted and subsequently overhauled to ensure that they remain in good working order. Should the equipment be found to be damaged, or irreparable, then replaement units will be required. Wire rope drum bearings should be inspeted and overhauled or replaed as required. 5.6 Eletrial Equipment The eletrial equipment within the motor winh housing appears to be working satisfatorily with no operational problems reported by the EA. A visual external examination of the eletrial equipment revealed no obvious problems and all equipment appeared to be in good order. However, in order to omply with urrent standards, it is strongly reommended that the eletrial installation should be subjeted to a Periodi Inspetion Report (PIR) under the auspies of BS 7671 to ensure the safety of the equipment installed. NB: No information has been made avahable to the surveyors to suggest that a urrent PIR has been issued for this site. This inspetion should be onduted by a ompetent NICEIC registered eletrial inspetor, who will issue a PIR (that remains valid for three years) to the Environment Ageny. The PIR generally assesses whether the installation is satisfatory or not by omparison to the requirements of BS It also reommends work that needs to be arried out to omply with the standard if the installation is deemed to be unsatisfatory Health and Safety Items of a Health and Safety nature were outside the remit of the survey. However, it was noted that a number of issues are present at the site. These are obvious non omplianes with handrail and aess spae requirements. There are also diffiulties in maintaining muh of the equipment by virtue of diffiult aess. 6. CONCLUSIONS The mehanial and eletrial equipment installed at the vertial lifting gate is reported to be operating effetively and reliably by the loal Environment Ageny operations delivery staff. However, it should be remembered that muh of this equipment has not been hanged sine the original installation approximately 25 years ago. Most gate installations would be expeted to have refurbishment intervals of around 25 years, hene it ould be onsidered that refurbishment at this point was timely. Do Ref C0395_006_do Rev A 29 Mehanial Survey of the Vertial

30 IKGALI Kenneth Grubb Assoiates Ltd On this basis alone, it would be wise to plan for the systemati refurbishment of wearing parts within the equipment to ensure long-term reliable future operation. It is reommended that opies of the any existing reord drawings should be soured prior to any refurbishment work on site. Review of manufaturing data always assists in obtaining a better understanding of the aims of the original design. The orrosion protetion system for many parts of the equipment is now in need of refurbishment. In terms of speifi onlusio'ns made for the equipment surveyed, the following notes are listed as appliable: The gate struture itself will require remedial ation to refurbish the existing orrosion protetion system. The use of sarifiial anodes on the gate to help prevent future degradation should be onsidered. The bottom setion of eah of the two side gate guide slots is in urgent need of repair. This will involve repair to the metalli setion of the ast in guides and the loal onrete as required. The use of sarifiial anodes on the metalli setions of the guide to prevent future degradation should be onsidered. The gap in the bottom omers of the seals should be filled or repaired as required to affet a ontinuous seal. Consideration should be given to the future possible usage of the gate. If the gate operation were to hange to inlude sluiing, then there is a strong ase for the re-instatement of the original roller design as this is the onventional design for a vertial lift sluie gate. It will be possible to ahieve this with an improved design that is not prone to seizure. All elements of the eletrial system assoiated with the operation of the gate should be overed separately by a dediated Periodi Inspetion Report for an Eletrial Installation issued in aordane with BS Requirements for Eletrial Installations by an approved ontrator or onforming body enrolled with the National Inspetion Counil for Eletrial Installation Contrating NICEIC). The bottom setion of the gate will require reonstrution to enable sluiing/souring. Do Ref C0395_006_do Rev A 30 Mehanial Survey of the Vertial I..: e

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