Design-Build Delivery of Cement Imports Dock Configured for Future Liquid Exports

The Port of Corpus Christi Authority (POCCA) is USA’s largest oil export port; however, in recent years, POCCA has implemented a strategic initiative to diversify its business and incorporate bulk cargo handling capabilities. As part of this initiative, POCCA recently completed an expedited and successful design-build delivery of a new cargo dock in the inner harbor geared toward cement imports from Handymax vessels with the option of future conversion to a liquid bulk dock for Aframax vessels. The imported cement is taken off the ship with a rail-mounted ship unloader to a high-level conveyor supported at the back of the dock to shoreside silos. The dock layout provides space for future liquid bulk handling systems. This paper describes the streamlined delivery process and optimized dock structure framing that will serve as a model to the port community. The design and construction of the new cargo dock was executed using a two-step design-build process consisting of contractor prequalification and a technical/financial final bid submission. Scope included dredging of the dock pocket, construction of the marine structures, and coordination of the owner procured special ship unloader and cement conveying topside equipment. The design accounted for the future 60-ft dredge depth of the inner harbor and consideration of passing effects of a Suezmax vessel. To meet the expedited timeframe, the winning design-build team adopted a design consisting of an open pile-supported structure, approximately 681 ft long and 52 ft 6 in. wide and connected to the shoreline at its east end with a 180-foot-long access trestle. Monopile dolphins at the ends provided ship mooring capability for both Handymax and Aframax vessels. To expedite construction, the design-build team adopted a modular design using plumb and batter precast, prestressed concrete piles supporting precast concrete pile caps, beams, and deck panels. The project was successfully delivered in about 15 months from commencement and has become a prized addition to POCCA’s marine assets.