DOCKZILLA HELPS STEVEDORING OPERATION ADD CROSS DOCK IN A PINCH
A stevedoring company needed to quickly add capacity at the Port Freeport in Brazoria County, Texas as a gap stop when a permanent construction project was running behind. In order to meet the deadline of the first ship arrival, the company needed to be set up to offload shipping containers of fruit onto a cross dock at the port that will then be inspected and leave the port via semi trailers. Dockzilla answered the urgent call with its modular cross dock design that moves from concept to design to install lightyears faster than permanent construction.
Results at a Glance:
- Designed 24-position covered cross dock that could be installed in the parking lot.
- Dockzilla’s steel structure acted as the foundation for the covered cross dock building, all drawings were Professional Engineer (PE) stamped.
- Modular concept allowed Dockzilla to negate manufacturing time by using refurbished components to ultimately transform what was a distribution warehouse into a covered cross dock.
- Utilized split deployment install to get the cross dock up and running in 4 days, and added the canopy in under two weeks while navigating inclement weather.
- TWIC (Transportation Worker Identification Credential) certified Dockzilla team installed inside the secure area at Port Freeport.
Begin Accepting Containers at Port ASAP
Our customer, a stevedoring company, had a hard deadline that permanent construction could not meet. They needed to be ready to accept shipping containers on behalf of a leading fruit company, unload containers and quickly transfer the goods to semis.
Project Must-Haves:
- Mock-speed deployment of built-to-spec cross dock to sub in for a delayed permanent building construction project.
- 24 cross dock positions, 12 on each side of the building, and inclusive of building and all dock equipment.
- Covered loading to protect workers from the hot Texas sun.
- Wind-loaded structure to endure coastal weather.
- Ability to move and reuse structure once construction on their nearby permanent building is complete.
The Solution
Pre-Engineered & Ready to Install
Dockzilla’s modular approach allows us to custom design each project based on our customer’s use case with pre-fabricated building and loading dock components. Time was of the essence in this situation and Dockzilla jumped into action to quickly transform an empty lot at the port into a 24-position cross docking hub, all while racing against the clock to ensure it was operational to handle loads of fruit pre-scheduled to arrive. Dockzilla managed the entire process from engineering to project management and installation.
Steel Structure as Foundation
The modular cross dock, made up of 30 steel platform sections, was engineered by Dockzilla to resist all wind, seismic and forklift loading. No footings were required as the platforms acted as the foundation and were sufficient ballast for all wind loading and uplift.
All Dock Equipment Included
Dockzilla’s cross dock design include all loading dock equipment based on the customer’s specifications. A forklift ramp and edge of dock levelers at 24 dock positions were attached to the cross dock which was surrounded by fall protection safety barriers.
Adjustable to Accommodate Grade
Adjustable base plates on each platform allows the cross dock to conform to the existing concrete. This not only saved time, but the design eliminated significant costs for civil work.
Wind-Loaded Protection
The high-strength canopy over the cross dock protects workers from the elements and is wind-rated for the regular gale force winds at Port Freeport.
Seamless Canopy Integration
A TWIC-certified Dockzilla team minimized the lead time with a split deployment install approach. The cross dock was installed to immediately begin operations and the high-strength canopy was added a week later.
Arrives Pre-Fabricated
Each section was prefabricated for fast on-site assembly. This also means the stevedoring company can quickly dismantle and relocate the cross dock once their permanent building is ready.
The Results
Light Years Faster Than Brick-And-Mortar
When a permanent construction project was delayed, Dockzilla jumped in to fill in the gap with a stand-alone, fully loaded 24-position cross dock at Port Freeport with a wind-rated cover. This ensured that the stevedoring company could receive their critical shipments as scheduled, avoid costly demurrage fees, and never missing a beat when their construction project didn’t go as planned.
Built-to-Spec Solution
Dockzilla engineers worked with the stevedoring customer to design each element of the covered cross dock solution for optimal efficiency. The Professional Engineer (PE)-stamped plan, including the cross dock and all loading dock equipment, was engineered, manufactured and installed by Dockzilla for a seamless integration.
Asset That Can Be Relocated, Reused & Reconfigured
The refurbished, modular steel platforms that were used to quickly stand-up this first-mile cross dock in Texas were previously used to construct a mid-mile cross dock in Florida. And, when the platforms are no longer needed at Port Freeport in Texas, they’re assets that can be reused, relocated and reconfigured to create a stand-alone structure or to create a building extension.
CROSS DOCKING PLATFORM
Dockzilla’s freestanding distribution platforms create high-speed cross docking and transloading capabilities on any property.
DISTRIBUTION WAREHOUSE
Dockzilla’s Distribution Warehouse combines modular buildings and loading dock equipment to stand up a high-speed fulfillment center and last-mile distribution anywhere needed.