InstallatIon, operatIon & maIntenance manual
Contents
1. INSTALLATION OPERATION amp MAINTENANCE MANUAL Fender Team on the safe side Welcome to the FenderTeam Installation Operation and Maintenance Manual Fenders are safety critical systems which protect people the environment ships and structures from harm They need to perform on demand as the designer intended for their entire service life even in the harshest locations To do this fenders must be installed used and maintained correctly This Installation Operation and Mainte nance Manual provides guidance and tips for each stage but it cannot cover every possible scenario This manual is intended to complement any local national or interna tional rules and regulations which must take precedence At Fenderleam we want users to benefit from the high quality systems which have been supplied Our specialists are on hand to guide or assist with all matters your local FenderTeam office will be pleased to help Fenderteam is a world class designer and manufacturer of fenders and bollards Our systems are used in ports harbours and terminals around the world and trusted by the largest and most respected consultants contractors and operators We want every FenderTeam product to give trouble free service and optimum performance for many years to come gt gt FENDER TEAM A team of experts all dedicated to providing the best performing and most reliable fender systems and accessories Headquartered in G2. 2 Unroll the fender so it is free to inflate 3 Use fork protectors when moving the fender 4 Keep chocks available to stop the fender rolling as it inflates 5 Ensure the compressor has a dryer dont Request a full instruction manual for fill the fender with moist air pneumatic fenders from FenderTeam The 6 Only lift from the lifting points or from process is simple if these basic rules are the chain and tyre net followed 7 Avoid contact with sharp edges OS Large fender sizes gt 2 5m 1 Small inflation valve Large fenders are fitted with over 2 Valve cap pressure safety valves which can 3 Pressure gauge be at either end of the fender 4 Small hose connector Over inflation of pneumatic fenders 5 Air hose to compressor is dangerous Always use an accu 6 Pressure check valve rate gauge with the correct scale 7 Large inflation valve confirm the required inflation pres 8 Air control valve sure and monitor continuously during inflation Cartyre gauges are not suitable for pneumatic fenders Fender Mooring Tips 4 gt 1 Sling type pneumatics are light and can be affected by rough weather and waves Oversize mooring chains can dampen motions or add ballast weights to chains 2 Only connect chains to the fender end fittings never to the chain net or other part of the fender 3 Constant motions cause vibrations and Shackles or other parts may come loose These should be ef
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4. Re 0 6 Anti galling A4 50 5531 6A 0 6Po3 Not recommended maximum preload is only 0 30y refer to FenderTeam 023 O12 69 136 235 465 811 1297 1947 3124 Not recommended maximum preload is only 0 30y refer to FenderTeam ih Ee pei 0 6Po2 A470 SS316SH as Thread Lubrication Galvanised Fixings Galvanised bolts should be lubricated with a Molybdenum Disulphide MoS grease or paste Oiling is possible but this degrades the marine environment and makes future disma ntling difficult Preventing loosening E ANN 0 23 012 149 291 503 996 1739 2780 4172 6694 Thread Lubrication Stainless Steel Fixings Stainless steel can suffer galling or cold welding Bolts lock and can no longer be tightened or dismantled The old fixing must be cut out and a new one installed Anti gall paste Is strongly recommended for stainless steel bolts Copper based greases and g Ds 2 i others are unsuitable A threadlocking adhesive is the best way to stop fixings from loosening in service It is applied to threads before assembly and only cures anaerobically Many grades are available depending on materials and environ mental conditions but a medium viscosity type such as Weiconlock is preferred Other methods include tab washers locking pins and tack welding bolt heads to the washers For further advice please contact Fende
5. even cause maintenance issues In areas prone to heavy marine growth and strong currents or tides marine growth can increase drag forces or substantially increase the air weight of the fender system Always remove heavy growth for inspection Also make full allowance for increased fender weight due to marine growth when lifting out for major maintenance MAINTENANCE INCIDENT REPORT FORM If any damage is caused to your FenderTeam fender system regardless of cause then this must be reported to FenderTeam immedi ately Failure to do so may affect warranty PORT REPORTED BY PHONE GENERAL Incident date Fender location Suspected cause RUBBER DAMAGE FACE PAD DAMAGE OTHER COMMENTS FOLLOW UP Client Sent to FenderTeam terms Please provide all relevant information as well as photographs and maintenance records where applicable BERTH NAME POSITION EMAIL Last inspection date FENDER PANEL DAMAGE CHAIN SYSTEM DAMAGE PHOTOS file names Please take overview and close up photos submit in high resolution where possible Indicate the file name s and respective fender position s FenderTeam contact Download this form from http www fenderteam com en downloads html MAINTENANCE AFTER SALES amp WARRANTY Fenderleam are committed to providing support and assistance during commissioning and long into the fu ture We offer standard and extended warranties as well as guidance on inspecti
6. safe and successful job Spirally Welded Piles When spirally welded piles are used for Prepare a large enough working area to handle Donut fenders the external weld should and prepare the fenders be ground flat in the area contacted by usua TORRE the Donut bearings from the lowest to grinding or shot blasting l l Support the Donut highest tide levels Protruding welds may fender on bearers and increase wear on the bearings and in ust chocks to prevent some cases can cause the Donut to seize rolling on the pile Use a suitable spreader bar or long leg sling to ensure chains or strops clear the pile during installation Fender weights are indicated on the drawings or are available from FenderTeam Lift the Donut fender using the sling taking care not to damage paintwork or the skin Ensure the Donut fender is hanging vertically before lowering onto the pile Use a tag line to guide the Donut tube over the pile checking to ensure After installation check the Donut fender bearings do not snag on is free to rotate rise and fall with the tide the end of the pile Continue lowering until the Donut floats and ALWAYS the sling can be safely removed Chock the Donut fender when stored wv Grind welds flush on the piling exterior Guide the fender bearings over the piles to avoid snagging v INSTALLATION PNEUMATIC FENDERS 1 Release the straps which hold the fender onto the pallet or skid
