Port of Auckland - 4 High Container Stacking Conversion

Client: Port of Auckland

Sector: Port & Logistics

Role: Project Director (Ramy Mekhael)

Duration: 23 Months

Challenge

Port of Auckland needed to increase container terminal capacity to accommodate forecast growth to 1.1 million TEU per annum without expanding the physical footprint of the Fergusson Container Terminal. Achieving this required the complete transition from an ageing fleet of 3-high straddle carriers to a modern 4-high fleet while maintaining operational performance, safety, and business continuity throughout the transition.

Ramek's Role

• Programme leadership and governance across multiple interdependent projects

• Monthly update exec. reporting to the Project Management office (PMO)

• Development & coordination of the overall programme, business objectives, and delivery framework

• Executive stakeholder management and steering committee leadership

• Coordination of engineering, operations, infrastructure, training, and planning workstreams

• Programme risk management and benefits realisation including reduction of operational impact

• Oversight of operational readiness and infrastructure readiness activities

• Direct project leadership for the 4H Straddle Window Wash Tower project

Programme Scope

The programme coordinated multiple enabling projects required to support the transition to a fully operational 4-high straddle carrier fleet, including:

• Transitional workshop facility expansion

• Conversion of automated 4H straddles to manual operation

• Decommissioning of ageing 3H straddle carriers

• Twin-spreader upgrades across the 4H fleet

• Operator training and operational readiness

• Fleet equipment fit-out and deployment

• Straddle wash tower and maintenance infrastructure upgrades

Outcomes

• Established the pathway for the transition to a 100% 4-high straddle carrier fleet

• Enabled future terminal capacity growth from approximately 700,000 twenty foot equivalent (TEU) to 1.1 million TEU annually without increasing terminal footprint

• Increased workshop servicing capacity from 12 to 45 straddle carriers

• Delivered operational, engineering, infrastructure, and training readiness across the business

• Reduced cost of maintaining old straddle carrier fleet

• Improved long-term asset reliability, maintainability, and operational resilience

• Delivered a coordinated programme approach across multiple business units and project teams

Project Impact

The 4 High Transition Programme is a critical initiative in Port of Auckland's long-term container terminal strategy. By enabling containers to be stacked four high instead of three high, the programme significantly increases terminal storage capacity within the existing footprint, avoiding the need for costly & difficult land expansion. Through integrated planning across engineering, infrastructure, operations, and training, the programme positioned the port to accommodate future freight growth while maintaining safe and efficient terminal operations.

Client Testimonial

David Siauw - Portfolio Delivery Manager, Port of Auckland