Presented by: Magenthran Ruthenavelu at the 2009 Railways and Harbours Conference in Cape Town.

1. Railways and Harbours Conference
March 2009
Expansion of the Cape Town Container Terminal

2. EXPANSION OF THE CAPE TOWNEXPANSION OF THE CAPE TOWN
CONTAINER TERMINALCONTAINER TERMINAL
Presentation Structure
1. Port Orientation
2. Status Quo – Port Characteristics
3. The Need for Capacity Expansion
4. Options Considered & Approved Scheme
5. CTCT Expansion – Construction Aspects

3. Cape Town

4. • FIGURE II
Main breakwater
V&A Waterfront
Duncan
Dock
Ben
Schoem
an
Dock
C
ontainerTerm
inal
Cape Town Container Terminal
Orientation

5. Cape Town Container Terminal
Orientation

6. 2. Status Quo – Port Characteristics
Cape Town Container Terminal

7. • Infrastructure Characteristics
• Basin at depth -14m CD Port
• Quay length: 1372m (5 berths at various depths)
• Type of quay construction: Block Wall
• Original design vessel: 2500 TEU vessel, Draft = 11.7m, length = 270m, beam = 31.8m
• Terminal Characteristics
• Straddle carrier operation
• Stack area:
• concrete paving with approx. 11,000 ground slots (function of stack height),
• reefer points of 1,600
• Ship to Shore Cranes:
• Number = 6 and relatively old
• Constraint = reach, height, lifting capacity, availability of spares & end of economic
lifespan
• Yard equipment
• Straddle Carriers & Haulers/Trailers
• Above average age
• Limited stack height
Cape Town Container Terminal
Existing Characteristics

8. G.P.
Reefer
MT
Cape Town Container Terminal
Existing Layout

9. 3. The Need for Capacity Expansion
Cape Town Container Terminal

10. TEUThrough-Put(‘000)
CTCT TEU Forecast
-
250
500
750
1,000
1,250
1,500
1,750
2,000
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
CTCT (Historical)
Capacity
Projected Demand 8%
Projected Demand 10%
Cape Town Container Terminal
The Need for Expansion

11. 4. Options Considered & Approved Scheme
Cape Town Container Terminal

12. Fundamental capacity constraints:
• Stack area – insufficient stacking space
• STS Cranes – needs replacement
• Yard equipment – cannot cope with current & projected volumes
Cape Town Container Terminal
Expansion Options Considered
Options for capacity growth:
A. Reclamation option within port (Quay
501/502)
B. Stack capacity in Port Industrial Park
Site
C. Reclamation option within port (Duncan
Dock)
D. Seaward reclamation

13. • 300m seaward reclamation for additional stacks
• STS crane replacement (6 off)
• Yard equipment replacement (straddle carriers
+ haulers/trailers)
• Reshuffling of stacks & increase in reefer points
Extensive delays in completing EIA and
obtaining successful RoD. Needed to
expedite an alternate solution in order to
bring additional capacity on line to suit
immediate demand.
Cape Town Container Terminal
Preferred Option: Reclamation

14. Reconfiguration
Basin Deepening
Container Handling Equipment
Quay Refurbishment
Cape Town Container Terminal
Alternative Option: Reconfiguration

15. • CTCT development structured in 3 phase approach
• Phase 1 & 2 capex approved (R4.2b)
• Phase 3 future concept
Cape Town Container Terminal
Approved Expansion Scheme

16. • Berth Capacity
• Quay refurbishment (deck on piles)
• Increase berth depths to 15.5m below Chart Datum
• Design vessel: TEU = 6000, LOA =350m, Beam = 45m, Draft = 14.0m
• STS Crane Capacity
• Replace existing cranes (6) with Super Post Panamax size
• Increase cranes (+2) to match increased stack capacity
• Yard Equipment Capacity
• Convert from Straddles to RTGs
• To allow future capacity increases to match berths
• Stack Capacity
• Demolition of non-essential infrastructure
• Increase stacking foot print with more dense stacking
• Efficiency Improvements
• Truck Staging Area
• PIP Site Bridge
• Comms & Instrumentation (including Gate Automation & CCTV)
• Standardisation of Operational System (NAVIS)
• Entrance / exit modifications
Cape Town Container Terminal
Approved Expansion Scheme

