Completing the South Texas Gateway Terminal Permitting, Design, and Construction in 18 Months

This paper discusses the development of a new marine terminal to meet the demands for oil export from the Permian Basin. By the end of 2018, it was clear that the originally proposed VLCC terminal design would not be approved by the USACE and had to be redesigned. The consortium could not extend the schedule for the development of their new South Texas Gateway Terminal. Buckeye Partners selected a team of engineering and construction firms to meet the aggressive schedule to permit, redesign, and construct the first berth of the marine terminal within 18 months and complete the facility within 24 months. The new terminal configuration included approximately 3.5 M cubic yards of excavation/dredging, 2 modular loading platforms, 2 modular trestles, 2 access ramps, 8 breasting dolphins, 12 mooring dolphins, interconnecting walkways, berth equipment, and piping to accommodate vessels ranging from ocean going barges (OGB) to very large crude carriers (VLCC). The aggressive schedule required focused design criteria, permit applications, accelerated design for long lead items, procurement and coordination, and communication and collaboration between the Buckeye team, regulatory agencies, and contractors. The first phase included the development of permit plans and coordination with the USACE, Port of Corpus Christi, Aransas-Corpus Christi Pilots, local agencies, and full mission bridge simulations. The second phase included geotechnical subsurface investigations, environmental criteria assessment, simultaneous design of dredge material placement areas, access and waterside structures, piping, and the start of demolition of an existing shipyard and graving dock. The third phase included procurement, offsite fabrications and transport to site, and coordination with contractors for changing site conditions. The paper discusses the planning, design criteria, permitting coordination, construction issues, the various alternative delivery methods, selection of the most cost-effective and schedule driven options, and lessons learned for future terminal projects.