Liverpool 2 Phase 2: A new deep-water container terminal at the Port of Liverpool

The Peel Ports Liverpool 2 project represents a major £400 million investment to establish a new deep-water container terminal at the Port of Liverpool. Phase 2 of the project includes the addition of three ship-to-shore cranes (STS) and ten cantilever rail-mounted gantry cranes (CRMG), enhancing the existing infrastructure from Phase 1, which has been operational since November 2016 with five STS cranes and 12 CRMG cranes. This expansion significantly boosts the terminal’s capacity, allowing it to handle two 380-meter vessels simultaneously, and positions it as a leader in quayside to HGV automated transfer technology in Europe. 

Ayesa was appointed as the lead designer for all structural, civil, and geotechnical works for Liverpool 2 Phase 2. Our scope of work included: 

• Designing a six-meter high, 160-meter long wind wall 
• Structural foundations for 52 container bays and six reefer bays 
• Designing two gantry crane rails and ancillary structures 
• Constructing six steel frame reefer gantries with four levels 
• Installing 1.8km of machine guard fencing and gates 
• Developing new substation structural foundations 
• Undertaking civil works for mechanical and electrical installations 
• Creating approximately 1.5km of terminal road pavements, including swept path analysis 
• Implementing a surface water drainage system with soakaway drainage 
• Installing fire and potable water mains 

Ayesa also provided detailed geotechnical characterisation of the site, which revealed significant deposits of dredged fill, buried spoils, and an old quay structure that traversed the site. These findings complicated the civil and structural design elements. 

Providing sufficient anchorage depth for the renewed 75-tonne mooring bollards was challenging due to the old quay wall’s construction. We solved this by incorporating an innovative spreader plate design, which allowed loads to be transferred to a bearing pile landward of the old quay structure. This approach prevented the need for large reinforced concrete upstands, saving costs and avoiding disruptions to berth operations. 

Initially, Peel Ports proposed founding all key structural elements on deep bored foundation piles to address problematic ground conditions and long-term settlement of dredged infill deposits. However, our detailed geotechnical modelling demonstrated the adequacy of ground-bearing support systems. By using a segmented beam foundation system with movement joints, we accommodated up to 180mm of settlement from the container stacks. Steel shims could then be installed as needed to maintain a level surface over the facility’s lifespan. This strategy eliminated the need for foundation piles, resulting in significant savings of approximately £1.5m. 

During the initial tender design and value engineering phase, we further optimised the structural pavement design to identify additional savings. We zoned the entire site and designated appropriate pavement thicknesses based on traffic loading requirements, focusing on areas with the heaviest plant operations. This targeted design approach brought significant cost savings, particularly in the large empties yard.