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8. 0 09 0009 090090 098 09 09 08 00990 09 06 0 0 09009 090 0 09 00 09 0900 09 09 009 0900 009 08 9 09 00 09 09 09 09 0 0 0 9 0 09 09 090908 00089 090900 00 9 0 00 0 090009 0900909090 0080900000 60 9 9 0 0 9 9 9 0 09 0 0 9 09 0 0 9 9 0 9 9 0909 0 09 00 09 09 9 0 9 0 0 9 9 0 9 09 0 0 09 9 00 09 0900909090 09 09 08 0909 08 9 0 090 09909090 0 9 00 09 090009 09 0990900 00 08 9 0900 09 09 09 09 09 0 9 00 0 09 009 09009 09 0009 00 90 090 000009 0909000900 0080900000 6 9 9 9 9 9 9 9 9 09 0 0 09 9 0 9 9 09 0 9 9 9 09 0 09 00 9 09 9 9 9 0 0 9 09 09 0 09 0 0 0 9 00 09 0009 09 09 0 09 09 08 0 09 00 09 09 0 0 0 090 9 09 0 0 09 0 0 09 09000 09 09 0900 0008 9 09 0 0 9 09 0909 09 0 0 09 0 09 0 090908 0009 09 0900 00 eee reece reece eee ee ee ese eee 60 9 9 0 0 9 9 9 9 09 0 0 9 09 0 0 9 09 0 9 9 9 0 0 09 0 0 9 9 9 0 9 0 0 9 9 0 9 0 0 0 0 09 00 0 0900 09 090 9 09 08 0 09 90 9 09 0 0 09 09 0 9 090 0 09 00 09 09000909 0909090 008 9 0900 09 09 090 09 09 0 9 0 0 0 09 0909 00 009 09 0009 00 9 0 090 0 0000909000 0900008090 000006 9 9 0 9 9 9 9 9 9 0 0 09 09 0 9 9 09 0 9 9 090 0 09 0 09 9 09 9 0 9 0 0 9 09 09 0 9 0 0 0 09 00 0 00 00 098 09 09 08 00900 9 0900 09009090 00900 0 090009 09 0999098 00908 9 09 00 09 09 909 0 0 009 09090 090908 00009 09 0900 00 90 00 000009 0900900908 0900000060 9 9 0 0 9 9 9 9 09 0 0 09 9 0 0 9 9 0 9 9 098 0 09 08 9 09 9 9 9 0 0 9 09 09 0 09 0 0 0 9 00 09 09 00909090 09 09 08 009 909 9 09 0 0 090 0 9 0909 0 09 00 09 09000909 08
9. 009099 08 09089 9009000999 0000000 9 9 9 0 9 0 9 9 0 9 09 0 0 9 09 9 9 09 0 0 9 0 0 9 09 0 0 0 09 0 9 9 0 0 0 09 0989 9 09 0 0 9 09 0 9 09 09 0 9 09 0 0 09 0 0 09 0900 9 09 0 0 0 00 9 09 090 0 0 009 09 090090 09 09 0900 0 0908 09 0908 0 0 09 09 090 0 0 090 009 090 09 0009090000 0908090908 0008909009 0009909090 0 0 60 9 9 9 0 9 0 09 9 9 9 09 9 0 9 09 0 9 09 0 0 09 0 0 9 09 0 0 0 09 0 9 9 008 0 09 0989 9 9 0 0 9 09 0 9 0 09 0 9 09 09 0 090 0 0 0900 9 09 0 0 09 00 9 09 090 0 0 00909 09090909 09009 0900 0008 09008 0 0 09 0 09 0 0 0 090 0909 090 0 0900 0090000009 09 08 0008 9 0909000090 0900000 559 9 9 9 9 0 9 9 9 9 09 0 0 9 09 0 9 09 0 0 09 09 0 9 09 0 0 0 09 0 9 09 0 0 0 0 098 9 09 0 0 9 09 9 9 09 0 0 09 090 0 09 008 000 09 09 0 0 0 00 9 09 090 0 09 00 09 0909090 09 09 09090 00908 090908 000909 090 0 0 090 00 090 0 0900 0090000909 0908 00089 0900900090 55595955 9 9 9 0 0 9 09 9 9 9 09 0 9 09 9 0 9 09 0 9 09 0 0 9 09 09 0 09 09 0 9 9 0 0 0 0 090 9 09 0 0 9 09 0 9 09 0 0 9 09 09 0 090 0 0 0900 09 09 0 0 0 008 9 09 090 00 009 09 09000 09 0 9 0900 0008 099 08 0 0 090 090 0 0 090 009 00 09 0900 0090000089 098 00089 0900909009 00009000 000 55 9 9 9 0 9 0 09 9 9 9 09 0 0 09 0 0 9 09 0 9 9 0 0 9 09 0 0 09 09 0 9 09 0 0 0 0 098 9 9 0 0 9 09 0 9 0 0 0 09 09 0 9 9 0 0 09 09 0 0 9 0 0 0 09 00 9 09 090 0 0 00 09 090 09 0 09 0 9 0900 00908 09 09 00 0 09 09 09 09 0 0 0 090 009 090 09 0900 0090000980 0908 00089 0909000990 000000 595 9 9 9 0 9 0 09 9 9 9 09
10. 09090 00908 9 0900 09 09 009 09 09 0 09 090 0 09 0908 00009 0909009090 0909 090 0000909 0900900099 60 9 9 9 0 9 9 9 9 9 0 0 09 9 0 0 09 09 0 9 9 9 09 0 09 0 0 9 09 9 09 9 0 0 9 09 09 0 9 0 0 09 09 0 0 0 09 0 0 09 090 9 09 08 0 09 90 0 0900 00909090 009000 09000 09 00909090 00908 9 09 00 9 09 9 09 09 09 0 09 090 0 09008 00009 09 0900 08 9 06 090 0000090009 0090008090 00000 9 9 0 0 9 09 9 9 9 0 0 9 09 0 0 09 9 0 9 9 090 0 09 08 9 09 09 0 9 0 0 9 09 0 0 9 0 0 9 09 00 0 00009 090 9 09 08 009 90 9 09 00 0 0 0 9 0909 0 09 090 0 09000 09 00909090 0008 9 0900 09 0900 09 09 0 900 09 090908 00009 09 09009 090 090 090 000090 0900900990 6 9 9 9 9 9 9 9 9 09 0 0 09 09 0 0 09 09 0 9 9 090 0 09 08 9 09 9 9 9 0 0 9 09 09 9 09 0 0 0 090009 09000098 0 09 08 0 09 90 09 0900 0 0909 090 0 09 00 0 09000 09 099068 009 08 9 09 00 9 09 009 0 0 0 9 0 09 0 090908 0000 09 0900 00 9 0 00 0 00009 09009 0900900008 59559 55555555 9 9 0 0 9 9 9 9 09 0 0 9 9 0 0 9 9 0 9 9 98 0 09 08 9 09 9 0 9 0 0 9 9 0 9 09 0 0 0 09 00 09 00009 090 9 09 08 00990 9 0900 090 09 090 0 09 090 09 00009 09 0890900 0008 90900 09 09009 09 09 0 09 009 0 090908 09009 09 0900 08 909 00 000009 090090 0900909008 0900000000 6 9 9 0 0 9 9 9 9 09 0 9 09 9 0 9 09 09 0 9 9 9 09 0 09 00 09 09 9 0 9 0 0 9 09 09 0 09 0 0 0 09 00 0 0900 09 0909 09 09 008 0 09 90 9 09 0 0 0090909 0 0 09 0 0 09 090009 09 0909090 009 08 9 090 0 9 09 0909 09 0 0 09 09090 090908 00089 0909009 00 90 090 0 0900009000 090900809
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12. 9 09 09 0 0 09 0 0 9 0 0 09 0900 9 09 0 0 0 00 9 0 00 0 0 00 09 090 09 0 09 0 09 0900 009098 090908 0 09090 090 0 0 090 00 090 0 0900 0090000989 00089 9009000990 00900006 9 9 9 0 9 9 09 9 9 9 09 0 0 9 09 0 9 09 0 0 09 0 0 9 09 0 00 09 0 9 9 0 0 0 09 098 9 9 0 0 9 09 0 9 09 0 0 9 09 0 0 9 0 0 09 0900 9 09 0 0 09 00 9 09 00 0 0 009 09 090009 0909 0900 0008 09008 00090 90009 090 090 00 0 09009 0909000008 0908 00089 0900900090 00900000 555 9 9 9 0 9 9 9 9 9 9 09 0 0 9 09 0 9 09 0 0 9 09 0 9 09 0 0 09 09 0 9 09 0 0 0 09 0909 9 9 0 0 9 0 0 9 09 0 0 9 09 0 0 09 0 0 09 09 090 09 09 0 0 0 00 9 0 090 0 0 009 09 090 0909 09 0 9 0900 00908 090908 0 0 0909 090 09 0 090 009 09009 0900009000 0008909099 0099000900 000 559 9 9 9 0 9 09 09 9 9 9 09 0 0 9 9 0 9 09 0 9 09 0 0 9 09 0 0 0 09 0 9 9 0 0 0 09 0909 9 09 0 0 9 09 0 9 0 0 0 9 090 0 090 0 09 0900 09 09 0 0 0 008 9 0 090 0 0900909 09000 0909 09009 00908 090908 09 0 09 0 90 0 09090 0909 00 0 0900909 0900000909 08 00089 0900900990 09000000 55 9 9 9 9 09 9 9 9 9 9 0 0 9 09 9 9 9 0 9 9 0 0 9 090 00 09 0 9 09 00 0 09 098 9 09 0 0 9 09 0 9 09 0 0 9 09 0 0 9 0 0 09 000 09 090 0 09 00 9 0 00 09000909 090090 09 09 0900 00908 090908 0 090909 090 00 090 00 0900 0900009000 09908 0908 9090090090 0900900000 Presented by Fender gt Team on the safe side
13. 900 09 09 0 9 09 0 0 009 08 009 08 0 0 009 00 0 09 090 009 00 0 00000000 0800908 0008 090900 0000990000 000 9 9 9 0 9 09 09 9 0 9 09 0 0 9 09 0 9 09 0 0 9 0 0 9 09 0 0 09 09 0 9 9 00 0 09 090 9 09 0 0 9 09 0 9 09 09 0 9 09 0 0 00 0 09 0900 09 0 0 0 0 00 9 09 090 0 0 00 09 090009 09 09 0900 00908 090 08 0 0 9 09 90 9 0 090 009 00 09 09009 09 0900000899 08 00089 0900900090 00000000 559 9 9 9 0 9 9 9 9 9 9 09 0 0 9 09 0 9 09 0 0 0 09 0 9 9 0 0 09 09 0 9 09 0 0 0 09 098 9 09 0 0 9 09 0 9 09 0 0 9 09 0 0 09 00 09 09 090 9 09 0 0 0 00 9 09 090 0 0 009 09 090 09 0 09 0 09 09 00 0 09 009 09 09 009 0 0 09 09 090 0 0 090 009 090 0 0900009000 09090908 00089 0900000990 0900000 9 9 9 0 9 9 09 9 9 9 09 0 0 09 9 0 9 09 0 0 09 0 0 9 09 0 0 09 09 0 9 9 0 09 0 0 098 9 9 0 0 9 09 9 9 09 0 0 9 09 09 9 09 0 0 09 090 0 9 0 0 0 0 008 9 09 090 0 0 00909 0909090 09 009 0900 0008 090908 0 09 09 09 90 0 0 090 00 090 09 09009 09 0900009089 0908 000809 0900900090 000 55 9 9 9 0 9 09 9 9 9 9 09 0 0 9 09 0 9 09 0 0 09 0 0 9 9 0 0 09 09 0 9 09 0 0 0 09 098 9 09 0 0 9 09 0 9 09 09 0 9 09 0 0 9 0 0 09 00009 0 0 0 0 00 9 09 090 0 09009 09 0909090 09 09 0900 0008 090908 090090 090 0 09 090 009 090 0 0900009000 00890908 0008 9 09009 0009000000 006 55 9 9 9 0 9 0 09 9 0 9 09 9 0 9 09 0 9 09 0 9 09 0 0 9 09 0 0 0 09 0 9 9 0 0 0 09 09 0 9 9 0 0 0 0 0 9 09 09 0 9 09 0 0 0909 00 09009 09 09 0 00 008 9 09 090 9 0 00909 090009 09 09 0900 0008 09008 00 09 0 090 00 090 0909 00 09 0900909 0900
