Smart Berth Systems
Contrary to the belief that the Ports 4.0 concept will introduce sweeping changes, the reality is that most ports will experience a gradual and ‘imperfect’ transformation. While advanced ports like Rotterdam and Singapore serve as models for less developed ports, the majority still depend heavily on manual labour and physical operations which, over time, will be influenced and improved by greater access to data. This means that progress will involve the steady integration of sub-systems, much like assembling pieces of a puzzle, rather than a sudden, drastic overhaul. The pace of change will largely be influenced by the scale of the transition, the cost of modernising operations and also the influences of the labour force in implementing these, especially in ports that are heavily unionised.
To begin with, it’s essential to strengthen the critical interface between ship and port, both on land and at sea, by leveraging a combination of technologies and physical innovations that connect port operations. This enables operators to analyse performance and use data to improve decision-making. These systems integrate assets such as mooring equipment, ship performance monitoring, and navigation systems, all supported by cloud and Internet of Things (IoT) technologies.
Fresh approach
The United Nations Conference on Trade and Development (UNCTAD) has called on port authorities to accelerate the adoption of advanced technologies to enhance clearance times and labour productivity. This push comes as the IMF projects global economic growth – baseline 3.2% over the near term – placing additional pressure on ports to accommodate larger vessels and increased trade volumes. Simultaneously, ports must meet stringent environmental, social, and governance (ESG) requirements to reduce emissions and improve safety.
Upgrading berthing and mooring operations is crucial due to their impact on efficiency, environmental sustainability, and safety. As port operators are well aware, traditional mooring systems using ropes are time-consuming and hazardous, with the significant risk of accidents. For example, the UK Protection and Indemnity (P&I) Club reported in 2016 that 5% of injuries during mooring operations in the preceding 20 years were due to equipment failure.
There are scalable approaches to improving the safety, efficiency and environmental aspects of berthing vessels. Firstly, dynamic line tensioning systems can improve the accuracy of vessel mooring by using situational data to adjust mooring lines, ensuring the appropriate amount of tension is applied automatically to restrain the vessels, therefore narrowing any manual margins of error that could contribute to a rope snapping.
The bigger but more impactful leap for the industry is the gradual adoption of rope-free mooring systems. These use vacuum technology to rapidly secure vessels at berth, reducing motion from external forces and providing live data to improve ports and vessels’ productivity. Although this is a new way of working, the benefits are considerable. A recent Trelleborg study on the use of vacuum mooring systems reported reductions to mooring and turnaround times, fuel consumption and carbon emissions. It focused on an Australian port in the state of Victoria which is subject to tidal constraints and navigation through a narrow channel with limited passing options. Using data averaged over a two-year period from a live feed obtained from a port in the Baltic Sea operating 12 vacuum mooring pads, it identified that mooring times could be reduced from a total of 50 minutes to three minutes.
A different study also demonstrated that the same vacuum mooring solution significantly reduced surge and sway for a container vessel, increasing berth operability from 65% to 95%. Collectively, these significant reductions limit personnel involvement, reduce human error, and enhance safety while drastically cutting fuel consumption and emissions.
Transitioning to automated mooring systems requires a mindset shift among port operators, looking beyond the cost of implementing systems to recognise the longer-term productivity benefits. The development of product specifications and standards to guide the adoption of vacuum-based mooring systems will also be a crucial element in building confidence in making this transition. These guidelines need to be expedited and we would encourage the leadership teams of port operators to recognise the strategic, commercial and regulatory benefits of implementing these new generation mooring systems.
Testing of smart fender designs is underway in two locations – Europe and the Middle East – with fully supply targeted for 2025
Fender design shift
The latest guidelines from PIANC, WG211, represent a significant shift in fender design best practices – encouraging a green port philosophy, and underscoring the importance of considering the lifecycle and recyclability of assets like fender systems. Offering comprehensive recommendations for fender systems, the guidelines stress the importance of rigorous testing, site-specific information and take a whole system approach covering application, engineering, design fabrication and testing, and installation and maintenance. This approach integrates the fender system as an essential component of marine infrastructure. As vessel sizes and port congestion increases, the role of fenders in ensuring maritime safety and operational efficiency becomes critical.
The WG211 guidelines include a dedicated chapter on sustainability, highlighting the importance of integrating environmental considerations into fender design. They encourage the use of sustainably sourced rubber and technologies that reduce the carbon footprint of the fender system. This comprehensive approach aims to enhance environmental stewardship across the industry, ensuring that fender systems not only meet functional requirements but also contribute positively to global sustainability mandates such as the United Nations’ Sustainable Development Goals (SDGs). Many operators might not see this as a priority but demonstrating the sustainability credentials of infrastructure will continue to increase driven by factors such as Scope 3 emissions reporting and broader environmental scrutiny throughout supply chains.
Looking ahead, digitalisation will also help ports to understand their operational conditions better which will result in optimised fender designs, reduced costs, and more efficient port operations. They will become smarter and able to collect berthing data regarding the accuracy and speed of berthing operations.
These data capabilities will assist in optimising fender design and lowering costs. Coupled with improved inspection processes and maintenance schedules, the service life of these assets will also be extended. To drive this, Trelleborg will be prototyping smart fenders in two ports this year. One is based in the Middle East and one is in Europe. We are aiming to supply smart fenders, by 2025, that will be able to capture berthing data which in turn will help with their maintenance and influence future designs. Also, our fenders will have QR codes on them to enable operators to easily access useful information about the system such as manufacturing, design, sustainability and maintenance. It will also send reminders for regular inspections to the end users when these are due.
The future
The maritime industry is undergoing a significant transformation through the integration of IoT technologies, driving efficiency, sustainability, and safety. Innovations such as Trelleborg Marine & Infrastructure’s automated mooring systems and the latest WG211 fender guidelines from PIANC highlight this shift. The future of port development lies in the strategic integration of these advanced technologies and sustainable practices, in addition to ongoing consideration of fender selection and design – taking specific factors such as cyclic conditions into account.
Ports will experience gradual transformation, characterised by incremental integration of sub-systems rather than sudden overhauls. Strengthening the interface between ship and port through connected technologies will enable data-driven decision-making and performance optimisation. By embracing innovations in mooring and fender systems, the maritime industry can achieve significant gains in efficiency, safety, and environmental stewardship, steering towards a more sustainable and efficient future.