17. Cape Town Container Terminal
Quay Refurbishment & Berth Deepening

18. Cape Town Container Terminal
Reconfiguration

19. 6. CTCT Expansion – Construction Aspects
Cape Town Container Terminal

20. Cape Town Container Terminal
Construction

21. Quay Refurbishment &
Berth Deepening
• Deepen basin (-15.5m CD)
• Dredging 1.23 million m3 of
sand, clay & rock
• New front crane rail
beam on piles
• Suspended reinforced
concrete deck
Cape Town Container Terminal
Quay Refurbishment & Berth Deepening

22. Trailing Suction Hopper
Dredger (Gefion R) dredging
in Ben Schoeman Basin
Disposal of dredged material
at approved offshore
disposal site
Cape Town Container Terminal
Soft Dredging

23. Drilling & blasting of rock
Cape Town Container Terminal
Pre-treatment of Rock

24. Lifting of split hopper bargeArrival of dredging spread
on combi vessel -
comprising backhoe dredger
& 2 split hopper barges
Cape Town Container Terminal
Rock & Hard Dredging

25. Backhoe commences
dredging
Installing
backhoe spud
legs
Cape Town Container Terminal
Rock & Hard Dredging

26. Dredged rock in barge
awaiting disposal
Dredging of rock
Cape Town Container Terminal
Rock & Hard Dredging

27. Completed pile casingWelding of steel pile casings
Cape Town Container Terminal
Quay Refurbishment: Piling

28. Pitching of pile casing into
piling frame / access platform
Lifting of steel pile casing
Cape Town Container Terminal
Quay Refurbishment: Piling

29. Pitched pile and application
of vibrating piling hammer
Cape Town Container Terminal
Quay Refurbishment: Piling

30. Drilling of rock socket using wirth
drill rig & placing of drill string
Cape Town Container Terminal
Quay Refurbishment: Piling

31. Fabricating of reinforcing cage and placement
Cape Town Container Terminal
Quay Refurbishment: Piling

32. Tremie
concreting of
socket
Placing of temporary
bracing, precast concrete
pile collars and air lifting to
clear drilled socket
Cape Town Container Terminal
Quay Refurbishment: Piling

33. Culemborg batching plant
and precast yard
Cape Town Container Terminal
Quay Refurbishment: Precasting

34. Precasting of
transverse beams
Preparation work on
quayside rebates
Cape Town Container Terminal
Quay Refurbishment: Precasting

35. Placing of precast units
Cape Town Container Terminal
Quay Refurbishment: Precasting

36. Cape Town Container Terminal
Quay Refurbishment: Precasting

37. Cape Town Container Terminal
Quay Refurbishment: Precasting

38. Cape Town Container Terminal
Quay Refurbishment: Basic Stabilisation

39. Cape Town Container Terminal
Quay Refurbishment: Quay Furniture

40. Area 370, 380
and 390 not
included in
scope
Stack area – Sectional completions

41. Cape Town Container Terminal
Reconfiguration: Rubber Tyred Gantries

42. Cape Town Container Terminal
Reconfiguration: Non-Stack Areas

43. Cape Town Container Terminal
Reconfiguration: Non-Stack Areas

44. Cape Town Container Terminal
Current Status of Construction

45. Cape Town Container Terminal
Current Status of Construction

46. Cape Town Container Terminal
Current Status of Construction

47. Aerial Photos by Aerial Perspective: www.aerialphoto.co.za
Cape Town Container Terminal
Current Status of Construction

48. Cape Town Container Terminal
THANK YOU!