What is the effect of vessel call size on terminal operations?

Understanding Vessel Call Size in Terminal Operations

Vessel call size refers to the number of containers exchanged (loaded and discharged) during a single vessel visit to a terminal. As vessels have grown dramatically in size—now exceeding maximum capacity with substantially larger exchange sizes—terminal operations face unprecedented industry challenges. Larger vessel calls create intense peaks in workload, requiring terminals to handle massive container volumes in compressed timeframes. This fundamental shift impacts every aspect of terminal operations, from berth productivity and yard management to equipment deployment and resource planning. Addressing these challenges requires a combination of strategic infrastructure investments, operational adjustments, and advanced planning techniques.

What is vessel call size and why does it matter for terminals?

Vessel call size is the total number of container moves (loading and discharging) handled during a single ship’s visit to a terminal. It’s a critical metric that directly influences operational planning, resource allocation, and infrastructure requirements at container terminals.

Over the years, shipping lines have dramatically increased vessel sizes to achieve economies of scale. The container shipping industry now deploys vessels with substantial capacity and exchange sizes at major hub ports. This evolution has fundamentally transformed terminal operations.

Larger vessel calls matter because they create intense operational peaks that ripple through the entire terminal system. When a mega-vessel arrives, terminals must mobilise significant resources to maintain acceptable productivity and service levels. This concentrated workload affects berth utilisation, yard space requirements, equipment deployment, and labour planning.

For terminal operators, understanding and effectively managing increased call sizes has become essential for maintaining competitiveness. Terminals that cannot efficiently handle larger vessel calls risk losing business to better-equipped competitors as shipping alliances optimise their port rotations.

How does increased vessel call size affect berth productivity?

Increased vessel call size creates complex challenges for berth productivity by concentrating workload into intense operational peaks. This relationship between call size and berth productivity significantly impacts terminal throughput capacity and vessel turnaround times.

With larger vessel calls, terminals face several berth-related challenges:

• Higher quay crane density requirements to maintain acceptable vessel turnaround times
• Extended berth occupancy periods, potentially limiting berth availability for other vessels
• Increased berth utilisation that can lead to vessel queuing during peak periods
• Greater coordination demands between quayside and yard operations

Berth productivity must scale proportionally with vessel call size to maintain acceptable waiting times. Without sufficient quayside capacity, larger calls quickly lead to congestion and extended vessel waiting times at anchorage.

The relationship between call size and productivity isn’t linear. Larger calls demand a more integrated approach to berth management, including optimised crane deployment strategies and carefully planned vessel berthing windows.

What yard management challenges arise from larger vessel calls?

Larger vessel calls create substantial yard management challenges by introducing intensive container flow peaks that must be absorbed efficiently. These sudden surges in container volumes strain yard capacity and operational systems in multiple ways.

The primary yard management challenges include:

• Increased temporary storage requirements as large numbers of containers arrive or depart simultaneously
• Higher risk of yard congestion that can impede horizontal transport between quay and stack
• More complex stack planning to accommodate container groupings by destination, weight, and type
• Intensified equipment utilisation during vessel operations followed by potential idle periods
• Greater difficulty in maintaining optimal yard density without increasing reshuffling moves

These challenges are particularly acute for terminals with space constraints or those using equipment with limited flexibility. With larger vessel calls, the traditional approach of sizing yard capacity for average throughput becomes inadequate—terminals must plan for peak conditions while avoiding excessive investment in rarely-used capacity.

How can terminals adapt their operations to handle larger vessel calls?

Terminals can successfully adapt to larger vessel calls through a combination of infrastructure investments, operational adjustments, and advanced planning techniques. The most effective approach is an integrated strategy that addresses berth, yard, and gate operations as an interconnected system.

Key adaptation strategies include:

• Implementing dynamic berth planning systems that optimise vessel positioning and crane assignments
• Developing segregated yard areas for mega-vessel operations to prevent disruption to other terminal activities
• Adopting appointment systems for external trucks to smooth landside demand during peak vessel operations
• Investing in automation and semi-automation technologies to increase operational flexibility
• Using planning tools to identify and resolve operational bottlenecks before they occur

Terminals successfully handling larger vessel calls typically employ sophisticated tools to test operational scenarios and validate improvement strategies. Strategic investments in staff training and certification programmes are also essential for optimizing performance during peak operations.

Key takeaways: Future-proofing terminal operations for evolving vessel sizes

Future-proofing terminal operations for evolving vessel sizes requires a forward-looking approach that balances immediate operational needs with long-term strategic planning. As vessel sizes and call volumes continue to evolve, operational flexibility becomes a critical success factor.

Essential strategies for terminal operators include:

• Conducting robust scenario planning that accounts for uncertainty in future vessel sizes and call patterns
• Implementing modular development approaches that allow for phased capacity expansion
• Investing in equipment and systems with the adaptability to handle varying operational intensities
• Developing strong interfaces between terminal subsystems to maintain productivity during peak periods
• Establishing data-driven performance monitoring to continuously improve operational response to large vessel calls

Terminal design should be viewed as a long-term exercise that must accommodate at least a 10-year horizon. Given this timeframe, robustness to change becomes essential, especially regarding vessel call sizes and patterns.

By adopting a holistic perspective that considers the entire terminal operation—from berth to gate—operators can develop resilient solutions that maintain performance levels even as vessel call sizes continue to evolve.

If you’re interested in learning more, reach out to our team of experts today.