Yearbook of Engineering Achievement 2023 Entries

Velasco Terminal Berth 8 McCarthy Building Companies, Inc.

Project Location: Freeport, Texas Project Start Date: 6 January 2020 Project Completion: 28 April 2023 Project Team: Port Freeport, McCarthy Building Companies, Inc., Moffatt & Nichol Project Summary: Port Freeport, sixty miles from downtown Houston, is one of the fastest-growing ports in Texas and is undertaking expansion to handle an increased flow of goods. In 2020, Port Freeport hired McCa - rthy Building Companies as the Prime General Contractor to execute the Velasco Terminal Berth 8 expansion–a $129 million project which later grew to $140 million with the addition of a Roll-on Roll-off dock adjacent to Berth 8. McCarthy first had to construct this project’s bulkhead portion, which was a critical component of the Freeport protection levee system and vital for flood control purposes. This infrastructure expansion doubles the capacity of Port Freeport’s import and export operations and allows simultaneous ship-to-shore operations of multiple post-Panamax ships. Impact: Because the Velasco Terminal Berth 8 project site was located on the water, there were many environmental and spill prevention plans in place to prevent leaks from equipment, as well as debris from getting into the water. One interesting aspect of the project modified to allow long- term benefits to the area was the modification of the under-dock slope protection system. Initially, the plan was to place loose rip-rap rock on the slope to prevent material sloughing. After consideration from the project team, it was decided to utilize a fabric formed concrete mattress. This mattress, in place of the rip-rap rock, allows for more connected slope protection and prevents loose rocks from sliding into the dredge template. By doing this, dredging maintenance will be more efficient due to reduced debris in the template in the long term.

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