Evaluation and Design of a Foundation System for Automated Stacking Cranes at the Port of Los Angeles, Berths 144-145 Automated Terminal

The Port of Los Angeles (POLA) recently completed the Berths 144-145 Backland Redevelopment Project. This phase of the first automated container terminal on the west coast of the United States consists of four fully automated stacking blocks and two mini automated stacking blocks. This terminal is one of the first terminals in the world to deploy automated shuttle carriers as horizontal transport in conjunction with automated stacking crane (ASC) blocks. The 33-acre site went fully operational in August 2014. Each 1,100-foot long block has two ASCs, which are mounted on rail and can handle one over-five stack. The ASCs are fully autonomous; they are used to stack containers inside the block and to pick up and deposit containers at both ends of the block. The ASCs require very tight tolerances on their foundation during both construction and operation. Therefore, the crane rail foundation is the most important design element of ASC blocks. The key function of ASC rail foundation is to support the crane loads and maintain the crane tolerances. The ASC foundation in this project consists of rails supported on prestressed concrete ties with ballast. The crane rail foundation design challenges included the variable nature of the subgrade over the length of the ASC block, the influence of adjacent container stacks, liquefaction, seismic loads, crane tolerances, drainage, and conflicts with existing utilities. This paper presents the methodology used to evaluate various crane foundation systems, the design of the rail and ballast-tie foundation system, liquefaction and settlement assessments, and lessons learned from construction challenges.