The Bollard Guide

Trelleborg Marine Systems | Takes the pressure off

Contents
1. Introduction 2. Bollard Range / Technical Information
2.1 Tee bollards 2.2 Horn bollards 2.3 Kidney bollards

1. Introduction
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Whether its a Tee, Horn or Kidney whatever the shape or size of bollard your application requires, Trelleborg has a high-performance option to suit. Trelleborg bollards are precision engineered and manufactured in a variety of metals including premium grade SG ductile iron and cast steel to offer unprecedented levels of service life and resistance to corrosion and impact. We understand that safety is your number one priority. Thats why Trelleborg Marine Systems provide safety-critical bollard, anchoring and xing solutions quickly to our customers bespoke specication. This guide is designed to take the pressure off by providing you with detailed and specic information of our full range of bollard solutions including installation, maintenance and specication advice, plus much more.

3. Bollard Materials and Manufacture

3.1 Design 3.2 Materials 3.3 Micro Structure 3.4 SG Iron Vs Cast Steel Bollards 3.5 Material Specication 3.6 Quality Assurance 3.7 Coating Systems

4. Bollard Selection
4.1 Selection 4.2 Mooring Line Angles

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5. Installation
5.1 Introduction 5.2 Concrete Recess 5.3 Fixing Options

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6. Maintenance 7. Bollard Information 8. Reference Material

8.1 Codes and Guidelines

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2. B  ollard Range / Technical Information

Trelleborg bollards come in many popular shapes and sizes to suit most docks, jetties and wharves. Standard material is spheroidal graphite (commonly called SG or ductile iron) which is both strong and resistant to corrosion, meaning Trelleborg bollards enjoy a long and trouble free service life. The shape of Trelleborg bollards has been rened with nite element techniques to optimize the geometry and anchor layout. Even at full working load, Trelleborg bollards remain highly stable and provide a safe and secure mooring.

2.1 Tee bollards Features

General purpose applications up to 300 tonnes Suitable for steeper rope angles

Features
High quality SG iron as standard Strong and durable designs Very low maintenance Large line angles possible Standard and custom anchors available
1 Tee bollard 2 Horn bollard 3 Kidney bollard
Dimension

Bollard capacity (tonnes) 15 40 235 340 410 335 80 155 160 205 130 30 60 M24 5 500 60 30 40 255 350 450 375 100 175 200 225 150 30 60 M30 5 500 60 50 50 350 500 640 540 150 250 260 320 220 30 60 M36 5 500 70 80 70 380 550 640 550 160 250 280 320 230 15 45 N/A M42 6 800 90 100 80 410 600 790 640 175 325 350 395 245 10 40 80 M42 7 800 100 150 90 435 700 900 750 200 350 400 450 300 10 40 80 M48 7 200 90 500 800 1000 850 225 375 450 500 350 L* L* L* M56 8 300 125 670 980 1200 950 200 475 550 600 350 L* L* L* M56 10 1000 140

A B C D E F G I J K L1 L2 L3 Anchors Qty Anchor length

1000 1000 110 110

P*

P* =bolt protrusion = recess depth L* P  Lease contact Trelleborg Marine Systems for corrosponding anchor locations

[units: mm]

2.2 Horn Bollards Features

General purpose applications up to 200 tonnes Suitable for steep rope angles  Two lines may share a single bollard (subject to bollard capacity)

2.3 Kidney bollards Features

General purpose applications up to 200 tonnes Avoid steep rope angles where possible Suitable for warping operations

Dimension

Bollard capacity (tonnes) 15 40 370 400 410 335 80 155 160 205 130 30 60
M24

30 40 410 440 480 405 100 175 200 240 165 30 60

M30

50 50 500 600 640 540 150 250 260 320 220 30 60

M36

80 70 520 660 650 560 160 250 300 325 235 15 45 N/A
M42

100 80 570 750 800 650 175 325 350 400 250 10 40 80
M42

150 90 585 850 920 770 200 350 400 460 310 10 40 80
M48

200 90 660 930 1000 850 225 375 450 500 350 0 36 36
M56

A B C D E F G I J K L1 L2 L3 L4
Anchors

Dimension

Bollard capacity (tonnes) 15 40 260 340 320 320 220 220 160 160 160
M24

30 40 280 370 360 360 260 260 200 180 180

M30

50 50 320 480 540 540 400 400 260 270 270

M36

80 70 330 530 560 460 320 420 280 280 180 50

M42

100 70 350 550 590 490 175 175 350 450 300 295 195 50
M42

150 80 405 728 760 660 250 250 500 600 400 380 280 50
M48

200 90 435 800 1000 850 300 300 600 750 450 475 375 50
M56

A B C D E F G F+G H I J K L
Anchors

Anchor length 500

500 55 5

500 65 5

800 85 6

800 95 7

1000 105 7

1000 105 8 [units: mm]

