Considerations for the Design of Fully Automated Container Yards Based on a Case Study

Abstract: Container terminal automation has increasingly become more popular in the last decades around the world and is steadily making its way to the US market with the goal of improving productivity and efficiency. The level of automation is generally classified as semi-automated and fully automated terminals. Fully automated terminals are such that the container transfers between the wharf and the yard are all automated. There are currently a limited number of automated terminals currently operating in the US, with that number expected to increase in the coming years. The design of this kind of terminals is highly specialized where Designers need to be aware of key considerations.

The design of a fully automated container yard requires a careful multi-disciplinary evaluation of civil, structural, geotechnical, paving, drainage, electrical, communication, and instrumentation matters. A thorough understanding of automated operations and the associated permitting requirements are crucial. All matters are interconnected and require close coordination.

Automated yards have particular conditions that differ from non-automated yards. The yard geometry, location relative to the waterfront, and its stacking configuration as well as the container stacking equipment characteristics vary from place to place. Typically, a combination of automated stacking cranes (ASCs) and straddle carriers are employed. The layout of automated yards is unique and, unlike non-automated terminals, have limited areas where trucks will transit, depending on the density of stacking operations and the ASC characteristics. For fully automated yards, the trend is the implementation of linear operations involving a landside bay area for incoming truck traffic, a series of container stacks, and a waterside bay for unmanned straddle carriers to take the containers to the STS cranes located on the waterfront or bring containers back to the stacking areas. Electrical, communication, and instrumentation design are essential components for proper automation and takes precedence over other items.

This paper utilizes a case study of a fully automated container yard recently designed in a region of very high seismicity with a significant throughput for one of the busiest ports in the West Coast of the United States. The case study presents key lessons learned and how the Designer approached the yard design considering all relevant disciplines. Specifically, the paper describes the critical issues faced during the design process, such as estimating an appropriate number of traffic counts for selection of automated equipment, determination of the container terminal layout considering the anticipated yard operations, optimizing the ASC crane rail gauge to maximize stacking space, seismic and structural design of ASC runways and truck traffic pavement, the incorporation of electrical/instrumentation requirements into the design, and the coordination with local authorities for permitting, which sometimes are not applicable to automated terminals. The case study also presents a description of construction-related issues encountered at the time this paper was prepared. The paper has the end goal of providing a baseline to Owners, Operators, Planners, and Designers for future automated yards and terminals in the US and abroad, as their development is expected to increase in the following years.

How does this project / topic contribute to the advancement of the industry and profession?: This topic contributes to the advancement of the profession and the industry by illustrating how key challenges were resolved during the design phase and by providing a real-life example of a successful automated container terminal design that other marine/port designers and end users may benefit from.

Does the project / topic implement new and innovative techniques, materials, technologies, and delivery methods?: The paper presents an innovative design approach of a fully automated container terminal, which are limited in the US and abroad. It considers challenging conditions not encountered in all ports, such as high throughput and high seismicity.

What was the most challenging aspect of your project / topic and how did you handle it to ensure success?: The most challenging aspect was to design for the anticipated operations considering the site constraints and current design guidelines not covering the design of automated terminals. This was overcome by comparing the available design guidelines in detail and refining them for the specific project application and objectives.

Who is the target audience for this paper?: The target audience for this paper are marine terminal Owners, Operators, Planners, and Designers, who will benefit to learn about a successful case study of an automated terminal in the US.