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15. arance between the boom tip and block been considered and is it sufficient Is the crane operator experienced and qualified Has a qualified crane signal person been assigned and a method of communication between the crane operator and signal person established Is someone assigned to control the load with the use of a tag line Is the area clear of obstacles including power lines pipelines and unnecessary personnel crane operator signal person supervisor and other relevant people Has there been a pre lift meeting between the u wv This checklist is provided for guidance only A project specific checklist should always be prepared by the contractor responsible for fitting the fenders INSTALLATION INSTALLATION EQUIPMENT Always use the correct equipment for fender preparation and installation This is important for safe working and avoids unnecessary damage to the fender ALWAYS Use undamaged and certified lifting equipment Use soft slings with lifting eyes for handling rubber and painted items E Check weights and centroids before lifting m Use suitable shackles when lifting from v padeyes Use spreader beams to avoid excessive angles on slings or chains Ensure that components are stable and cannot fall before removing slings Check that ground conditions are firm enough for crane operations NEVER Use makeshift tools that were not designed for the job Use unnece
16. cessful job Check the template against the fender bolt pattern brackets and other bolted parts Accurately locate the anchors on the structure according to the design Template drawings or ready to use templates are available from FenderTeam Prior to placing the main fender system it is suggested to install ancillary items like brackets and support chains Clean out sockets and check all threads before offering up the fender system Prepare a large enough working area to preassemble fenders well away from any cutting grinding or shot blasting Place the fender panel face down supporting it on suitable bearers to protect PE pads and paintwork Lift the FE elements into position with soft slings or eyebolts and hooks Take care not to damage the rubber Fit all bolts through the fender flange using the special washers Tighten bolts until the washer embeds 2 3mm into the rubber Fit suitable shackles to the lifting points on the panel and connect a chain sling of suitable size Component weights are indicated on the drawings or are available from FenderTeam Place protective materials under the bottom of the panel where it rotates Ensure the lifting area is clear and that it is safe to start lifting Commence the lift and rotate the panel until it is vertical Long panels may require a double lift using a second crane Tag lines can be used to control the panel when
17. close inspection should also be made after any incident which may have damaged the fenders or supporting structure Always record the event cause and conse quences immediately Where there is clear damage this should be reported to FenderTeam immediately using the form on page 28 2 Interim maintenance will include but is not limited to the repair of any cuts and surface damage to the rubber Paint spills should be removed by water jetting Accident damaged rubber units with deep cuts or clear signs of overload should be immediately replaced Please consult FenderTeam for advice 3 Interim maintenance will include touching up of paintwork where underlying steel or primer is exposed according to paint manufacturers instructions Close attention should be paid to edges where ropes may abrade also around chain brackets Bird droppings can aggressively attack paint and if this is an ongoing issue bird spikes or similar should be fitted Repairs to dents and other minor damage should be carried out with careful attention paid to cause and possible loss of strength as a result 4 Interim maintenance will include replacement of worn UHMW PE pads in particular all pads with remaining wear allowance insufficient to last until the next scheduled maintenance Close attention should be given to cuts and heavy localised wear often caused by inappropriate or poorly maintained ships Pad fixings should be renewed when new pads are fitted takin
18. dentified Y N V1 Se bt LEELIRLLL See SC I BE CCE gt X lt Very High Risk gt 10 js Each hazard should be ranked according to its likelinood Events may occur in isolation or combine to create another identifiable event The judgement of likelihood could be based on experience similar activities or other criteria Severity Outcomes for people the environment and property should be considered separately Likelihood and prioritized SAFETY UNLOADING AND STORAGE Fenderleam pack every shipment with the greatest care Fender components are often transported in 20 and 40 containers Open top and flat rack containers may be used to make unloading easier Any container parts that could obstruct the unloading of goods should be removed or rolled back A level clean and dry area of ground should be prepared in readiness to store the Shipment after unloading Locate all lifting points before beginning to move items and remove any packing straps Parts up to 2 1m across can be removed vertically from open top containers Parts between 2 1m and 2 3m in width will need to be extracted via the end opening after first removing any smaller parts in the way Always use appropriate lifting equipment for each component taking great care to protect any paintwork or vulnerable parts while lifting Smaller pa
19. e cr Well maintained fenders will remain safe last 2 Life Cycle Management of Port Structures longer and cost far less than the disruption Recommended Practice for Implementation caused by loss of use or claims following a breakage MAINTENANCE MAINTENANCE CHECKLIST It is advisable to prepare a checklist for In the event that fender damage is identified routine preventative maintenance The table during a maintenance inspection please below is a suggested template for collecting contact FenderTeam for advice this information GENERAL General condition Excellent Good Average Poor Very Poor RUBBER FENDER PANEL tussim em eeese maes UHMW PE FACE PADS CHAINS Seek ee sire COMMENTS PHOTOS file names FOLLOW UP Download this form from http www fenderteam com en downloads html MAINTENANCE INSPECTION PERIODS An inspection and maintenance programme is needed to identify maintenance wear and damage as well as the likely causes at an early stage Three levels of inspection and maintenance are recommended The table LEVEL 1 Close visual inspection eye seyans INSPECTION AND MAINTENANCE PROGRAMME Rubber fenders Steel panels frames Other fender steelwork Corrosion protection systems UHMW PE face pads Anchors amp bolts Chain shackles amp adjusters Valves and end fittings Marine growth Notes 1 A
20. e clean and v free from contaminants NEVER Unpack before components are needed except for visual check of quality and quantity on receipt Risk damage by using unnecessary force Move goods with unprotected lift forks or hooks Drag components over the ground x Weld grind shot blast or similar near the storage area or assembly site SAFE LIFTING Lifting and manoeuvring large fenders from the shore or from floating platforms is a safety critical operation Where there are large tides or strong currents the lift must be carefully planned and executed to be completed in a short time window Er claw HR LUN ass Eee Mo F ids Fumo m mc Rango am oen Se Wal cana CRITICAL LIFT PLAN A lift plan should be prepared for every case taking account of the worst combinations of lifting requirements and potential hazards Theassembled weight of the complete fender system should be checked on site before the final lift is attempted SAFETY Large lifts often require multiple cranes for stable support of large loads In marine projects where access can be limited many lifts require a large outreach Suitable cranes must be selected with care to consider site access and ground condi tions Lifting capacity should be considered at pick up swing and set down radius PRE LIFT CHECKLIST Is the crane configured according to the lift plan wv Has the crane been inspected and is its conditi