Anchor length 500

500 55 4

500 65 4

800 85 5

800 85 7

1000 95 7

1000 105 7 [units: mm]

P* Qty

55 5

P* Qty

55 4

P* =bolt protrusion = recess depth

P* =bolt protrusion = recess depth

3. B  ollard Materials and Manufacture

3.1 Design
Bollards and holding down bolts are designed with a minimum Factor of Safety against failure of 3.0 for SG Iron material grade 65-45-12. Designs are typically based on the following:
BS 5950:2000 BS 6349 Part 2:1988 AS 3990:1993 Structural Use of Steelwork Marine Structures Mechanical Equipment Design

Ductile cast iron is the preferred material for all bollard applications. Grey cast iron is cheaper per unit weight, but the need for thicker wall sections and poor impact strength outweigh this. Cast steel remains popular in some countries but needs regular painting to prevent corrosion.

3.5 Material Specication

Trelleborg bollards are produced to the highest specications. The table gives indicative standards and grades but many other options are available on request.
Material Standards* Grade(s)* EN-GJS-450 or 500 65-45-12 or 80-55-6
Gr 8.8 (galvanised) Gr 8.8 (galvanised) A325 (galvanised)

3.6 Quality Assurance

Bollards are safety critical items and quality is paramount. Independant 3rd party witnessing of test available at additional cost on request. A typical quality documentation package will include: Dimensioned drawings of bollard and accessories Bollard and anchorage calculations (if required) Inspection and test plan  Factory inspection report including certicate of conformance  Physical, chemical and materials properties report for casting and anchorages Installation instructions

3.3 Micro Structure

Ductile Cast Iron BS EN 1563 (Spheroidal Graphite Iron) ASTM A 536 ISO 898 BS 3692 ASTM

Anchor bolts (galvanised)

Ductile cast iron (SG)

Grey iron
Blasting (standard) Blasting (high performance)

Detailed calculations can be supplied on request. Different factors of safety can be used to suit other national standards and regulations.

3.4 SG Iron Vs Cast Steel Bollards

There is a perception that a stronger material means a stronger Bollard. When steel is selected however, the bollards are generally made smaller to achieve the same SWL capacity and safety factors. Smaller Bollards have the disadvantage of having a smaller bend radii for the mooring lines. As longevity of mooring ropes is a factor of their loading cycle and bend radii, decreased mooring line life can be expected. Where cast steel bollards must be used please contact your local ofce for pricing, availability and lead time. It may be possible to utilise the relevant SG iron pattern a cast steel bollard.

N/A ISO 12944

Sweep blast SA2.5

Paint (standard) Paint (high performance)

BS3416 ISO 12944

Non-Coal Tar Epoxy (2 coats)

3.2 Materials
Trelleborg bollards are offered in Spheroidal Graphite Cast Iron (SG Iron), referred to as Ductile Cast Iron, because of its superior strength and resistance to corrosion. Ductile cast iron combines the best attributes of grey cast iron and cast steel without the disadvantages.
Benets Ductile Cast Iron (Spheroidal Graphite) Grey Cast Iron Cast Steel Lowest service life cost High strength Good impact resistance High corrosion resistance Low cost per weight Excellent corrosion resistance High strength High impact resistance Good cost per weight Low strength Low impact resistance Regular maintenance to prevent corrosion Disadvantages

* In all cases equivalent alternative standards may apply. Other high performance paint systems available on request.

3.7 Coating Systems

Bollards are supplied as factory standard with a protective coating suitable for most projects. High performance epoxy or other specied paint systems can be factory applied on request in a choice of colours and thicknesses. Standard available coatings include (uncoated, zinc oxide primer or high performance epoxy). Bitumous coatings (Coal Tar)are no longer commercially available and in most countries no longer allowed in marine installation. They have been discontinued on Trelleborg bollards. Bollard anchors are typically supplied Hot Dip Galvanised (HDG) with a minimum coating thickness of 85 microns. High strength stainless steel anchors may be available on request. Wear and abrasion from ropes means paint coatings need regular maintenance. Ductile iron bollards are far less susceptible to corrosion than cast steel bollards, which can rust quickly and will need frequent painting to retain full strength.

