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Trelleborg Marine Systems

Super Cone
SCK Cell
Installation Manual
Ref. M1108, v1.0-EN
www.trelleborg.com/marine
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INTRODUCTION
M1108, v1.0-EN
Trelleborg AB, 2008
Assembly and installation
Precautions must be taken when handling and installing all types of fendering systems. Prevention of damage and
correct installation will maximise the system performance and life cycle.
This manual is prepared as a guide in handling, assembling and installing Super Cone and SCK Cell type fender systems.
Attach fender to the frontal frame
Mounting the fender system
Installing the chain
Chain anchors and anchor installation
Anchor and U-anchor installation
The type of fender foot anchor and chain anchor is
dependant on the following:
Existing or new structure
Steel or concrete structure
Prefabricated or built in-situ
Site conditions
The most commonly used systems are as noted below.
Systems for special applications will be detailed on the
construction drawing that are provided for each individual
project.
Existing concrete structures
Type EC1 anchors are normally used:
Core a hole in the structure of the diameter and length
as noted on the project construction drawings.
It is important that these dimensions are followed as
the chemical anchors are sized to suit the detailed
dimensions.
Thoroughly clean out the hole with pressurized air and or
brushes to remove all dust, debris and moisture.
Insert the chemical resin into the core hole.
Insert the steel anchor into the hole whilst rotating
between 200300 revolutions per minute and ensuring
the anchor is fully inserted into the hole during rotation.
B
B
B
B
B
B
B
B
B
Rotate for approximately 10 seconds or until additional
torque is required to rotate the anchor due to the
chemical anchor setting.
Anchors should be left for between 2448 hours before
fenders are attached.
New structures
Type NC3 anchors are normally used:
The anchors should be frmly fxed to the formwork and
tied to the reinforcement to prevent movement during the
concrete pour.
Theads should be cleaned and lubricated with water
resistant grease before installation of bolts or nuts.
Location of xings
A template should be used to ensure anchor points are
accurately positoned.
B
B
B
B
Check anchor quantities before
installation begins
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INTRODUCTION
M1108, v1.0-EN
Trelleborg AB, 2008
Use a template to
mark the anchor
bolt positions on
formwork.
Refer to project construction drawing
for bolting positions.
Anchor location
(6 bolt system).
NC3 anchor
EC2 anchor
Cast-in anchor for new concrete.
Anchor for existing concrete.
Always use a bolting
template
Typical xing detail for fender foot.
For full anchor details please see the
Trelleborg Marine Systems Catalogue,
Section 9: Accessories.
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ASSEMBLE FENDER TO FRONTAL FRAME
M1108, v1.0-EN
Trelleborg AB, 2008
Place the frontal frame face down to the ground and supported on timber bearers.
With the assistance of a crane lift the rubber fender on to the top of the frame ensuring that all bolt holes are aligned.
Insert one bolt at a time and only turn enough to ensure the threads are engaged and in line.
Once all bolts are loosely inserted and holes aligned tightening may be commenced. Firmly fasten all bolts and then
torque down ensuring that adjacent bolts are not tightened in sequence.
Torque settings are shown on the attached sheet for the various bolt sizes.
Timber
Facing
panels
Supplementary
wire rope
Sling to
crane
Steel
washer
Turn the fender head
facing downard and
lower the fender to the
collar plate.
Loosely ft all nuts before tightening
Align the bolt holes
position and tighten the
bolts to the fender.
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ASSEMBLE FENDER TO FRONTAL FRAME
M1108, v1.0-EN
Trelleborg AB, 2008
Have timber and bolster material
on hand before lifting
Bolster
(belt, hemp
sack, etc.)
Chain
Alternate
lifting points
Ratchet
lever
hoist
Nylon
sling belt
Chain
Support
(timber, etc.)
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MOUNTING THE FENDER SYSTEM
M1108, v1.0-EN
Trelleborg AB, 2008
Always use nylon lifting slings
Always use a nylon sling when lifting or supporting any rubber fender.
Attach the lifting chain or wire rope to the lifting point on the frontal frame and another to the nylon slings ftted
around the fender.
The lifting chain lengths should be adjusted to ensure the fender base will align with the face of the structure and the
top of the frontal frame is level.
Once the fender is aligned with the cast-in anchors insert one of the top bolts not used for bracing, ensure that the
fender foot washer is ftted before loosely tightening the bolt into the cast-in anchor ensuring the bolt is straight and the
threads aligned. Remove brace when at least one bolt is attaching each element to the wharf.
Loosely ft all bolts and washers into the cast-in anchors. Tighten all bolts in asymmetrical order until the rubber
under the foot washer is compressed 23mm. Bolts should not be tightened beyond recommended torques in the
attachments.