21. ent should always be carried ry out to determine the hazards and most suitable PPE Depending on the location and type of work additional PPE should be worn such as gloves safety glasses and shoes earplugs or ear defenders hard hats respirators coveralls high visibility vests safety harnesses and personal flotation devices PFDs Safety boots SAFETY E Project No Task Activity EUM UU EE Date Prepared Hazards Likelihood Severity RISK ASSESSMENT Erojeetaitie wn A A X oz e Ref Key hazards associated with this activity task Likelihood Severity Score gt 2 Falling from height SS 3 Fallingintowater SSS lifting objects with acrane 7 Collisions with plant or materials o Crane collapse ortoppling Frequent ar event likey to occur many times SSS ETT ENTE Catastrophic rio el loss or irreversible environmental available as an 5 Excel spreadsheet Severe injury occupational illness major system Serious damage or reversible severe environmental damage template for Injury requiring medical attention illness system FenderTeam damage or mitigatible environmental damage customers Possible minor injury minor system damage or minimal environmental damage During fender installation maintenance and Risk Matrix operation each activity or task should be A matrix is commonly used to assess risks considered and individual hazards i
22. ents and associates do not accept the responsibility or liability for any errors and omissions for any reason whatsoever reason When using this technical manual to develop a design customers are strongly recommended to request a detailed specification calculations and certified drawings from FenderTeam specialists prior to construction and or manufacture FenderTeam constantly strives to improve the quality and performance of products and systems We reserve the right to change specification without prior notice All dimensions material properties and performance values quoted are subject to normal pro duction tolerances This manual supersedes the information provided in all previous editions It should also be used in conjunction with current FenderTeam product catalogues If in doubt please consult FenderTeam Flag 2015 FenderTeam AC Germany This manual is the copyright of FenderTeam AG and may not be reproduced copied or distributed to third parties without the prior consent of FenderTeam in each case FenderTeam is a Registered Trade Mark of FenderTeam AG Date 03 2015 Version IOM Manual EN 02 NOTES 9 9 9 9 9 9 9 9 09 0 0 09 9 0 9 9 09 0 9 9 09 09 0 09 08 09 09 9 9 9 0 0 9 09 0 0 09 0 0 0 9 00 0 0900 09 098 09 09 08 00900 9 0900 0909090900 0900 09 090009 09 09899090 00908 9 09 00 9 09 9 09 09 09 0 09 0090090908 00089 09 09009 00 9 06 090 0 0000909009 0008090000 00 0 9 9 0 0 9 9 0 0 9 0 0 09 9 0 0 09 09 0 9 9 0
23. ermany and with local offices in France and the USA plus a network of well established local representatives FenderTeam has earned a reputation as a reliable partner in the international port harbour and waterways markets Fender we are specialists in the design manufacture and sale of fenders and fender systems Team our team of partners employees reputable and approved suppliers all share one ethos a passion for fenders and to serve the port industry Collectively we have decades of experience and specialized knowledge in this niche market which is highly safety critical to people ships and port infrastructure Our skills and know how ensure well engineered fender solutions high quality products and fair prices CONTENTS SECTION 1 SAFETY Risk Assessment Unloading and Storage Lifting SECTION 2 INSTALLATION Installation equipment Setting out Anchors Grouts Bolts SPC Cone and CSS Cell Fenders FE Element Fenders V Fenders and FE V Fenders Cylindrical Fenders Foam Fenders Donut Fenders Pneumatic Fenders Hydropneumatic Fenders SECTION 3 OPERATION Installation Acceptance Report Operations Limits Operations Checklist SECTION 4 MAINTENANCE Maintenance Maintenance Checklist Maintenance Inspection Periods Incident Report Form CONTENTS 05 06 07 08 09 10 10 11 12 13 14 15 16 17 18 19 20 22 23 25 26 27 28 SAFETY SAFETY During the installa
24. fectively secured using suitable split pins tie wires locking nuts tack welds or threadlocking adhesive see p11 to prevent loosening 4 Where the structure could abrade the fender body then it should be fitted with PE pads or timber rubbing strips to reduce wear and tear 5 Where mooring chains contact the corner edge of a structure rubber tubes should be fitted around the chains to prevent them from abrading the concrete and to help protect the galvanised finish 6 To reduce sideways drift of fenders with long mooring chains at high tides when the mooring chains are slack make one chain longer or add some ballast to one side INSTALLATION ALWAYS Ensure at least two fenders are in contact with the moored ship Inflate the fender with dry air NEVER Permit excessive fender motion which may cause snatch in moorings HYDROPNEUMATIC FENDERS Please ask FenderTeam for the Hydropneu matic fender instruc tions before inflating the fender or deploy ment Hydropneumatic fenders require some special techniques to install add the ballast weight and to trim the fender to the correct draft by water filling The performance of Hydropneumatic fenders is affected by the air water ratio and the initial pressure FenderTeam can provide site training and supervision on request OPERATIONS INSTALLATION ACCEPTANCE REPORT When installation is complete FenderTeam require an Installation Accep
25. g care to use the correct size and material grade of bolts nuts and washers 5 Interim maintenance will include retightening of loose bolts and anchors Any missing locknuts locking tabs or split pins should be replaced at the same time The correct preload should be applied to fixings The effects of surface corrosion on friction and bolt torques should be considered If in doubt then consult FenderTeam for advice 6 Interim maintenance will includes measurement of chain link and shackle diameter particularly in the inter tidal zone Reference should be made to design corrosion allowances Components must be changed if diameter is likely to reduce below permitted minimum before the next scheduled maintenance Special attention should be given to weak links where fitted as these are smaller diameter Initial pressure pneumatic fenders Every month 7 MAINTENANCE gives average periods for temperate climates These should be more often in harsh environ ments such asthe tropics If you are uncertain about any aspect of inspection or mainte nance please consult FenderTeam LEVEL 2 LEVEL 3 Interim Major mainte Notes maintenance nance or overhaul 4 6 years Every six months 1 2 years and must protect other parts of the chain system from damage in the event of overloads 7 The initial inflation pressure of pneumatics should be monitored and adjusted every month If pressure drops gradually or unexpectedl
