Bollards. Operation & Maintenance Manual A EUROTECH BENELUX COMPANY

Transcription

1 Bollards Operation & Maintenance Manual A EUROTECH BENELUX COMPANY

2 The QuayQuip approach QuayQuip is the specialist mooring division of Eurotech Benelux BV. It designs, makes and commissions engineered solutions for a vast range of marine and port construction applications. Every project makes full use of our collective expertise with steel, rubber and engineered plastics. QuayQuip uses the extensive resources available within the group, its sister businesses and other technical partners. The group enjoys access to over fifty engineers and specialists in disciplines which include: Fender design and applications engineering Mooring systems design Shiploader and bulk materials handling technology Structural analysis including advanced FEA Steel fabrication, casting and forging production Materials experts QA/QC inspection and management systems Third party external design checks Projects undertaken by QuayQuip are professionally designed and managed. Customer satisfaction is our first priority and we live up to our hard-earned reputation for delivery quality, technology and value for money all backed by extended warranties. More about QuayQuip If you want to know more about QuayQuip s other product ranges, or read our latest news, please visit our website at After registering you can download catalogues, product guides, our corporate brochure and useful utilities. Fenders A EUROTECH BENELUX COMPANY Tie Rods Engineering the Future 2

3 Content Introduction to Bollard Maintenance Steelwork and castings Paint Systems and Corrosion Protection Anchors and Fasteners Inspection Schedule Bollard Inspection Form Bollard Incident Report Form Disclaimer 1 Introduction to Bollard Maintenance This manual provides general guidance on inspection and maintenance procedures and routines which, if adopted, will help to ensure long and trouble-free service of the bollards and related hardware. Bollards are usually safety critical items on a quay, wharf or terminal. They are frequently subjected to heavy working loads and environmental extremes. Even the very best bollards require periodic inspection and routine maintenance to continue protecting vessels and structures as designed. The service life of a properly maintained bollard will vary due to many factors. Some of the common causes of bollard damage and reduced service life include: Improper installation of anchors and bollard Damage caused during assembly or installation Mooring ropes Inadequately tightened fixings Excessively tightened fixings Unauthorised modifications Grinding and other works in close proximity to bollards Spillage of paint and solvents Bird guano All inspection and maintenance procedures should be adapted by the user and operator to conform to the relevant or applicable safety, operational and regulatory requirements at local, national and international level. It is strongly advised that mooring and operational procedures at the facility incorporate references to bollard design limits, particularly the bollard working load. 3

4 Despite all reasonable precautions, accidents can still happen. To quickly return the mooring to full service, owners and operators should consider investing in a minimum spare parts package. Apart from a few standard items, bollard are bespoke items and purpose designed for each facility. Bollards take time to manufacture and transport often as long as the original supply so limited spare parts stocks will reduce the risk of disruptions. 2 Steelwork and castings Bollards are not designed for direct contact with ship hulls or berth structures in normal operating conditions. Steelwork does not require any periodic maintenance other than regular visual checks and more thorough inspections after any heavy overload. Inspections should check for signs of damage, loose or missing bolts and corrosion (see Section 3). Overload inspections During accidental and overload conditions applied forces can overstress the steel or casting and cause localised bending, deformation and dents. In most cases this damage cannot be repaired and the bollard must be replaced. Any damage caused by repairs to protective coatings should be made good (see Section 3). The integrity of bollard fixings should be checked to ensure there are no missing, bent or loose bolts. Accidental damage must be made good at the earliest opportunity as continued use without proper repair or replacement of the bollard can cause further damage to both bollard and concrete. This may void any warranty. In case of any doubt, all damage should be photographed and referred to QuayQuip with a report on the circumstances. 3 Paint systems and corrosion protection Bollards are routinely protected from corrosion by high performance paint systems. Paint manufacturers cannot guarantee the precise life expectancy of their paint systems before the first major maintenance in seawater immersion and splash zones. A coating s life expectancy in temperate climates is typically years with normal use and with routine touch-up of local paint damage. In hotter and more corrosive environments, coating life may be reduced. Paint coating type Various paint systems are used according to client specifications and application. Many systems are modified epoxy, to class C5M of ISO 12944, but this may vary according to case. Please refer to the bollard manufacturing drawings or project specifications. In-situ repairs Most paint coatings can, with care, be locally repaired and made good on site. Paint manufacturers often update their formulations and their current recommendations on repair systems should be sought before undertaking paint repairs. Surface preparation requires special care to ensure good adhesion between old and new coatings. Again, advice should be sought from the paint manufacturer on types, procedures. And health and safety requirements should be observed. Quality Control Quality control should be carried out in accordance with the specification and the material supplier s recommendations and datasheets. 4

5 Work should not proceed if any of the controlling conditions in the specification cannot be achieved and maintained. Daily reports shall be completed and filed in preparation for signing off and release Health, safety and environment Operatives should be equipped with suitable protective clothing, gloves, masks and eyewear. Copies of the COSHH Assessments for the materials and safety data sheets should be issued to site operatives prior to work commencing. Only suitably qualified and experienced personnel should carry out paint repair works. All debris should be cleared on a daily or more frequent basis. Empty paint containers should be disposed of in the correct manner. If there are substantial areas of paint degradation, then the bollard should be removed to a suitable workshop, stripped down, blast cleaned and repainted before it is reinstalled onto the berth. 4 Anchors and fasteners QuayQuip bollards are connected to the structure and assembled using galvanised or stainless steel anchors and fasteners. The most common fastening materials are grade 8.8 spun galvanised or 316 (1.4401) stainless steel. Depending on the application and client specifications, other grades and finishes may also be used. In most cases threads are metric coarse pitch. Galvanised fixings Galvanising relies on zinc to provide cathodic protection to the fixing. The spin galvanising process clears threads of excess zinc during manufacture, but also leaves a reduced thickness of zinc (a smaller zinc reservoir to provide cathodic protection). In temperate climates galvanised coatings will provide protection for about 5 years in the seawater immersion and splash zones. In hotter and more corrosive climates this time may be substantially shorter. Once the zinc is depleted, corrosion of the fixing begins and this will weaken the connection. Routine inspections Anchors and fasteners should be routinely inspected for damage and corrosion. In case of any uncertainty, please refer to QuayQuip. 5 Inspection Schedule During the full term of the bollard warranty, annual inspection reports and incident reports should be submitted to QuayQuip to comply with warranty conditions. 5

