Abstract: The Port of Houston Authority(PHA) has seen significant growth in container volumes. To accommodate the increase in demand at Barbours Cut Terminal (BCT), the PHA undertook rehabilitating 87 acres(AC) of container yard (CY), which includes CY 6 and 7 and the north portions of CY 4 and 5. The terminal is active and operating at high density mode with an estimated throughput of 2 million Twenty-foot Equivalent Unit (TEU) per year. Operational requirements dictated that no more than 10AC be taken out of operation at any given time, potentially lengthening project construction duration. The project was supported by a MARAD grant and were constrained by grant timelines. Maintaining terminals existing refrigerated container capacity and keeping all Shore to Ship(STS) Cranes active throughout construction, were key operational requirements. An innovative approach of maintaining reefer capacity while minimizing the infrastructure investment and mitigating delays due to procurement of long lead items was arrived at. To increase safety, reliability and redundancy of the electrical system a redundant feed was added. To minimize operational downtime and change critical path, a pre-outage packaging and advanced procurement approach was used for certain elements. CY 4 & 5 N was the first package. It was initially split into two phases, As the design progressed it was discovered that the electrical feed for adjacent high mast light poles to the south, ran through CY 4 N. The design called for this ductbank to be removed. To accommodate this situation, a small connector phase was added. This early phase would require shutting down the north-south aisle between CY 4 & 5 N which would cut off circulation to the adjacent wharf. To mitigate this negative impact this early phase was split in two subphases. In addition, the construction work was planned to be performed during the nights and weekend, when PHA operations were minimal, was required. The second package was CY 6 & 7. Preliminary phasing options that limited the out of service area to 10 acres would not meet the PHA’s schedule. Per coordination with PHA, it was determined that if east/west traffic could be maintained this requirement could be waived. This resulted in 5 sub-phases starting in the south and working north towards the wharf. An additional benefit of this phasing was better coordination with adjacent wharf design/construction (through a separate contract PHA has with another consultant) minimizing overall BCT down time and loss of terminal capacity in areas directly behind the wharf. The design included a unique refrigerated container rack and associated substructure design for the PHA, roller compacted concrete pavement, jointed reinforced concrete pavement, sewer, firewater, stormdrain, electrical, telecommunication, high mast light poles and rubber tired gantry (RTG) crane tie-downs. Operational requirements, existing infrastructure, safety requirements, equipment procurement timelines, MARAD grant requirements; drove the packaging, phasing and procurement approach. This paper endeavors to describe the innovative design, phasing and packaging approaches used to meet operational needs, grant requirements and equipment procurement timelines.
How does this project / topic contribute to the advancement of the industry and profession?: The industry and profession are facing a new normal of long procurement timelines, a premium on operational capacity and an abundance of grant funding (with its restrictions). These combined exert unique constraints that make timely delivery of infrastructure projects challenging. This paper will outline the innovations in design, packaging and phasing that were used on the subject project, which can be used as a guide to find a balance and meet project delivery timelines.
Does the project / topic implement new and innovative techniques, materials, technologies, and delivery methods?: Yes, this project uses new and innovative techniques in design and construction of refrigerated container rack substructures in roller compacted concrete, the first that we are aware of. The approach to project delivery and packaging used are unique that enabled us to meet stakeholder needs and timelines.
What was the most challenging aspect of your project / topic and how did you handle it to ensure success?: Delivering a project that meets operational needs during construction in an active terminal while adhering to MARAD grant requirements was the most challenging aspect. Innovative approaches to design and construction, understanding clients long term goals, unique packaging and phasing concepts, helped make the project a success.
Who is the target audience for this paper?: The target Audience are Port Authorities, Terminal operators, third party developers. An entity looking to redevelop a terminal in today's environment of long procurement timelines with operationally constrained infrastructure, that are applying for or have any potential of receiving grant funding.
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