26. it is near to vertical Make certain that all fixing points are accessible particularly where there are large tides Use tag lines to help guide the fender into position avoiding damage to rubber and paintwork Align the bolt holes and loosely assemble all the bolts or nuts Tighten fixing equally on opposite sides It is mandatory that the crane should support the fender system until chains are connected and adjusted ALWAYS Check anchor positions before fitting fenders Use the correct fixings and washers Provide a safe working area for assembly Protect paintwork from damage during lifts Clean sockets and test fender bolts for fit Loosely assemble all bolts before tightening Use the proper lifting equipment Tighten correctly for rigid or elastic connections INSTALLATION SX SX P AND FE V FENDERS The following procedure is generic for the assembly and installation for all types of FenderTeam V and FE V fenders The actual fender design may vary from case to case FenderTeam are available to assist with defining the best sequence and precautions to ensure a safe and successful job Check the template against the fender bolt pattern brackets and other bolted parts Accurately locate the anchors on the structure according to the design Template drawings or ready to use templates are available from FenderTeam Prepare a working area away from cutting grinding and other possibly harmful operati
27. list is provided on the fender general arrangement drawing Please refer to this if possible when discussing spare parts with FenderTeam Top chamfer Tension chain Quay structure Chain anchor EN ve 5 b Chain LY X bracket Chain tension r Rubber fender Rubber fender anchor Weight chain S UHMW PE facing d Fender panel Shear chain MAINTENANCE The reasons for preventative maintenance Asset management is a systematic process of operating maintaining upgrading and 1 Safety and reduced risks disposing of assets cost effectively in a 2 Early identification of damage manner which benefits all users by adopting 3 Reduced operational costs a long term philosophy The foundations of 4 Less berth disruption an asset management system are defined in 5 Warranty remains valid ISO 55000 6 Fewer claims and less aggravation 7 Extended service life The goal of any maintenance programme is to avoid or reduce the consequences of failure of equipment whilst maintaining safety at all times and achieving this at the lowest cost This can be achieved by preventing a failure before it occurs with planned inspections and replacements FANY Report n 103 2008 By routinely recording equipment wear and tear it is possible to replace or repair worn components before they cause a system failure An ideal preventive maintenance program would ensure zero downtim
28. o fast at high temper atures The temperature of the concrete is also critical When damp conditions are expected please inform FenderTeam so that the correct grout can be supplied Not all grouts are suitable for installation in wet or damp locations Typical Curing Time Standard Grade Temperature of base concrete Gel time Dry base Wet base Typical Curing Time Express Grade Temperature of base concrete 1 Cartridge tempature should be at least 5 C Ensure icing does not occur in the hole Gel time Dry base Wet base Capsule Grout Systems M30 max cass BOUL rcc ERN capsules are i also available qup There is minimal waste but the capsules are easily broken if mishandled They are best suited to smaller anchors up to M30 size Please refer to FenderTeam if glass capsules are required for larger anchor sizes ALWAYS Check and confirm the required grout volume v for each anchor hole Verify that the drilled hole depth and diameter v is within tolerance Check the inside temperature of the concrete v and consider cure times Support anchors centrally in the hole and S prevent grout leakage with a seal NEVER Use broken or damaged glass grout capsules Use cartridges after grout has begun to cure X Install anchors when temperatures are too low for the grout to cure BOLT TIGHTENING Fender fixing bolts and anchors should be tightened correctly Too loose and they
29. ocate anchor bolt positions in the structure Templates are not intended to support the weight of anchors Always refer to the general arrangement drawing when preparing a template In the past templates have been made on site from steel or plywood Bolting Template Fender System OOo OOo FenderTeam can also provide templates printed on plastic coated fabrics These are dimensionally stable and can also be rolled or folded They are light enough to send by post or courier INSTALLATION TEMPLATE HOLE SIZES The correct hole size should be used in templates It is commmon to drill a smaller hole as a pilot to identify the position of the anchor and guide the drill for the full size hole After the template is removed the correct diameter hole can be drilled CAST IN ANCHORS Most new concrete structures use cast in anchors These should be placed in the correct location and secured to prevent movement during concrete pours A temporary bolt or stud is preferred for holding the cast in anchor into formwork and avoids the permanent assembly bolt from being lost or damaged Temporary stud washer amp nut e P4 27 Z 7 dimn I I 2 Formwork POOU OOU MMM K La PP Z D I P P Y eb E Ly d 7 LL f 4 s PA M20 M72 Y Avoid electrical 2 Pa contact i i NAIL PLATES Nail plates are a simple and effective way to support cast in anchors The
30. on acceptable Has the rigging equipment been inspected secured and is it in acceptable condition Is the supporting surface stable P Are proper crane mats placed under outrigger floats and at a 9o degree angle to the outrigger cylinders V Are crawler cranes on proper crane mats Are outriggers if applicable fully extended with tyres off the ground Is the crane within 1 of level Has the levelness of the crane been checked with a 1 metre or longer carpenter s level or other acceptable method The v target level in the crane cab can be used for initial leveling but should not be considered reliable for critical lifts Is the exact fender weight known P Is the location of the center of gravity of the load known and the crane hook positioned directly wv above it Was the load radius measured exactly For heavy lifts has the potential increasing load radius due to deflections in the boom tyre and or carrier been considered Was the boom length determined exactly P Was the boom angle determined exactly P Are wind conditions acceptable Typically if wind speeds exceed 40kph 25mph the lift should not be attempted Ideally wind speeds should not exceed 20kph 12mph Is the rope reeving balanced to prevent boom twist Is the rigging capacity acceptable Is the weight of the rigging known P Has the clearance between the boom and the load been considered and is it sufficient Has the cle
