Port Newark Container Terminal

Jacobs has supported Port Newark Container Terminal (PNCT) with its long-term development plan since 2002 through an on-call agreement and multiple individual projects. 

PNCT, located in Port Newark, New Jersey, occupies 292 acres and handled more than 1.4 million twenty-foot equivalent containers annually in 2019. The terminal is operated by Port Newark Container Terminal, LLC, which is a joint venture between Ports America and Terminal Investment Limited under a long-term lease agreement with the Port Authority of New York and New Jersey (PANYNJ). 

Jacobs has undertaken dozens of tasks, including the following:

Yard Improvements (2002-2006) 

PNCT engaged Jacobs to provide project management, design and supervision consultancy services for the construction of a container yard on a 15-acre site as an extension to the development of their container terminal. The yard was designed for straddle carrier operations and construction was phased to minimize disruption to existing terminal operations. Jacobs was Engineer of Record and facilitated PANYNJ TAA approvals.

Constraints to the construction included stacking of empty containers in one corner of the site, ongoing operation of the container yard and construction at the adjacent container terminal.

Deliverables consisted of data collection and review, developing layouts, developing design criteria, preliminary design, construction methodology and phasing, detailed design, bid documents (drawings, specifications, cost estimates, & schedule, bid process management, bid evaluation and recommendations, contract negotiations and award, and construction supervision.

Berth Deepening and Strengthening (2007-ongoing)

In 2007, Jacobs prepared a conceptual design study for PNCT for deepening and upgrading the berths along the Elizabeth Channel. In 2010, Jacobs prepared an updated and expanded version of that study, which also included two potential berths along the Newark Bay wharf. The study established the required live loading for which the wharf deepening is to be designed, identified existing conditions along the entire Elizabeth Channel wharf (Berths 51 through 63) and the 2,300-ft-long section of wharf along Newark Bay (Berths 30 through 36) with regard to water depth, cutoff wall, fender system, mooring fittings, and crane rail support system, developed conceptual designs of the principal elements of the project, and prepared an estimate of the cost to construct the project.

As part of the PNCT Long Term Improvement Plans (LTIP) managed all civil and structural design of Berths 53 and 55 deepening and wharf reinforcement, including installation of a new landside crane girder, replacement of the waterside crane girder, installation of a king-pile system to retain the embankment and the new girders, installation of new crane cable trench, replacement of fenders and bollards, and dredging of the area in front of the Berths to -50’ MLLW. Given the proximity of Newark Liberty International Airport (EWR), new cranes installed on Berth 53 are low-profile (sliding-boom) design. Designed new crane tie-downs and stowage pin hardware at Berth 59 to support operation of three new Super Post-Panamax (SPPX) cranes.

Jacobs also provided detail design of the electrical distribution for two container berths including 6 ship-to-shore cranes and the master planning for the entire wharf, which includes four berths and 12 cranes. The detailed design included 13.2 kV distribution to cranes, 480V auxiliary power to cranes, ground check and communications. We also assisted with design of new substation which serves up to six of the new cranes.

Jacobs prepared permit applications and obtained federal, state, and local upland and waterfront permits for the construction completed and underway, and is in the process of preparing applications for all required permits, including NEPA documentation, for upcoming construction work.

Long Term Improvement Plan (2011-2015)

Jacobs assisted PNCT with its $500 million long term expansion program. Jacobs was the Engineer of Record for design and construction oversight of 12 major terminal improvement projects, which included engineering design for a new Light Duty Straddle Carrier Shop maintenance facility and concept design of a new Heavy Duty Straddle Carrier Shop. Both buildings were for heavy industrial use and included all necessary utilities.

Phase 1 Yard Expansion (2012) 

Jacobs assisted PNCT with 33-acre expansion of yard and truck queuing area and expanded yard handling that increased capacity by 25%. Contaminated warehoused were demolished and challenging geotechnical soil conditions were present.

USDOT TIGER Grant Application (2014) 

Jacobs prepared a USDOT TIGER 6 Grant application for the container terminal. Work included high-level planning, estimating and application preparation. A $15 million grant was awarded based on the submitted application. Work included preparation of USDOT Benefit-Cost Analyses, application preparation, and preparation and submission of NEPA documentation.

NEPA Permitting (2014-2016) 

Jacobs successfully prepared and submitted documentation to the USDOT for National Environmental Policy Act (NEPA) and received approval for PNCT’s expanded and relocated gate and terminal access project. 

Jacobs also successfully prepared and submitted documents to MARAD for NEPA approval for four other projects, including the deepening of Berths 55 and 57, Phase 3 Terminal expansion, new heavy-duty straddle carrier maintenance shop, and the West Yard Buildout with a new administration building and 23 acres of new yard.

Phase 3 Yard Expansion and Marsh Street Depot (2016-ongoing) 

Jacobs is developing US Army Corps of Engineer and New Jersey Department of Environmental Protection permit application documents for the dredging and wharf improvements associated with the Berths 53 and 55 deepening and reinforcement work. PNCT commissioned Jacobs to provide planning, engineering, and construction support services for demolition of existing warehouses to expand the container storage yard and to develop an empty container depot at Marsh Street. Jacobs is also developing rail access and yard improvements for the peninsula to allow for the storage of up to thirty two (32) 5-car train sets for loading and unloading.

Additional Crane Tie Downs (2016-ongoing)

Jacobs designed four new 65T crane tie downs to be installed in the existing wharf structures. These tie downs will serve four new SPPX ship to shore cranes. Construction is underway and is phased to allow operations to continue through operations.

Heavy Duty Straddle Carrier Shop (HDSS) (2020 – ongoing)

Jacobs is performing detailed architectural and engineering design for the new HDSS, which will include storage, offices, and bays and facilities to maintain container handling equipment. Jacobs also led field investigations, permitting, owner (Port Authority of New York and New Jersey) approval, and will be providing bid and construction support services. The building is required to provide adequate clearances for the maintenance shop for the newly acquired heavy duty straddle carriers.