Fully support the fender during the above process and whilst connecting the necessary chain systems.
Alternate
lifting point
12mm depth
Lift the frame and
fender to the anchor
mounting positions.
Fasten the bolts
and tighten them in
asymmetrical order.
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INSTALLING THE CHAIN
M1108, v1.0-EN
Trelleborg AB, 2008
Tighten weight chain
while system is fully
supported
A typical chain assembly is described below:
Chain arrangements other than described may be applicable and these will be as detailed on the fender system
construction drawings.
Layout the chain system on the wharf beside the fender system and ensure all components are available and assembled
in the correct order.
Measure between the frontal frame chain cleats and the chain fxing points on the wharf face and ensure the chain as
laid out on the wharf will suit the measured dimension. In some installations chains are supplied with excess links which
may be required to be removed.
Check that the chain system fts the wharf and frontal frame chain attachement points.
Loosely install the chains between the frontal frame and the wharf chain mounting points.
Lift the frontal frame 1 to 2% higher than the fender height and then tighten the weight chain.
Loosen but do not remove the frontal frame support from the crane.
Adjust the weight chain to ensure the frontal frame and fender are aligned with no sag of the fender under the frontal
frame weight.
Tighten the tension and shear chains as much as possible without rotating the frontal frame. A sag in the tension and
shear chains that would allow the frontal frame to rotate 50mm is acceptable as long as the frontal frame is sitting
vertically. If frontal frame is not vertical the tension/shear chains will require to be tightened until the frontal frame is
vertical.
When all chains are ftted and adjusted the supports to the fender and frontal frame may be removed.
Once all bolts are tightened and chains installed touch up any damaged paintwork.
B
B
B
B
B
B
B
B
B
B
1 to 2% of
fender height.
Tensioning
device
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HOW TO HANDLE FENDERS
M1108, v1.0-EN
Trelleborg AB, 2008
Never rest the rubber on a rough
surface
Never rest or drop a rubber fender
on its side
Bolster
Never wrap rope, chains or wire
ropes around a fender for lifting.
Always use a nylon sling.
Bolster
Nylon sling
only
Never lift a fender with forklift tines
against the fender body.
Fenders can be lifted by properly
attaching temporary slings to the
bolt mounting points.
Always use the correct handling equipment
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DISCLAIMER
M1108, v1.0-EN
Trelleborg AB, 2008
Trelleborg AB has made every effort to ensure that the technical specifcations and product descriptions in this
catalogue are correct.
The responsibility or liability for errors and omissions cannot be accepted for any reason whatsoever. Customers are
advised to request a detailed specifcation and certifed drawing prior to construction and manufacture. In the interests
of improving the quality and performance of our products and systems, we reserve the right to make specifcation
changes without prior notice. All dimensions, material properties and performance values quoted are subject to normal
production and testing tolerances. This catalogue supersedes the information provided in all previous editions. If in
doubt, please check with Trelleborg Marine Systems.
Trelleborg AB, PO Box 153, 231 22 Trelleborg, Sweden.
This catalogue is the copyright of Trelleborg AB and may not be reproduced, copied or distributed to third parties without
the prior consent of Trelleborg AB in each case.
Fentek, Rubbylene and Orkot are Registered Trade Marks of Trelleborg AB.
www.trelleborg.com/marine
tms@trelleborg.com
Trelleborg AB has made every effort to ensure that the technical specifcations
and product descriptions in this catalogue are correct. The responsibility
or liability for errors and omissions cannot be accepted for any reason
whatsoever. Customers are advised to request a detailed specifcation and
certifed drawing prior to construction and manufacture. In the interests of
improving the quality and performance of our products and systems, we
reserve the right to make specifcation changes without prior notice. All
dimensions, material properties and performance values quoted are subject
to normal production and testing tolerances. This catalogue supersedes the
information provided in all previous editions. If in doubt, please check with
Trelleborg Marine Systems.
Trelleborg Marine Systems is part of Trelleborgs Engineered
Systems Business Area and specialises in the safe berthing
and mooring of vessels within ports and harbours, on offshore
structures and in waterways around the world.
We bring together the industrys best known and respected
brands for fendering and mooring systems with the unrivalled
collective experience and knowledge of its sales and
engineering staff. Our customers beneft from great choice and
helpful support at every stage from initial concept and detailed
design right through to supply, commissioning and after-sales
service all provided by our network of regional offces and
local agents.
Presented by
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Tel: +1 540 667 5191
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tms.middleeast@trelleborg.com
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tms.scandinavia@trelleborg.com
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Tel: +34 945 437 906
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UK
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Harbour Marine
Tel: +61 3 9575 9999
sales@harbourmarine.com