31. on and maintenance programs to ensure our fender systems always provide the best performance and protection The standard warranty period is 12 months from installation or 18 months form shipping date although longer warranties are available on request Performance guarantees are available if the option of fender performance testing is carried out Extended paint warranties can also be provided In all cases the warranties given are subject to berth operators conducting periodic inspections in accordance with FenderTeam recommendations and the timely submission of reports and photographs This allows any Issues arising to be detected early rectified and monitored Warranties do not cover accidental damage normal wear and tear visual appearance or the effects of environ mental degradation over time In the unlikely event of a valid claim for faulty materials and or workmanship FenderTeam will repair or replace the defective components Compensation values cannot exceed the cost of supplied materials less any reduction for normal use and in no circumstances are costs of removal or reinstal lation or any consequential costs or losses accepted It is recommended that users adopt an asset management system based on ISO 55000 or PAS 55 DISCLAIMER Every effort has been made to ensure that the technical specifications product descriptions and design methods are correct and represent current best practice FenderTeam AG subsidiaries ag
32. ons Place V fenders on their flanges and allow them to recover from small distortions induced during shipment which will assist with anchor alignment later Mount UHMW PEor steel panel to Fender head SX P only See page n for bolt tightenery Pass a soft sling around the front and inside faces of the fender away from the flanges Component weights are indicated on the drawings or are available from FenderTeam Lift the V fender from the sling taking care not to damage the rubber Place protective materials under the end of the V fender where it rotates FE V fenders are best assembled in a wooden cradle The PE shield is placed centrally and the individual FE elements are lowered into position Bolts should pass through the PE shield with the nut on the element side Always use the correct washers to distribute loads and do not over tighten the bolts as this could damage the PE shield Pass a soft sling around the front and inside faces of the fender away from the flanges The assembly weights are indicated on the drawings or are on request from FenderTeam Raise the FE V fender carefully from the cradle using the sling taking care not to damage the rubber or PE shield Place protective materials under the end of the FE V fender where it rotates Align the bolt holes and loosely assemble the bolts or nuts using the special washers provided It is recommended that the crane sho
33. pe class y 7 Deadweight Co S Displacement tonne Length overall metres Breadth metres Laden draft metres Air draft metres Bow flare degrees Beltings Special features Berthing speed m s Berthing angle deg Draft limited approach open semi open closed Rubbergade Fenderdrawingna VIO ww Download this form from http www fenderteam com en downloads html OPERATIONS OPERATIONS CHECKLIST It is advisable to carry out a berth inspection collecting this information In the event that before vessel arrival and after departure fender damage is identified please contact The table below is a suggested template for FenderTeam for advice PRE ARRIVAL INFORMATION wsdmme TO mojvsewo O mea we PRE ARRIVAL BERTH INSPECTION Pilot yes no Vessel yes no Linesmen linesmen yes no Risk mitigation measures taken POST DEPARTURE BERTH INSPECTION aa E R ee Download this form from http www fenderteam com en downloads html MAINTENANCE MAINTENANCE When maintaining a fender system it is All moulded rubber fender units and steel important to use the correct terminology panels are identified with a job specific serial This avoids confusion when ordering spares number These should also be identified when ordering spare parts The full parts
34. permanent bolt may need to be longer to allow for the recess caused by the nail plate s thickness ansa dur c ac WUT SY x 1 d ud d d y LX Avoid electrical contact between anchors and concrete reinforcements INSTALLATION RETROFIT ANCHORS Existing structures may require retrofit anchors These are threaded studs which are bonded into drilled holes using high strength resin grout Always refer to the FenderTeam drawings to confirm details of hole depth and diameter andforthe size and quantity of grout capsules required per hole Cartridge Grout Systems Cartridge grout systems are available in standard and express fast cure grades in different cartridge sizes and in coaxial or standard tubes Manual pneumatic electric and battery powered cartridge guns are available depending on the size of the job and grout volume per hole Clean the hole with a nylon brush and blow out any remaining debris of the correct diameter and depth Blow out debris Push and rotate the anchor stud into the hole Clean any grout leakage immediately Inject the correct volume of grout Refer to manufacturer instructions on temperatures Fenders or brackets should only be connected after the grout is properly cured Allow the grout to cure Refer to table for cure times at different temperatures Grouts will not cure if the temperature is too low or they will cure to
35. rTeam INSTALLATION SPC CONE AND CSS CELL FENDERS The following procedure is generic for the assembly and installation of SPC Cone and CSS Cell fender systems The actual fender design may vary from case to case FenderTeam are available to assist with defining the best sequence and precautions to ensure a safe and successful job ALWAYS Check the template against the fender bolt pattern brackets and other bolted parts Accurately locate the anchors on the structure according to the design Template drawings or ready to use templates are available from FenderTeam Prior to placing the main fender system it is suggested to install ancillary items like brackets Chains may be connected to the panel or structure first Clean out sockets and check all threads before offering up the fender system Prepare a large enough working area to preassemble fenders well away from any cutting grinding or shot blasting Place the fender panel face down supporting it on suitable bearers to protect PE pads and paintwork Lift the SPC or CSS fender into position with soft slings or eyebolts and hooks Take care not to damage the rubber Fit all bolts through the fender flange using the special washers Fit suitable shackles to the lifting points on the panel and connect a chain sling of suitable size Component weights are indicated on the drawings or are available from FenderTeam Place protec
36. rom FenderTeam Lift the cylindrical fender assembly by the sling taking care not to damage the rubber To allow slack in the supporting chains offer the cylindrical fender up to the berth face higher than its final mounted position Connect the shackle to the support brackets not forgetting to insert the split pins Slowly lower the cylindrical fender until its chains are tight Check that the chain angle is equal on both sides of the fender INSTALLATION FOAM FENDERS The following procedure is generic for the assembly and installation for OceanGuard fender systems FenderTeam are available to assist with defining the best sequence and precautions to ensure a safe and successful job ALWAYS Check the template against the fender bolt pattern brackets and other bolted parts Accurately locate the anchors on the structure according to the design Template drawings or ready to use templates are available from FenderTeam Clean out sockets and check all threads before offering up the fender brackets Install the support brackets prior to placing the fender system Prepare a large enough working area to handle and prepare the fenders well away from any cutting grinding or shot blasting Support the fender on bearers Connect all support chains to the end termination shackles It is useful to identify each chain if the system has more than one chain at each end Fender