Ductile Cast Iron (Spheroidal Graphite) Lowest service life cost High strength

Grey Cast Iron

Cast Steel

Low cost per weight Excellent corrosion resistance Low strength Low impact resistance

High strength High impact resistance Good cost per weight Regular maintenance to prevent corrosion

The standard material for Trelleborg Marine Systems Bollards is ASTM A536 Grade 65/45/12 Spheroidal Graphite Cast Iron. This material has been selected as it has superior corrosion resistance over cast steel and is the best consolidation of price, performance and material strength.
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Good impact resistance High corrosion resistance

4. Bollard Selection
4.1 Selection
Bollards should be selected and arranged according to local regulations or recognised design standards. The design process should consider: Mooring pattern(s) Changes in draft due to loading and discharge Wind and current forces Swell, wave and tidal forces Mooring line types, sizes and angles Ice forces (where relevant) Mooring loads should be calculated where possible, but in the absence of information then the following table can be used as an approximate guideline.
Displacement Up to 2,000 tonnes 2,00010,000 tonnes 10,00020,000 tonnes 20,00050,000 tonnes 50,000100,000 tonnes 100,000200,000 tonnes Approx. bollard rating 10 tonnes 30 tonnes 60 tonnes 80 tonnes 100 tonnes 150 tonnes 200 tonnes

4.2 Mooring Line Angles

Mooring line angles are normally calculated as part of a comprehensive mooring simulation. Standards and guidelines such as BS6349: Part 4, ROM 0.2-90 and PIANC suggest mooring line angles are kept within the limits given in the table below. In some cases much larger line angles can be expected. Trelleborg bollards can cope with horizontal angles of 90 and vertical angles up to 75. Please check with your local ofce about applications where expected line angles exceed those given in the table as these may need additional design checks on anchorages and concrete stresses.

Suggested Line Angles (BS6349, ROM 0.2-90, PIANC)

Head & stern lines* Breast lines* Spring lines* Vertical line angle (x) * Relative to mooring angle 45 15 90 30 510 <30

over 200,000 tonnes

Where strong winds, currents or other adverse loads are expected, bollard capacity should be increased by 25% or more.

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5. Installation
5.1 Introduction
Bollards must be installed correctly for a long and trouble-free service life. Anchors should be accurately set out with the supplied template. Bollards can be recessed (as shown) or alternatively surface mounted. Once the grout has reached full strength, anchors can be fully tightened. Mastic is often applied around exposed threads to ease future removal.

5.3 Fixing Options

6. Maintenance
Like all equipment in the marine environment, regular inspection and maintenance is critical to achieving maximum life expectancy. Trelleborg recommend a regular scheduled inspection of equipment such as bollards as part of any berth. Key items that need to be focussed on during the inspection and maintenance include:

Fuse bolts available on special request.

1. Paint
Bollards are supplied as factory standard with a protective coating suitable for most projects. High performance epoxy or other specied paint systems are usually applied at the factory on request in a choice of colours and thicknesses. Wear and abrasion from ropes means paint coatings need regular maintenance. Like all epoxy coating systems, maintenance is integral to increasing life expectancy. Trelleborg recommend regular inspection of the bollards

5.2 Concrete Recess

2. Grout
Installation and grout lling requires extra care to avoid damage to factory applied coatings. Similarly regular inspection and possible repair of grout under and around the bollard is critical to the ongoing integrity of bollard performance. Should grout be cracked or damaged it is recommended that it be replaced.

*refer to dimensions tables

Recessing the bollard is generally recognised as superior to surface mounting. Recessing the base prevents the bollard from working loose on its bolts or cracking the grout bed especially relevant for high use locations.

Repair and upkeep of the coating system is dependant upon the coating system selected. Trelleborg try to utilise commercially available coating systems to ensure local products can be sourced and system repair procedures are in line with the coating system manufacturers guidelines.

3. Hold Down Bolts

Hold down bolts are critical to bollard performance. Ensuring correct torque settings will ensure bollards and hold down bolts achieve optimum performance. These are critical to be checked during installation. Visual checks on hold down bolts should be undertaken during regular maintenance to ensure no loosening of bolts has occurred.

4. Bollard Materials
Ductile iron bollards are far less susceptible to corrosion than cast steel bollards, which can rust quickly and will need frequent painting to retain full strength. Regular inspection of the bollard materials is recommended. Trelleborg are happy to assist in providing inspection services on berthing and mooring equipment.
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7.  Bollard Information
Calculations Standard Designs

Bollards are provided with engineering calculations, which describe bolt group pullout forces, shear loadings and bolt tensions.
Jetty Design

Consideration of the suitability of the jetty structure is by others. This includes concrete structure reinforcement for reduced edge distances and shear bracing. Matters concerning the structural requirement of the jetty should be forwarded to the jetty designer.
Jetty Construction Materials

