Reverse stacking of containers
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The document describes a proposed futuristic container terminal storage and distribution system using reverse stacking of containers. Key points: - Current stacking is limited by crane height to 6-7 tiers; proposed system uses "reverse stacking" from below special cell guides to increase density - It would replace many equipment types (straddle carriers, reach stackers etc.) with autonomous container transporters to stack into the cell guides - Calculations show the proposed system could stack 3-20 times as many TEUs in the same area, utilizing space more efficiently with containers accessible from all sides.
Reverse stacking of containers
- 1. FUTURISTIC CONTAINER TERMINAL STORAGE & DISTRIBUTION SYSTEM BY REVERSE STACKING OF CONTAINER 1 Presented by : Mr. D. BANERJEE NAVNAUTIK PTE LTD
- 2. PRESENT METHOD OF CONTAINER STACKING Shipping containers are stacked normally one on top of the other from the ground by a lifting machine, eg. crane. So the height of stacking is limited by height to which the lifting machine can stack. The present stacking height in the industry is generally up to 6-7 container tier high. 2PRESENT STACKING OF CONTAINERS CELL GUIDE IN SHIP
- 3. Present day shipping container storage and handling system requires : 1. Extensive and expensive land area in premium waterfront; 2. Complicated handling facility with multitude of equipment; 3. Extensive man-power of various skills to support this complicated system. Based on the ISO standard ISO 668 & ISO 1496-1 : 1990 and today’s in transport technology a fundamental approach has been taken to propose a State-Of-Art storage, handling and distribution system. 3
- 5. FORCES TO BE APPLIED IN STACKING TEST 5 ISO 1496-1 : 1990 (E) APPENDIX 1 HOW MANY TIERS CAN ISO CONTAINERS BE STACKED VERTICALLY SO AN ISO CONTAINER CAN SAFELY WITHSTAND A VERTICAL TEST LOAD OF 192T WITH A FACTOR OF SAFETY OF 1.8
- 6. NO THEORATICAL STACKING HEIGHT OF CONTAINER = 192 TONNES OF TOTAL WEIGHT OF CONTAINER 20’ 40’ WT (t) HT (Tires) = 192T / (3) WT (t) HT (Tires) = 192 / (5) (1) (2) (3) (4) (5) (6) 1 EMPTY 2.3 83 3.75 38 2 MAX. GROSS 32.5 6 32.5 6 3 AVERAGE WEIGHT OF 8T/CONTAINER 8 24 8 24 4 AVERAGE WEIGHT OF 14T/CONTAINER 14 13 14 13 FROM THE TEST LOADS AS PER APPENDIX 1 GENERAL PURPOSE CONTAINER WILL BE SUBJECTED TO VERTICAL FORCE 192T WITH A FACTOR OF SAFETY OF 1.8 6 1. CAN BE CONSIDERED FOR STORAGE FOR EMPTY CONTAINERS. 2. ONLY PRACTICAL FOR ISO TANK CONTAINERS. 3 & 4. ACTUAL RANGE OF GROSS WEIGHT OF SHIPPED CONTAINERS. SO BASICALLY ISO CONTAINERS CAN BE STACKED TILL THE TOTAL WEIGHT OF THE STACK REACHES 192T. ESTIMATION OF STACKING HEIGHT APPENDIX 2
- 7. ~6m REVERSE STACKING CELL GUIDE ARRANGEMENT OF CELL GUIDES FOR REVERSE STACKED CONTAINERS 7 CELL GUIDE IS SUSPENDED AT A HEIGHT ABOVE GROUND TO PROVIDE FREE PASSAGE OF AUTONOMOUS CONTAINER TRANSPORTERS (ACT) (~ 6000 mm) VOIDSPACEBELOW CELLGUIDE CELL GUIDE ENTRY CONTAINER CORNER FITTING SUPPORT BLOCK C/W TWIST LOCK AND HYDRAULIC LOCKING PINS (8 NOS) SUPPORT BLOCK C/W TWIST LOCK WITHOUT HYDRAULIC LOCKING PINS REVERSE STACKED CONTAINERS