37. rts and assemblies will usually be sent in closed containers These can be easier to unstuff at the destination port or other nearby facility then the goods sent by van to site optionally a flatbed or open top trailer for better access on request Very large parts above 2 3m across are usually shipped on open flat rack containers which simplify access for lifting Please inform FenderTeam immediately of any damage incurred in transit before goods are unloaded The shipping insurer will require clear photographs and statements to determine liability and settle claims In the rare event of serious damage to the cargo the insurer may choose to send a surveyor to inspect and record the damage Minor coating damage due to transport local handling or installation is normally the contractors responsibility to touch up and should be carried out after installation unless the affected areas will be submerged or hard to access If you are in any doubt or have further queries please contact your FenderTeam office ALWAYS Check the delivery matches the shipping v documents and diagrams Remove and recycle packing and support v materials Store goods in a safe enclosure until they are needed Use soft slings with lifting eyes for handling rubber and painted items Check weights and centroids before lifting Support goods on suitable bearers on dry level ground Avoid damage to paintwork Check threads and sockets ar
38. ssary force which may cause damage Move goods with lift forks or hooks x Drag components over the ground x Weld grind shot blast or similar nearthe storage area or assembly site Lifting Chains or Slings Ensure the correct number length and capacity of lifting chains or slings are available for each lift Fork Protectors Avoid damage to rubber fenders and paintwork with fork protectors Sockets and spanners Always use the correct size purpose made spanners and sockets Flogging Spanners can help when tightening large fixings Prybars Use prybars with care to align fixing holes or align parts using a centre pin or dowel SETTING OUT New concrete structures use cast in anchors to securely mount the rubber fender unit chain brackets and other assemblies Existing structures use retrofit anchors bonded into post drilled holes For all structures it is essential to position the anchors correctly to match the hole locations on the fender assembly It is also necessary to avoid interferences with obstacles such as reinforcement bars Any electrical contact between anchors and reinforcement bars will form a galvanic cell when water is present and this can promote corrosion Cast in anchors should be electrically isolated from other permanently embedded steel in the structure Retrofit anchors are usually insulated by the resin grout annulus TEMPLATES A template should be used to correctly l
39. tance Report IAR to initiate the warranty period Failure to provide an IAR may invalidate or delay warranty claims mokr e www mens we we DELIVERY DATE BERNER WARRANTVPEROD sa ee INSPECTION OF Contractor FenderTeam Fender spacing Fixings correctly installed and tightened ERN MI Droop and sag of fenders within limits Fender positions serial numbers recorded Face pads and fixings undamaged ft All paint damage touched up Spare parts inventory checked SNAGGING LIST Contractor FenderTeam Damage noted to Rubber Steel fabrications Paintwork PE Pads Brackets Chains and accessories Anchors bolts and other fixings Actions SIGN OFF contactor wm B B Download this form from http www fenderteam com en downloads html E HOE LL id She sc KERRY OPERATIONS Ports should have clear operating practices and procedures This is especially important for the safety critical berthing mooring and departure process It is vital that all berth users are made aware of the performance limits of fenders and operate safely within these Safe practices and procedures should be developed for each port and where appli cable for each berth or terminal within the port With respect to fenders this should include Identifying hazard s to personnel vessels and port s
40. tion operation and CONSTRUCTION SITE maintenance of fenders there are a number of potential hazards A Safety Management System SMS provides the framework for identifying these hazards assessing the probability they could happen and the Unauthorised entry to this site is strictly forbidden consequences or outcome for personnel the environment structures and ships An SMS may also include financial exposures Safety management is all about under standing risks and adopting strategies for eliminating reducing or monitoring them Many techniques are used to mitigate risks High visibility clothing must be worn which might otherwise result in unexpected loss or harm A matrix is commonly used Om Eye protection must be worn combinations is then categorised according to the likelihood it might occur and the where each hazard either alone or in possible outcome or severity of an event Each hazard Is given a risk score with suitable measures or procedures to minimise risk and maximise safety No hat No boots No entry PERSONAL PROTECTIVE EQUIPMENT Eve protein h M Personal protective equipment PPE is worn to minimise exposure to serious M workplace injuries and illnesses which may result from contact with physical mechanical chemical electrical or other site hazards High visibility 4 coveralls 1 Everyone entering a working area i should be properly equipped A RN assessm
41. tive materials under the bottom of the panel where it rotates Ensure the lifting area is clear and that it is safe to start lifting Commence the lift and rotate the panel until it is vertical Long panels may require a double lift using a second crane Tag lines can be used to control the panel when it is near to vertical Make certain that all fixing points are accessible particularly where there are large tides Use tag lines to help guide the fender into position avoiding damage to rubber and paintwork Align the bolt holes and loosely assemble the bolts or nuts Tighten fixings equally working diametrically until the washer embeds 2 3mm into the rubber It is recommended that the crane should support the fender system until chains are connected and tensions are properly adjusted Check anchor positions before fitting fenders Use the correct fixings and washers Provide a safe working area for assembly Protect paintwork from damage during lifts Clean sockets and test fender bolts for fit Loosely assemble all bolts before tightening Use the proper lifting equipment Tighten correctly for rigid or elastic connections INSTALLATION FE ELEMENT FENDERS The following procedure is generic for the assembly and installation of FE element fender systems The actual fender design may vary from case to case FenderTeam are available to assist with defining the best sequence and precautions to ensure a safe and suc
