A EUROTECH BENELUX COMPANY · A Eurotech Benelux Company QuayQuip is the specialist fendering division or Eurotech Benelux BV. ... brochure and useful utilities

A EUROTECH BENELUX COMPANY

Installation

2© QuayQuip BV, 2014

A Eurotech Benelux Company

QuayQuip is the specialist fendering division or 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 the best 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.

Introduction

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 www.quayquip.com. After registering you can download catalogues, product guides, our corporate brochure and useful utilities.

Tie Rods Engineering the Future

Bollards& Mooring Systems

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© QuayQuip BV, 2014 A Eurotech Benelux Company

General Instructions

QCN Cone Fenders

QCL Cell Fenders

QME Elements

V Fenders

QSA Arch Fenders

QCY Cylindrical Fenders

Torque Values,Caution and Disclaimer



DOs and DON'Ts

Do Don’t

Always check each delivery against the QuayQuip packing instruction and diagrams.

Never open packing until the contents have been identified.

Always store goods in a safe store or compound until required.

Never open packing until needed for installation, to avoid loss on site.

Always carefully remove plywood packing, steel supports, and recycle in accordance with the local laws.

Never use force to open packing.

Always lift the components using the lifting eyes of a soft sling.

Never use hooks or lift truck forks for moving components.

Always lift vertically and check the weights and centre of gravity.

Never drag or scrap the components along the ground.

Always lay components carefully on dry firm ground and supported by dunnage.

Never drop the components or lay them directly onto rocky or waterlogged ground.

Always be prepared with appropriate tools for site assembly prior to installation.

Never perform other works such as welding, grinding or shot blasting in the vicinity of the storage or assembly areas.

Always assemble and transport components laying them face down prior to lifting.

Never assemble the components in situ unless absolutely necessary.

Always use the correct tightening torques.

Never over-tighten, especially rubber fixings.

Note:If at any stage the paint work, galvanizing, rubber or UHMW-PE is cut or damaged during the above processes, QuayQuip should be notified immediately. This should be done in writing with a short report including photographs and description on how the damage occurred. It is quite likely that small damages can be adequately repaired on site and QuayQuip can advise on a suitable repair procedure.

Failure to report such damages, however minor, could lead to a degradation in performance and service life and could invalidate the warranties.

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At QuayQuip, we take meticulous care when packing our goods prior to shipment. Our despatch department routinely make loading diagrams and take photographs of each container as it is being loaded. Before shipment, it is advisable that you ask your nearest QuayQuip office for this information before shipment as this will assist you when unloading on site.

In general, the majority of our fender systems are shipped in 40’ and 20’ open top containers, as this makes it easier to load and unload large bulky items. On receiving an open top container it may be necessary to swing out the door header beam, remove the roof bows and roll back the tarpaulin. This will provide sufficient access for the safe unloading of the goods.

Once the container is opened, a firm flat area of ground should have been made ready for the goods to be stored. The lifting points on each item or package shall be located and all lashing straps to the inside of the container removed prior to lifting.

Components of up to 2,100mm in width can be lifted through the roof of the container. The maximum width that can fit in an open top container is 2,300mm. Components of this size will need to be carefully lifted through the end door and any smaller items that would obstruct this are to be unloaded beforehand. Always ensure the appropriate lifting equipment is used and absolute care is exercised to avoid damage to paintwork during unloading.

Smaller components might be shipped in standard containers with solid roofs. It may therefore be difficult to unload these on site with the lifting plant available. In such circumstances, we would recommend that these containers should be un-stuffed at the port of arrival or a suitable handling facility and the goods transferred onto trucks for ease of unloading on site.

For components wider than 2,300mm QuayQuip ship these on open flat rack containers which are very accessible for unloading.

Any damage that may have occurred during transit should be notified to QuayQuip immediately and photographed prior to unloading the container.

In all cases, if in doubt, please contact your nearest QuayQuip office for instructions on packing, lifting weights and lifting points

Arrival of Goods



QCN Cone Fender Installation Method

It is essential that the anchor bolts are accurately located prior to installation. There are three main types of installation:

1 New concrete with cast-in anchors.2 Steel structures with bolted connections.3 Existing concrete with resin (chemical) anchors.