6 Notes A In addition to periodic visual inspections, a close visual inspection should also be conducted after any berthing incident, mishap or exceptional impact affecting the bollards. The circumstances of each such event should be immediately Maintenance Interval Component Visual Inspections Interim Full See Notes Steel structures Annual As required years A-B-D-E Paint system Annual As required 10 years A-B-D Anchors and fixings Annual As required years A-C-D recorded, in case damage is sustained but not visible or obvious. Any incident report should be submitted to QuayQuip straight away. B C D E Interim maintenance includes localised touch-up of steel paintwork damage caused by mooring ropes, bird fouling etc, as well as repairs to dents and other minor damages caused by accidents, overload or other unforeseen events and factors. Interim maintenance includes retightening of loose fixings (with the addition of locking tabs or other mechanisms to prevent reoccurrence) and replacement of all damaged or missing fixings. Full maintenance follows a detailed inspection and a decision on possible repair, refurbishment or replacement of bollards, coatings and fixings. It is suggested this be carried out in conjunction with a QuayQuip engineer. Unless otherwise specified, no allowances for corrosion of steel are made in the designs. If in doubt on any aspect of inspection or maintenance, please consult QuayQuip. 6

7 Bollard Inspection Form Client s Name Installation Site Year Installed Date Inspected Inspector s Name Inspector s Position Telephone STEELWORK AND CASTINGS NOTES Damage: Wear Yes No Bending Yes No Other deformations Yes No Missing fixings Yes No PAINT AND CORROSION PROTECTION NOTES Minor paint damage Local wear and scrapes Yes No Impact damage Yes No Installation damage Yes No Heavy corrosion & major damage Yes No ANCHORS AND FIXINGS NOTES Correctly tightened Yes No Thread damage Yes No Bent or deformed Yes No Missing fixings Yes No Corrosion (galvanised) Yes No Pitting (stainless steel) Yes No Please return this form duly completed by to QuayQuip Ltd (info@quayquip.com) after each periodic inspection. Failure to provide timely self certified inspections may invalidate fender warranties. CLIENT SIGNATURE 7

8 Bollard Incident Report Form Client s Name Inspector s Name Installation Site Inspector s Position Year Installed Telephone Date of Damage DAMAGED COMPONENTS PLEASE DESCRIBE INCIDENT CIRCUMSTANCES Steel and castings Yes No Paint system Yes No Anchors and fixings Yes No LOCAL CONDITIONS Time of day Tide level Current speed Current direction Temperature Wind speed Wind direction Attach photos, diagram, etc if possible. VESSEL DETAILS Name of vessel Type of vessel Please return this form duly completed within 7 days of each accident or incident by to QuayQuip Ltd (info@quayquip.com). Failure to report damage promptly may invalidate fender warranties. Deadweight Displacement CLIENT SIGNATURE Length Docking Aid used Yes No 8

9 Disclaimer The content of this Guide is provided for information only and without responsibility. QuayQuip BV make no representations about the accuracy, reliability, completeness or timeliness of the information in this Guide. QuayQuip BV may, in its sole discretion, revise the information contained herein at any time without notice. QuayQuip BV s obligations and responsibilities regarding its products are governed solely by the agreements under which they are sold. Unless otherwise agreed in writing, the information contained herein does not become part of these agreements. This Guide does not contain any guarantee or agreed quality of QuayQuip BV products or any warranty of merchantability, fitness for a particular purpose and non-infringement. QuayQuip BV may make changes in the products or services described at any time without notice. This Guide is provided on an as is basis. To the extent permitted by law, QuayQuip BV makes no warranty, express or implied, and assumes no liability in connection with the use of the information contained in this Guide. QuayQuip BV is not liable for any direct, indirect, incidental, consequential or punitive damages arising out of the use of this Guide. Information contained herein is not intended to announce product availability anywhere in the world. Intellectual Property The trademarks, service marks and logos (the Trademarks) displayed in this Guide are the property of QuayQuip BV and/or its affiliates. Nothing in this Guide should be construed as granting any license or right to the Trademarks. Without the express written consent of QuayQuip BV the use of the Trademarks is prohibited. All text, images, graphics and other materials in this Guide are subject to the copyright and other intellectual property rights of QuayQuip BV and/or its affiliates. QuayQuip BV owns the copyrights in the selection, coordination and arrangement of the materials in this Guide. These materials may not be modified or copied for commercial use or distribution. Copyright 2014 QuayQuip BV. All rights reserved. 9

10 A EUROTECH BENELUX COMPANY English A4 Metric v Mooring Systems Fender Systems Floating Structures Port Furniture Castings Steel Fabrications Engineered Plastics Machine Parts HEAD OFFICE (NL) Sigarenmaker DJ Eersel P.O. Box AB Eersel The Netherlands Ph +31 (0) (NL)