- 8. 8 CONTAINER SUPPORT SYSTEM IN REVERSE CELL GUIDE 1. REVERSE CELL GUIDE 2. CONTAINER 3. CORNER FITTING 4. WELDABLE DOVETAIL TWIST LOCK 5. TWIST LOCK HANDLE (TO BE FITTED WITH REMOTE ACTUATION) 6. HYDRAULICALLY ACTUATED LOCKING PINS (8 NOS PER CONTAINER) 7. SUPPORT BLOCK (4 NOS PER CELL STACK) NOTE : EVERY CONTAINER CORNER FITTING SHALL BE FITTED WITH SUPPORT BLOCK WELDED TO TWIST LOCK 2 5 7 1 VIEW A VIEW A WELDED TOP PIN BOTTOM PIN 4 3 6 7 2 6 TOP PIN BOTTOM PIN 7
- 9. CONTAINER BASIC FACILITIES FOR REVERSE STACKING OF CONTAINERS 1. REVERSE CELL GUIDE 2. AUTONOMOUS CONTAINER TRANSPORTER (ACT) – It is driver-less electric vehicle to transport container 3. LIFTING TABLE (200T SWL) TO REVERSE STACK CONTAINERS. REVERSE CELL GUIDE 1 LIFTING TABLE 200t SWL 3 AUTONOMOUS CONTAINER TRANSPORTER (ACT) 2 9 APPENDIX 3 SUPPORT BLOCK C/W TWIST LOCK ALREADY FITTED AT THE CONTAINER BOTTOMS SUPPORT BLOCK C/W TWIST LOCK AND HYDRAULIC LOCKING PINS CELL GUIDE ENTRY REVERSE CELL GUIDE HYDRAULIC STABILIZER JACK (4 NOS) 4x75t SWL
- 11. STACKING UP ACT picks up container from vessel and proceeds to stacking area 11 QUAY CRANE LOADS CONTAINER ON ACT ACT LIFTING TABLE ALREADY FITTED WITH SUPPORT BLOCK C/W TWIST LOCK
- 12. STACKING UP ACT takes position below reverse cell guide. Hydraulic stabilizers deployed to anchor ACT. 12 NEW CONTAINER TO BE STACKED UP ACT LIFTING TABLE HYDRAULIC STABILIZER (4 NOS) REVERSE CELL GUIDE EXISTING STACKED CONTAINERS
- 13. CONTAINER BEING STACKED UP ACT LIFTING TABLE REVERSE CELL GUIDE HYDRAULIC STABILIZER (4 NOS) STACKING UP Container is lifted up, just to take up the load of already stacked containers. The hydraulic locking pins are released. 13 EXISTING STACKED CONTAINERS
- 14. NEW STACKED CONTAINER ACT LIFTING TABLE REVERSE CELL GUIDE HYDRAULIC STABILIZER (4 NOS) EXISTING STACKED CONTAINERS STACKING UP The container is raised further up so that the locking pins are inline with the bottom support blocks fitted on the lifting table. The hydraulic locking pins are engaged. 14
- 15. ACT LIFTING TABLE HYDRAULIC STABILIZER (4 NOS) STACKING UP The lifting table is lowered down leaving the support blocks attached to the bottom of the container. The hydraulic stabilizers retract. ACT is free to go to next assignment. 15 NEW STACKED CONTAINER REVERSE CELL GUIDE EXISTING STACKED CONTAINERS
- 17. ACT LIFTING TABLE HYDRAULIC STABILIZER (4 NOS) CONTAINER TO BE STACKED OUT REVERSE CELL GUIDE STACKING DOWN The container table is raised just to take up the load of already stacked containers. The hydraulic locking pins are released. 17 SECOND CONTAINER EXISTING STACKED CONTAINERS
- 18. ACT LIFTING TABLE HYDRAULIC STABILIZER (4 NOS) STACKING DOWN The table is lowered down so that the bottom support blocks of the second container are inline with the locking pins. The hydraulic locking pins are engaged. 18 CONTAINER BEING STACKED DOWN SECOND CONTAINER REVERSE CELL GUIDE EXISTING STACKED CONTAINERS
- 19. ACT LIFTING TABLE HYDRAULIC STABILIZER (4 NOS) REVERSE CELL GUIDE EXISTING STACKED CONTAINERS STACKING DOWN The table is lowered and the hydraulic stabilizers retracted. 19 STACKED OUT CONTAINER
- 20. ACT LIFTING TABLE STACKING DOWN 20 ACT is ready to leave to deliver the container to its next intended assignment.