Whichever type of installation you have, an anchor bolt template will be the most accurate method of locating anchors either in groups or combination. A template should be requested at the time of order enquiry.

Prior to installing the fender, it is advisable that the ancillary components such as chains and brackets are installed. This will make final adjustments to chains easier whilst the crane is supporting the weight of the fender.

Anchor Location

Chain Plate Attachment

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Prior to unloading of the fender components, it is advisable to prepare a suitable hard, flat surface to lay out the fender panel. Fender panels can take up quite a large area and it is worth considering this beforehand to allow access for cranes and personnel.

It is preferable to lay the fender panel face down and on timber battens as this will prevent scuffing of the fender pads and keep the panel clean.

The rubber cone shall be lifted by attaching two eye bolts to the mounting holes and then lifting by means of a 2-legged sling. Care should be taken not to damage or cut the surface of the rubber with any sharp objects during assembly and installation.

The cone should then be lifted and located on the mounting holes on the back of the panel and then bolted into position. The bolts for holding the cone should not be over tightened or even tightened to a specific torque. As a rule of thumb the washer should not bed into the rubber by more than 1–2mm.

Always check the lifting weights before commencing.

Preparation of Panel

Cone Attachment




Once the cone(s) have been fitted, a 2-legged sling can then be used to lift the fender. The fender panel will either have purpose made lifting lugs or upper tension chain lugs can also be used. It is advisable that shackles are used in the lugs prior to connecting the sling.


The first operation prior to lifting will be to lift the top end of the panel and tilt it around a soft fabric type material. This should be situated along the bottom edge to prevent damage to the paint.

Once the fender panel is upright you can then lift it away and slue into position.

Chain Attachment for Lifting

Lifting of Panel

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Before attachment of the fender, always ensure that adequate and safe access has been provided for all instances including inter tidal. Care should be taken when lifting the fender into position to avoid damage to the paint and rubber.

When the bolt holes have been aligned, it is advisable to loosely screw in each bolt using the crane to adjust fine movements. When all bolts are positioned, tighten them in sequence diametrically about the flanges.

It is recommended that the crane should support the fender weight prior to fitting of the fender chains as this will avoid the rubber drooping and will make it easier to tension the chain adjusters. When the chains have been tensioned the lifting sling may be removed.

Any damage to paint should be repaired in accordance with the recommended procedures.

Panel Attachment

Complete Installation



QCL Cell Fender Installation Method

Anchor Location






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Cell Attachment



The rubber cell shall be lifted by attaching two eye bolts to the mounting holes and then lifting by means of a 2-legged sling. Care should be taken not to damage or cut the surface of the rubber with any sharp objects during assembly and installation.

The cell should then be lifted and located on the mounting holes on the back of the panel and then bolted into position. The bolts for holding the cell should not be over tightened or even tightened to a specific torque. As a rule of thumb the washer should not bed into the rubber by more than 1–2mm.




Once the cell(s) have been fitted, a 2-legged sling can then be used to lift the fender. The fender panel will either have purpose made lifting lugs or upper tension chain lugs can also be used. It is advisable that shackles are used in the lugs prior to connecting the sling.





Lifting of Panel


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Panel Attachment





QME Element Installation Method

Anchor Location






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Element Attachment



The rubber elements shall be lifted by attaching two eye bolts to the mounting holes and then lifting by means of a 2-legged sling. Care should be taken not to damage or cut the surface of the rubber with any sharp objects during assembly and installation.

The elements should then be lifted and located on the mounting holes on the back of the panel and then bolted into position. The bolts for holding the cone should not be over tightened or even tightened to a specific torque. As a rule of thumb the washer should not bed into the rubber by more than 1–2mm.




Once the elements have been fitted, a 2-legged sling can then be used to lift the fender. The fender panel will either have purpose made lifting lugs or upper tension chain lugs can also be used. It is advisable that shackles are used in the lugs prior to connecting the sling.





Lifting of Panel


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Panel Attachment





V Fender Installation Method

Anchor Location

Preparation of Fender




Prior to unloading of the fender components, it is advisable to prepare a suitable hard, flat surface to lay out the fender. Fenders can take up quite a large area and it is worth considering this beforehand to allow access for cranes and personnel.

