Revitalizing Industrial Legacy: Transforming Steel Mill Ore Dock into Multi-Modal Transportation Hub

Abstract: Tradepoint Atlantic (TPA) embarked on an ambitious journey in 2014 by acquiring the Bethlehem Steel Mill in Sparrows Point, Maryland, with a vision to rejuvenate the 3,300-acre property into a vibrant multi-modal transportation hub. This endeavor included the reconstruction of a berth and the development of adjacent lands to support the burgeoning US offshore wind industry.
The selected inner berth, once dedicated to bulk material handling for the former steel mill, proved to be an ideal candidate for repurposing due to its robust infrastructure and strategic location. With adjacent lands primed for supporting various facilities, including stockpiles, manufacturing sites, and warehouses, the stage was set for a transformative project.
Originally constructed in the early 1900s, the berth presented structural complexities, comprising three sections with anchored steel or concrete sheet pile bulkheads. The presence of blast furnace slag as primary fill material posed unique challenges, compounded by soft clay soils beneath the surface.
WBCM undertook the task of designing structural improvements to ensure the berth and surrounding areas could withstand a 3,000 PSF live load capacity and accommodate heavy-duty cranes and transportation equipment. Innovative techniques, such as pre-augering the slag layer for pile installation, were employed to overcome the density-related constraints.
The comprehensive process, initiated in 2018, encompassed surveying, permitting, civil and structural engineering design, and construction oversight. TPA's collaboration with the local government of Baltimore County resulted in securing a $20M Transportation Investment Generating Economic Recovery (TIGER) grant from the US Department of Transportation, catalyzing the transformation of the former ore dock into a pivotal shipping port on the East Coast.
The completed improvements enable the seamless transportation and storage of diverse cargo types, including break bulk, dry bulk, offshore wind components, and roll-on/roll-off (RO/RO) cargo, heralding a new era of industrial revitalization and multi-modal connectivity.
Furthermore, TPA's strategic positioning south of the Francis Scott Key Bridge places it at the forefront of Baltimore's maritime infrastructure development. The recent accident underscores the critical need for alternative access points to the Federal Shipping Channel. TPA's expedited expansion as a container terminal, supported by the State, presents a timely solution to alleviate supply chain disruptions and maintain Baltimore's status as a prominent deep-water port on the East Coast.
As industries evolve and embrace sustainability, the transformation of industrial landmarks into multi-modal transportation hubs holds significant promise for enhancing regional economic competitiveness and fostering environmental stewardship. Through collaborative efforts and adaptive engineering strategies, similar projects can unlock the latent potential of industrial landscapes, driving prosperity and resilience in coastal communities worldwide.
In conclusion, the revitalization of the steel mill ore dock at Tradepoint Atlantic represents a paradigm shift in urban redevelopment, demonstrating how thoughtful planning, innovative engineering, and strategic partnerships can breathe new life into dormant industrial assets. As the global maritime industry navigates towards a more sustainable future, initiatives like these serve as beacons of progress, guiding the transformation of ports and waterfronts into vibrant, resilient, and interconnected spaces.

How does this project / topic contribute to the advancement of the industry and profession?: This project significantly contributes to the advancement of the industry and profession by pioneering offshore wind construction operations in Maryland and the United States. As one of the earliest projects of its kind, it serves as a prototype for sustainable wind energy infrastructure development. With a robust 3000 psf live load capacity, capable of supporting mobile harbor cranes and roll-on/roll-off operations, it sets a high standard for future offshore wind projects, driving innovation and progress in the sustainable energy sector.

Does the project / topic implement new and innovative techniques, materials, technologies, and delivery methods?: The project embodies a spectrum of new and innovative techniques, materials, technologies, and delivery methods. Specialized driving methods were essential for installing pile foundations through dense blast furnace slag, necessitating a combination of innovative approaches. Supplementary cementitious materials were employed to enhance concrete durability, while a passive cathodic protection system was utilized to extend the longevity of existing steel structural elements. These innovative solutions not only addressed project-specific challenges but also set benchmarks for sustainable and resilient infrastructure development.

What was the most challenging aspect of your project / topic and how did you handle it to ensure success?: The most challenging aspect of the project was navigating the complexities of existing buried structures and installing foundations in dense blast furnace slag. Anticipated obstructions and encountered challenges during construction required proactive measures for resolution. Pre-construction testing, frequent communication with the contractor, and meticulous site surveys using lidar and drone imagery were integral to identifying and addressing project challenges effectively. By leveraging a collaborative approach and deploying advanced surveying technologies, the project team ensured the successful execution of construction activities amidst challenging site conditions.

Who is the target audience for this paper?: The paper targets a diverse audience primarily comprising engineers, particularly marine structural engineers, who will glean valuable insights from the project's innovative engineering solutions. Geotechnical engineers, contractors, developers, architects, and waterfront property owners stand to benefit from the paper's comprehensive analysis of site-specific challenges and innovative methodologies employed for successful project delivery. Additionally, developers seeking to transform existing industrial facilities into multi-modal transportation hubs can leverage this project as a blueprint for securing funding and driving sustainable redevelopment initiatives.