42. tructures The likelihood of a hazard arising m Reviewing the consequences and outcome should an identified hazard occur Preparing a risk analysis Mitigating these risks where possible Ongoing training of all personnel who are unavoidably exposed to any degree of risk Regular operational reviews to identify new or changing risks Fenders need to perform faultlessly when called upon to protect a port structure ALWAYS Make a visual check of fenders before a ship arrives at the berth Check that the arriving ship is within the design limits of the fender Ensure that the Master and pilot are aware of safe berthing speeds and angles Make provision for escalating events such as deteriorating weather Monitor fenders and moorings regularly whilst a ship is on the berth Allow mooring lines or hull protrusions to snag on fenders Allow ships to berth on damaged or worn out fenders Permit non essential personnel near fenders during berthing OPERATIONS OPERATIONAL LIMITS Fender and mooring operating parameters These parameters should identity the safe should be available to all berth users pilots limits of fenders bollards and other dock linesmen Harbour Masters arriving vessels furniture The table below is a suggested and others involved in the berthing and template for summarising this information mooring process wm meww VESSELS Min Ship Max Ship Other ship Ty
43. uld support the V fender until all bolts are tightened ALWAYS Check anchor positions before fitting fenders Use the correct fixings and washers Provide a safe working area for assembly Protect paintwork from damage during lifts Clean sockets and test fender bolts for fit Loosely assemble all bolts before tightening Use the proper lifting equipment Tighten correctly for rigid or elastic connections CYLINDRICAL FENDERS INSTALLATION The following procedure is generic for the assembly and installation of Cylindrical Fender systems The actual fender design may vary from case to case FenderTeam are available to assist with defining the best sequence and precautions to ensure a safe and successful job ALWAYS Accurately locate the anchors on the structure according to the layout on the GA drawing Template drawings or ready to use templates are available as an option on request from FenderTeam Clean out sockets and check all threads before offering up the fender brackets Install the support brackets prior to placing the cylindrical fender Prepare a large enough working area to preassemble fenders well away from any cutting grinding or shot blasting Place the fender on bearers and pass a soft sling through the bore Very long fenders may require a spreader beam Pass the support chain bar or bracket through the fender bore Component weights are indicated on the drawings or are available f
44. weights are indicated on the drawings or are available from FenderTeam Lift the OceanGuard fender assembly by the sling taking care not to damage the skin A spreader bar or beam is recommended for long fenders To allow slack in the supporting chains offer the OceanGuard fender up to the berth face higher than its final mounted position to ensure there is some slack in the primary weight support chains Connect the weight support chains to the support brackets and insert the split pins into the shackles Large chains are heavy and may require extra cranage to assist connection Lower the OceanGuard fender and check that the chain angle is equal on both sides When the fender is correctly positioned connect any additional chains Chock OceanGuard fenders during storage to prevent rolling Fill voids in sheet pile impans to create a flat surface Install protective strips or facings over abrasive dock surfaces to reduce fender wear Consider adding ballast chains weights etc on floating installations to dampen fender motion Consider asymmetric chain lengths to maintain fender position if long mooring chains are used INSTALLATION DONUT FENDERS The following procedure is generic for the assembly and installation for all types of FenderTeam Donut fenders The actual fender design may vary from case to case FenderTeam are available to assist with defining the best sequence and precautions to ensure a
45. will undo too tight and they may fail There is no absolute bolt torque for every case This depends on the material surface finish toler ances and lubrication Elastic connections ie fender flanges must be treated differently to rigid connections ie fender brackets Fender Flange amp Embedded Connections When panels are fixed to embedded sockets inserts in the rubber e g SPC SX P fender INSTALLATION head then the connection should be tightened snug tight until the fender head and panel are flush Then use a flogging hammer to apply 1 8 to 1 4 turn to the bolt head Apply Loctite medium or equiv When fender flanges are being fixed there Is no defined torque A special washer is used to spread the clamping forces in the rubber The bolt should be tightened until the washer embeds 2 3mm into the rubber Bolts should beretightened by aquartertohalfaturn after seven days to allow for rubber relaxation Rigid Connections The table below is for guidance only and assumes the nut or female thread are stronger than the bolt High end friction values are assumed If the friction is lower this may result in less preload than intended Lubrication assumes that both the male and the female threads are thoroughly coated Bolt class Lubrication Preload Grade46 Oiled Friction Thread Head M20 Torque Newton metres or Nm 2348 6 047 047 8o 156 269 532 929 1484 2227 3570 2595 cen
46. y this can indicate a leaking valve or small puncture which should be replaced or repaired immediately Please consult FenderTeam for detailed procedures 8 Full maintenance should be carried out when paint coatings corrosion or damage demand removal of the fender systems for a more thorough overhaul The oppor tunity should be used to dismantle the fender system replace worn components repair damage and to shot blast and repaint all steelwork Special attention should be paid to the rubber fender units in particular any signs of ozone cracking Overhauls also provide the opportunity to rotate fenders on the berth moving heavily used systems to areas which are less used and vice versa Please consult FenderTeam for advice on major maintenance and overhaul to confirm spare parts availability and the optimum scope of works A FenderTeam engineer will visit site if required 9 Most design specifications do not include corrosion allow ances Therefore the deterioration of pain or galvanising coatings will inevitably increase steel stresses 10 Interim maintenance should include the replacement of the inflation valve and cap This can usually be done in situ with the appropriate tool and without first deflating the fender 11 Major maintenance of pneumatic fenders includes dismantling of the end fittings valves and replacing these components Chain and tyre nets should also be overhauled or replaced 12 Marine growth can hide or
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