Position the soft sling for lifting prior to assembly.

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Element Attachment


The rubber elements shall be lifted by attaching two eye bolts to the mounting holes and then lifting by means of a 2-legged sling. Care should be taken not to damage or cut the surface of the rubber with any sharp objects during assembly and installation.

The elements should then be lifted and located on the mounting holes on the back of the panel and then bolted into position. The bolts for holding the cone should not be over tightened or even tightened to a specific torque. As a rule of thumb the washer should not bed into the rubber by more than 1–2mm.


Once the elements have been fitted, a sling can then be used to lift the fender.

Always check the lifting weights before commencing and ensure that the sling will not slip off during lifting.



Before attachment of the fender, always ensure that adequate and safe access has been provided for all instances including inter tidal. Care should be taken when lifting the fender into position to avoid damage to the rubber.

Panel Attachment


The first operation prior to lifting will be to lift the top end of the panel and tilt it around a soft fabric type material. This should be situated along the bottom edge to prevent damage.

Once the fender is upright you can then lift it away and slue into position.

Lifting of Fenders

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QCL Cell

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When the bolt holes have been aligned, it is advisable to loosely screw in each bolt using the crane to adjust fine movements. When all bolts are positioned, tighten them in sequence about the flanges.





Sling Attachment for Lifting

QSA Arch Fender Installation Method

Anchor Location


Depending upon whether the fender is vertically or horizontally installed, it is not the easiest of items to lift.

The easiest method is to use a soft sling through the centre which is adequately tensioned to avoid slipping during lifting.




Prior to unloading of the fender components, it is advisable to prepare a suitable hard, flat surface to lay out the fender. Fenders can take up quite a large area and it is worth considering this beforehand to allow access for cranes and personnel.

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QSA Arch Fender Installation Method

Lifting of Fender

The first operation prior to lifting will be to lift the top end of the fender and tilt it around a soft fabric type material. This should be situated along the bottom edge to prevent damage.

Once the fender is upright you can then lift it away and slue into position.


When the bolt holes have been aligned, it is advisable to loosely screw in each bolt using the crane to adjust fine movements. When all bolts are positioned, tighten them in sequence about the flanges.

Fender Attachment




QCY Cylindrical Fender Installation Method

Anchor Location





Prior to installing the fender, it is advisable that the ancillary components such as chain brackets are installed.

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Sling Attachment for Lifting

Prior to unloading of the fender components, it is advisable to prepare a suitable hard, flat surface. Fenders can take up quite a large area and it is worth considering this beforehand to allow access for cranes and personnel.

When ready, a sling can be used to lift the fender.




Lifting of Fender

Fender Attachment

For ease of installation, the support chain or internal bar can be located in the bore of the fender to simplify final assembly.

Ensure that the chain will not drop or fall out during lifting by restraining it.



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It is recommended that the crane should support the fender weight prior to fitting of the fender chains as this will make it easier to attach the chains.

After the chains have been attached, the crane can release the load and the sling can be removed.



Tensioning Force and Torque Values

The bolts shall be tightened such that the bolt torque does not result in the rubber under the lip washer being compressed by more

than 1–2mm.

Molyslip Copaslip or a similar thread paste is recommended where greasing is required.

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Tensioning Force and Torque Values

Size

Bolt Quality

8.8 10.9 12.9 A2 - 50/70 AISI-301 1.4301A4 - 50/70 AISI-316 1.4401

kN Greased Ungreased kN Greased Ungreased kN Greased Ungreased kN Greased Ungreased