- 21. STACKED 40 FT CONTAINERS QUAY CRANE CONTAINER RECEIVING AREA ACT PASSAGE WAY TERMINAL LAYOUT VIEW A VIEW B ACT TERMINAL GATE IN OUT TRUCK SEASIDE LANDSIDE AUTONOMOUS CONTAINER TRANSPORTER (ACT) CONTAINER SHIP 21 PILLARS TO SUPPORT REVERSE STACKING CELL GUIDE OUTGOING CONTAINER IS FITTED WITH SUPPORT BLOCK C/W TWIST LOCK IS REMOVED INCOMING CONTAINER IS FITTED WITH SUPPORT BLOCK C/W TWIST LOCK ENTRY/EXIT FORMALITY AREA
- 22. VIEW A VIEW B 22 TERMINAL LAYOUT REVERSE STACKING CELL GUIDE ACT SPACED 4 M PROVIDES FREE ACCESS THROUGHOUT QUAY SIDE CRANE LOADING / UNLOADING PILLARS TO SUPPORT REVERSE STACKING CELL GUIDE
- 23. CONTAINER RECEIVING AREA ACT PASSAGE WAY 4 4 4 4 5 5 IN OUT 2 31. Terminal access formality area Security check Custom Etc. 2. To terminal process area 3. Delivery to receiver 4. ACTs can move through the stack area freely finding its way to the appropriate stack 5. ACTs sorting containers as per shipment requirement SEASIDE LANDSIDE 1 23 (VIEW BELOW CONTAINER STACK) TERMINAL TRAFFIC FLOW 4 m 16m PILLARS TO SUPPORT REVERSE STACKING CELL GUIDE SPACED 4x16 m
- 24. STACKED 20 FT CONTAINERS QUAY CRANE SEASIDE LANDSIDE CONTAINER RECEIVING AREA CONTAINER SHIP AUTONOMOUS CONTAINER TRANSPORTER (ACT) 4 4 4 4 5 5 IN OUT TERMINAL GATE 2 3 VIEW A VIEW B 1. Terminal access formality area Security check Custom Etc. 2. To terminal process area 3. Delivery to receiver 4. ACTs can move through the stack area freely finding its way to the appropriate stack 5. ACTs sorting containers as per shipment requirement 24 1 TERMINAL TRAFFIC FLOW PILLARS TO SUPPORT REVERSE STACKING CELL GUIDE ACT PASSAGE WAY
- 25. NO EQUIPMENT EXISTING TERMINALS PROPOSED REVERSE STACKED STORAGE TERMINAL 1 QUAY CRANES YES YES 2 CHASSIS YES NO 3 STRADDLE CARRIER YES NO 4 REACH STACKER YES NO 5 FORKLIFT YES NO 6 FRONT END LOADER YES NO 7 GANTRY CRANES YES NO 8 AUTOMATED GUIDED VEHICLE ( THESE NEED TO BE GUIDED ) YES NO 9 PROPOSED AUTONOMOUS CONTAINER TRANSPORTER ( ACT ) FITTED WITH LIFTING TABLE ( 200T LIFTING CAPACITY ) ( THESE VEHICLES LIKE DRIVERLESS CARS CAN NAVIGATE AND OPERATE BY THEMSELVES ) - YES 10 REVERSE CELL GUIDE FOR STACKING NO YES 25 COMPARISON OF EQUIPMENT NEEDED TO OPERATE A CONTAINER TERMINAL APPENDIX 4
- 26. ADVANTAGES OF THE PROPOSED REVERSE STACKED CONTAINER STORAGE SYSTEM OF TERMINAL LAYOUT 1. About 3 to 20 times as many TEUs can be stacked per square area as of storage. (see Appendix 6) 2. Much higher utilization of available premium terminal space. 3. No wastage of space for designated roadways for vehicle transport. 4. The entire terminal area is available for access all the time including the container storage area. ACT can freely move through the void area below stacks. 26
