Container Terminal Simulation (for TOS and GOS) for the Sohar Freight Facility - Hafeet Rail Project

Discrete Event Simulation & Terminal Operations Optimisation for Hafeet Rail Operations in Sohar, Oman

~50,000 sqm

PROJECT SCALE

Middle East

HINTERLAND ASSESSED

Container Yard

FOCUS INFRASTRUCTURE

2025

PROJECT DURATION

Project Snapshot

The Hafeet Rail Project, a 238 km cross-border railway network connecting Abu Dhabi in the UAE and Sohar in Oman, represents one of the most significant freight infrastructure investments in the Gulf region. To ensure the Sohar Freight Facility is operationally ready to handle projected container volumes, ASCELA developed a comprehensive Container Terminal Simulation covering yard operations, rail handling, truck gate movements, and hardstand utilisation.

The engagement required ASCELA to build a Discrete Event Simulation model using Arena Rockwell Automation software — integrating real-world traffic forecasts, equipment specifications, facility layout data, and operational assumptions to assess terminal efficiency, identify bottlenecks, and test multiple operational scenarios for decision-ready outputs.

The Challenge

Concurrent Multi-Modal Operations

The Sohar Freight Facility handles simultaneous truck and train operations at a shared hardstand, creating complex resource contention dynamics around Reach Stacker allocation, priority sequencing, and container handling capacity that required careful simulation logic.

Peak Hour Congestion

During peak operations, truck waiting times and queue lengths at the hardstand far exceeded the physical queuing capacity that the facility layout could accommodate, creating severe and sustained operational pressure that compounded throughout the operating day.

Reach Stacker Saturation

Reach Stacker fleet operated at near-total utilisation through most of the operating day, leaving no buffer for equipment downtime, maintenance windows, or unexpected demand surges, making the terminal highly vulnerable to operational disruption.

Yard Congestion

The simultaneous movement of trucks and trains through a shared hardstand created recurring congestion within the yard, with containers accumulating faster than they could be processed, progressively reducing available storage space and disrupting the flow of subsequent operations.

What we Delivered

A terminal that looks efficient on paper can collapse under peak load. At ASCELA, we stress-test operations before the first container moves, so decisions on equipment, priority, and layout are grounded in evidence, not assumption.

Discrete Event Simulation Model

A fully integrated Arena-based simulation model replicating yard, rail, and truck gate operations as interconnected processes, capturing equipment interactions, handling times, movement distances, and priority logic derived from the facility's design layout and operational parameters.

Scenario Sensitivity Analysis

Comprehensive scenario testing across variations in Reach Stacker fleet size, handling priority rules, and dedicated resource allocation strategies, providing decision-makers with a clear matrix of operational trade-offs and improvement pathways.

Base Case Assessment

Rigorous simulation of the planned infrastructure configuration, quantifying truck and train turnaround times, Reach Stacker utilisation, hardstand occupancy, gate lane throughput, and queue build-up across peak and non-peak operating windows.

Phased Operational Roadmap

Actionable recommendations on equipment investment, handling priority protocols, truck scheduling adjustments, and layout considerations, structured to guide both near-term operational decisions and longer-term capacity planning ahead of the 2032 demand ramp-up.

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ASCELA is incorporated in India, Singapore, South Africa, and UAE as independent entities.