Port of Houston Bayport Terminal


Project Focus

The Port of Houston is a 25-mile long complex of diversified public and private facilities. It is first in the United States in foreign waterborne tonnage and second in overall tonnage. The Bayport Terminal Container Yard Expansion allows the Port of Houston Authority to maintain its competitive advantage and meet the growing demand in container traffic. The expansion also opens up opportunities to garner additional trade and business. This $35.9 million project provides for 48 acres of roller-compacted concrete pavement with a 30-year service life, in a configuration that will enable flexible container operations during successive phases of the Bayport projects.

Project Details

Schedule & Complexity
McCarthy Building Companies of Dallas TX subcontracted IHC for this project, which expanded an existing 50-acre cargo facility to 95 acres of cargo container storage. The overall project scope of work included earthwork, aggregate base, cement-treated base, roller-compacted concrete pavement, and installation of drainage structures, overhead high-mast lighting, and electrical receptacles for refrigerated cargo containers on undeveloped land adjacent to Galveston Bay. IHC's $13.5 million scope of work on this project included placement of 89,535 SY of 14-inch RCC and 122,345 SY of 18-inch RCC. Work on the project began in early January of 2010 and completed 4.5 months later in mid-May 2010.

Construction & Innovation
Construction of 14-inch and 18-inch thick RCC pavements requires placement of the RCC in two lifts. The second lift must be completed within two hours of beginning the first lift placement. IHC produced over 200,000 tons of RCC from our state-of-the-art on-site Rapidmix 400 pugmill. The RCC was placed in lanes typically ranging from 19-foot to 26-foot in width. RCC was placed with two high density Ingersoll Rand ABG pavers operating in unison, often times with less than 200 ft between the bottom-lift paver and the top-lift paver. The compactive effort behind the pavers consisted of two 10-ton dual-drum vibratory rollers - one on each lift - followed by a pneumatic-tired smooth drum roller on the second lift to attain the required density and surface finish.

IHC placed over 200,000 tons of high-quality RCC without failing a single test result on the project for strength or thickness. RCC was placed and compacted to 98% maximum density. The specification required 550 psi flexural strength, which correlated to 3500 psi compressive strength. The RCC placed averaged 4440 psi compressive strength with a standard deviation of 580 psi, exceeding the stated specified strength results

Public Relations
IHC's standard Partnering principles allowed us to maintain effective two way communication with all stakeholders. Weekly progress meetings with the owner and the prime kept every one up-to-date and allowed us to meet or exceed their expectations. White noise backup alarms were implemented in order to meet noise restrictions and minimize impact on an adjacent neighborhood. Security fencing minimized entry of unauthorized personnel or accidental entry of customers during ongoing daily operations of the port. All work was performed well within contract specifications with minimum delays and maximum communication.

Upon completion of the project, Port of Houston's Chief Construction Manager, Jim McQueen, stated "...you guys just blew us away! The quality and cooperation we got from the IHC and staff was truly a sight to behold. I just hope you do not forget about us and bid more work."