- 27. 5. The most critical bottleneck is the Quay Cranes which generally serves at about on an average 30 TEU / hour. All the other facility can be designed to suit this rate of through put. 6. In existing system : Gantry cranes, straddle cranes can serve each bay (stacks) only one at a time. 7. Autonomous Container Transporter (ACT) will perform all activities from receiving containers from Quay Cranes to transporting to the appropriate stacking cell guide point and stack the container and vice versa. 8. ACTs will also do sorting and pre-stacking according to loading schedule independently and simultaneously. 9. No human presence is required in the entire operation except at central control, management centre and maintenance department. 27
- 28. This requires just three basic facilities : 1. Existing Quay cranes 2. Specially designed reverse cell guide, i.e. stacking the containers from the bottom of cell guide (top stacking cell guide is already used in Container ships). 3. Specially designed battery powered Autonomous Container Transporter (ACT) (based on driverless car technology for its navigation and operation. Rest of the multitude of equipment used in today’s system can be practically dispensed with (see Appendix 3 and 4). 4. Lifting Table (200 T SWL Lifting Capacity) Specially designed and programmed to reverse stack-up and stack- down containers into reverse cell guides. The technology is commercially existing in industry. 28
- 29. 29 NUMBER OF STACK ROWS = 9 EACH STACK IS 6X16 40 FT CONTAINERS PART PICTURE OF PSA TERMINAL 3 – SINGAPORE ACTUAL TERMINAL STUDY
- 30. LENGTH = 286.0 M (FROM PICTURE ONE CAN COUNT 9 STACK) BREADTH = 234.0 M (FROM PICTURE ONE CAN COUNT FOR EACH STACK 16 NOS 40 FT AND 6 ABREAST CONTAINERS HAVE BEEN ARRANGED). EXISTING LAYOUT NUMBER OF STACKS = 9 EACH STACK = 6 X 16 ( 40 FT CONTAINERS ) X 5 HIGH = 480 ( 40 FT CONTAINERS ) = 2 X 6 X 16 X 5 ( 20 FT CONTAINERS ) = 960 TEUS POSSIBLE MAXIMUM STORAGE = 960 X 9 = 8640 CONTAINERS – 20 FT = 480 X 9 = 4320 CONTAINERS – 40 FT 30 CONTAINER STORAGE DENSITY COMPARISON SAMPLE AREA IN PASIR PANJANG TERMINAL 3 – SINGAPORE (REF. GOOGLE PICTURE) APPENDIX 5
- 31. PROPOSED REVERSE STACKING CONCEPT SKETCH ATTACHED (NEXT SHEET) LENGTH = 286.0 M BREADTH = 234.0 M DIMENSION OF CELL GUIDE SLOTS FOR - 40 FT CONTAINERS = 16 M X 4 M - 20 FT CONTAINERS = 8 M X 4 M - NUMBER OF ROWS FOR - 40 FT CONTAINERS = 286 / 16 = 17.875 APPROX. 18 CONTAINERS - 20 FT CONTAINERS = 286 / 8 = 35.750 APPROX. 36 CONTAINERS EACH ROW - 40 FT CONTAINERS = 234 / 4 M = 58.5 APPROX. 58 CONTAINER SLOTS - 20 FT CONTAINERS = 234 / 4 M = 58.5 APPROX. 58 CONTAINERS SLOTS SO TOTAL NUMBER OF SLOTS - 40 FT CONTAINERS = 18 X 58 = 1044 TEUS - 20 FT CONTAINERS = 36 X 58 = 2088 TEUS 31
- 32. 32 40 FT CELL GUIDE SLOT (1044 SLOTS) 20 FT CELL GUIDE SLOT (2088 SLOTS) CONTAINER STORAGE DENSITY COMPARISON SAMPLE AREA IN PASIR PANJANG TERMINAL 3 – SINGAPORE
- 33. NO AVERAGE WEIGHT OF CONTAINERS ALLOWABLE STACKING HEIGHT IN 2088 SLOTS IN 1044 SLOTS COMPARED TO EXISTING LAYOUT STORAGE 8640 TEUs (3) x 2088 (4) x 2088 (5) / 8640 (6) / 4320 (1) (2) (3) (4) (5) (6) (7) (8) 20 FT 40 FT 20 FT 40 FT 20 FT (8640) 40 FT (4320) 1 32.5 T ( GROSS ) 6 6 12528 6264 1.45 1.45 2 EMPTY 83 38 173304 39672 20.88 9.18 3 8.0 T 24 24 50112 25056 5.8 5.8 4 14.0 T 13 13 27144 13572 3.14 3.14 33 CONTAINER STORAGE DENSITY COMPARISON SAMPLE AREA IN PASIR PANJANG TERMINAL 3 – SINGAPORE APPENDIX 6