Simulation-based Load Repetition Estimation for Automated Terminals to Support Pavement Design

Abstract: The cost of pavement construction and maintenance represents a significant portion of the overall investment for marine port and terminal development projects, directly impacting the terminal’s operational efficiency and long-term sustainability. Repeated loading affects the structural integrity and performance of pavement materials over time. It is important to consider both the magnitude and frequency of loads in designing heavy duty pavements that can withstand the operational demands of marine ports and terminals.
This paper highlights the critical need for careful pavement design to withstand the operational demands of such facilities, focusing on the adverse impacts of repeated loading on pavement materials. It necessitates a detailed examination of equipment load, based on vendor information and load repetitions, indicating the frequency of load-bearing vehicle movements across terminal surfaces. These elements are particularly vital in designing pavements for automated container terminals, where the lack of empirical data, owing to their novelty, presents unique challenges. Additionally, minimizing operational disruptions from pavement maintenance is essential for the smooth operation of these automated terminals.
Our investigation categorizes terminals into distinct operational zones, such as the gate area, crane operation area, and waterside traffic area, among others, to accurately estimate load repetitions. This estimation process, traditionally reliant on manual calculations and assumptions, is increasingly supplemented by simulation technologies, offering more precise and less subjective data.
This paper outlines our pavement design methodology, emphasizing the technique for calculating load repetitions, specifically in automated container terminals. Utilizing the sophisticated discrete-event simulation tool FlexTerm, we examine a variety of operations are examined, from automated guided vehicles (AGVs) supporting twin automated stacking crane (ASC) blocks to straddle carriers for rail mounted gantry (RMG) crane blocks, through several case studies. These case studies highlight the effectiveness of simulation tools in refining pavement design. We also introduce a theoretical model that assumes a uniform distribution of job locations, offering a formula that helps cross-validate the results derived from simulations.
Our findings affirm that simulation not only substantiates the pavement design process by offering accurate load repetition data but also acts as a vital instrument in optimizing the infrastructure of marine ports and terminals for future challenges.

How does this project / topic contribute to the advancement of the industry and profession?: This project advances the industry by providing a simulation-based approach to support pavement design in marine ports and terminals, emphasizing the use of advanced simulation techniques to accurately estimate load repetitions. This methodology enhances operational efficiency and sustainability, offering a model for future development projects.

Does the project / topic implement new and innovative techniques, materials, technologies, and delivery methods?: The project introduces innovative use of advanced simulation technologies for estimating load repetitions in pavement design, particularly in automated container terminals. This represents a significant shift from traditional methods that rely heavily on empirical data and assumptions, showcasing a novel approach to infrastructure planning and design.

What was the most challenging aspect of your project / topic and how did you handle it to ensure success?: The most challenging aspect was accurately estimating load repetitions in various terminal operational areas, especially for automated container terminals with limited empirical data. We addressed this challenge by integrating simulation technologies, which allowed for a more precise and objective estimation process, thereby enhancing the reliability of the pavement design.

Who is the target audience for this paper?: The target audience for this paper includes pavement designers, port and terminal planners, civil engineers, and decision-makers involved in marine port and terminal development. It also appeals to researchers and academics interested in the application of simulation technologies in infrastructure design and optimization.