Long Beach Container Terminal – Overhead Load Protection System
The Challenge
Long Beach Container Terminal (LBCT) operates one of the largest on‑dock rail yards in North America, with more than 48,000 feet of track and round‑the‑clock activity. The yard supports simultaneous operations, including train arrivals and departures, railcar switching, inspections and repairs, and container loading and unloading using six intermodal yard cranes spanning eight working tracks each.
Ground personnel operate in close proximity to moving equipment, including IBC carts, forklifts, pickup trucks, locomotives and specialist maintenance vehicles. When cranes pass overhead, personnel are exposed to serious risks from falling objects such as twistlocks, debris, tools or crane components, as well as the potential failure of suspended containers.
To manage this risk, vendors, maintenance teams and locomotive crews were historically prohibited from entering the rail yard while cranes were operating. While effective from a safety perspective, this restriction limited operational flexibility, complicated planning and reduced overall productivity.
The Innovation
LBCT significantly reduced overhead risk through the implementation of an Overhead Load Protection System. The system creates a safer working environment by restricting cranes from passing over personnel and vehicles in the rail yard.
By physically preventing overhead crane movement above ground crews, the system removes one of the most serious hazards in rail yard operations. In parallel, the solution introduced real‑time monitoring of personnel and vehicle locations across the yard, giving operations full visibility of who and what is moving at any given time.
This marks a shift from reactive, visual oversight to proactive, system‑driven protection—ensuring crane movements are automatically managed to safeguard people on the ground.
How It Was Implemented
Recognising the scale of risk in its on‑dock rail yard, LBCT began researching solutions nearly ten years ago. In 2022, Yardeye was selected as the preferred technology to deliver this safety milestone. Yardeye, originally developed in Germany and later acquired by Mi‑Jack, provided the foundation for real‑time tracking and crane restriction.
Implementation involved mapping the full geographic boundaries of the rail yard, defining operational process flows and identifying mounting locations on cranes and vehicles. Each crane was equipped with more than 20 antennas, sensors and readers, while LBCT and vendor vehicles were fitted with tracking technology supported by GPS, RFID and wireless networks.
Following installation, extensive testing and validation of hardware and software were completed before comprehensive training was delivered to ensure operational readiness. The Overhead Load Protection System went live in April 2025.
What Was the Result
Since commissioning, the system has operated successfully with zero overhead incidents and no safety events related to system operation. LBCT has also reduced downtime and improved planning efficiency, as vendors and service providers can now work safely in the rail yard while cranes remain operational.
Maintenance and repairs can be completed in a single visit rather than split across limited access windows, improving responsiveness and productivity. The system now provides LBCT with continuous visibility of personnel and equipment while actively protecting workers from overhead hazards.
Conclusion
The Overhead Load Protection System represents a step‑change in rail yard safety at Long Beach Container Terminal. By eliminating the need for personnel to work beneath moving cranes, the system reduces one of the most severe occupational risks while simultaneously supporting uninterrupted operations.
This innovation demonstrates how advanced monitoring and automated control can deliver both improved safety and enhanced operational performance in complex, high‑intensity terminal environments—setting a benchmark for large on‑dock rail facilities worldwide.
- Date
- 25/08/2026