M10 26 181 47 38 266 69 45 311 80 18 127 33 M12 38 379 81 55 557 119 65 652 140 26 267 57 M14 52 711 130 76 1044 191 89 1222 223 36 500 91 M16 70 1325 203 103 1946 298 121 2278 348 49 932 142 M18 89 2065 289 127 2941 411 149 3442 481 61 1408 197 M20 113 3328 407 161 4740 580 189 5546 679 77 2269 278 M22 140 5090 554 199 7249 790 233 8483 924 53 1928 210 M24 163 6908 705 232 9839 1003 272 11514 1174 62 2617 267 M27 212 11680 1031 302 16635 1468 353 19467 1718 80 4424 390 M30 259 17448 1400 369 24850 1993 432 29080 2333 98 6609 530 M33 321 26702 1905 457 38030 2713 534 44503 3174 102 8496 606 M36 377 37006 2446 538 52705 3484 629 61676 4077 120 11775 778 M39 451 52811 3165 642 75215 4508 752 88018 5276 143 16803 1007 M42 518 69668 3915 738 99224 5576 863 116.1 6526 165 22167 1246 M45 603 94560 4887 859 134.7 6961 1006 157.6 8146 192 30087 1555 M48 681 120.3 5880 969 171.3 8374 1134 200.5 9800 217 38274 1871 M52 812 171.3 7602 1157 244.0 10.83 1354 285.6 12.67 – – – M56 938 228.5 9454 1336 325.4 13.46 1563 380.8 15.76 – – – M60 1091 309.3 11.79 1554 440.5 16.79 1819 515.5 19.64 – – –

M64×6 1236 397.0 14.24 1761 565.4 20.28 2061 661.7 23.74 – – – M68×6 1411 517.4 17.28 2010 736.9 24.60 2352 862.4 28.79 – – – M72×6 1591 657.2 20.62 2265 936.0 29.36 2651 1095.3 34.36 – – – M76×6 1789 831.2 24.47 2548 1183.8 34.85 2981 1385.3 40.79 – – – M80×6 1999 1037.5 28.78 2847 1477.7 40.99 3331 1729.2 47.97 – – – M85×6 2277 1346.4 34.83 3243 1917.6 49.61 3795 2244.0 58.06 – – – M90×6 2573 1720.0 41.69 3665 2449.7 59.37 4289 2866.7 69.48 – – – M95×6 2898 2181.6 49.56 4128 3107.1 70.58 4830 3636.0 82.60 – – –

M100×6 4465 5177.7 80.37 6359 7374.3 114.46 7441 8629.5 133.94 – – –

[= Nm, = kNM]

To determine the necessary torque values, use the following formula:

MA = k · Fp;d . d

MA required torque, in Nm

Fp;d applicable force, in kN

d core section of the bolt, in mm

k friction factor

k = 0,18 for Hot-dip galvanised screw threads with normal metric thread, clean and dry (ungreased).

k = 0,15 for bolts with normal metric thread, clean and light oiled, like the manufacturer usually deliver.

k = 0,12 for bolts with normal metric thread of which the screw thread and the nut face are lightly greased with a Molyslip screw thread paste (or similar).

The mentioned values are calculated on the base of 70% of the breaking point and a frictional coefficient of 0.12 greased and 0.18 ungreased



CautionLifting and fitting of fenders over water is a potentially hazardous undertaking. This document is for guideline purposes only and is not intended to be used as a method statement or risk assessment for the final installation. This should be carried out by those responsible for the project installation.

Safety is paramount. Always ensure the following:

1 That the applicable Health (Welfare) and Safety Laws of the country of installation are strictly obeyed.

2 Only qualified and competent operatives shall carry out the work and all are wearing appropriate PPE.

3 Cranes and lifting equipment have been professionally assessed for the applicable lift loads and radiuses required to install the fenders, and they are suitable for the local environment.

4 Adequate access, such as scaffolding or staging has been provided for the installation operatives and that it has been duly authorised for use by the applicable regulatory bodies.

Your QuayQuip office is always on hand to advise on packing and individual lifting weights for each consignment. If in doubt please contact: [email protected].

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Disclaimer

Intellectual Property

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.

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.

A EUROTECH BENELUX COMPANY

HEAD OFFICE (NL)Sigarenmaker 14 | 5521 DJ | EerselP.O. Box 61 | 5520 AB EerselThe NetherlandsPh +31 (0) 497 53 22 44 (NL)[email protected]@quayquip.com

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A EUROTECH BENELUX COMPANY · A Eurotech Benelux Company QuayQuip is the specialist fendering division or Eurotech Benelux BV. ... brochure and useful utilities