The standard Bollard range has been developed based on the requirements of many facilities throughout the world. Some clients may request different designs based on familiarity, history etc. However the Trelleborg range meets most functional mooring requirements.
Grout

is impossible to calculate actual breakaway load making it highly unpredictable. Numerous injuries, deaths and damage to equipment have occurred due to broken mooring lines and mooring equipment. As a responsible manufacturer Trelleborg Marine Systems will not recommend these types of devices. For more information please contact your local Trelleborg Systems ofce.
Use of Anchor Plates

8. Reference Material
8.1 Codes and Guidelines
ROM 0.2-90 (1990) Actions in the Design of Maritime and Harbor Works BS6349: Part 4 (1994) Code of Practice for Design of Fendering and Mooring Systems PIANC Report of WG24 (1995) Criteria for Movements of Moored Ships in Harbours A Practical Guide (1995) EAU (2004) Recommendations of the Committee for Waterfront Structures PIANC Report of PTC II-30 (1997) Approach Channels: A Guide for Design (Appendix B Typical Ship Dimensions) Ministry of Transport, Japan (1999) Technical Note No.911 Ship Dimensions of Design Ships under given Condence Limits ROSA Defenses Daccostage (2000) Recommandations pour Le Calcul Aux Etats-Limitesdes Ouvrages En Site Aquatique defenses Daccostage PIANC Report of WG33 (2002) Guidelines for the Design of Fender Systems (2002) ETAG 001 (1997) Guideline for European Technical Approval of Metal Anchors for use in Concrete

Trelleborg recommends a non shrink grout, either cementious or epoxy type, with a minimum compressive strength of 60MPa. For Recessed Bollards Trelleborg recommends low viscosity high ow grouts to ensure full penetration around and under the base plate.
Holding Down Bolt Specication

Calculations are based on a concrete strength of 40MPa as this is commonly used at many new facilities. A higher safety factor has been applied to the concrete strength to allow for special variations in jetty structures, which means that it is acceptable to use 30MPa concrete however the safety factor for this part of the system is reduced. Final design of the jetty including steel reinforcement, edge distances, shear bracing and concrete strength is always the responsibility of the jetty designer.
Bollard Selection

The holding down bolts are described in the product list and each general arrangement drawing. The bolts are all ISO898-1 Grade 8.8 and hot dip galvanised, with one nut and washer set. It should be noted that as bollard bolts are so large that the testing criteria in most fastener codes are therefore not applicable. Proportional testing methods are used at half the bolt radius according to ASTM F606.
Holding Down Bolt Grades

Extensive testing by European, Australian and American design institutes has determined that a standard bolt head will produce the same pullout cone as similar bolts with an anchor plate. Trelleborg does not provide anchor plates with their standard bollard systems. Anchor plates may be added if required without any detriment to the system.
Load Testing

Trelleborg does not carry out any physical load testing of Bollards. The Bollards and holding down bolt systems are designed to sustain the applied tension and shear with adequate safety factors and physical testing is considered unnecessary.
Non Destructive Testing

The engineering required to select, locate and orientate Bollards is dependant on a range of parameters including vessel size, local weather, bathometry, currents, tides and the jetty conguration. The analysis to determine the layout of the jetty is the responsibility of the jetty designer and not the Bollard supplier.
Technical Support

Standard Bollards use Grade 8.8 bolts only. Alternative bolt materials can be used but require re-engineering, including calculations and drawings. Any modication to holding down bolt materials should be reviewed and approved by a qualied and certied engineer.
Breakaway Bollards

Each foundry heat is accompanied by a material mechanical property test report to evidence that the material has met the minimum strength requirement. Magnetic Particle Inspections, Die Penetrant Inspection or Ultrasonic Testing may be applied at an additional cost dependent on the extent of testing.

Technical advice, design and enquiries should be directed through your local Trelleborg Marine Systems ofce (see back page for details).

Due to the magnitude of the loads applied to Bollards it is extremely dangerous to have them breakaway in an uncontrolled manner. Due to variations in material properties and tolerances it

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Trelleborg Marine Systems | Takes the pressure off

ASIA PACIFIC Trelleborg Marine Systems Australia Tel: +61 2 9285 0200 tms.australia@trelleborg.com Trelleborg Marine Systems Melbourne Docking & Mooring Group Tel: +61 3 9575 9999 mooringsales@trelleborg.com Trelleborg Marine Systems Asia Tel: +65 6268 8005 tms.asia@trelleborg.com Trelleborg Marine Systems China Tel: +86 1351 532 29988 tms.china@trelleborg.com PT Trelleborg Indonesia Tel: +62 21 797 6211 tms.indonesia@trelleborg.com Trelleborg Marine Systems Japan Tel: +81 3 3512 1981 tms.japan@trelleborg.com INDIA, MIDDLE EAST & AFRICA Trelleborg Marine Systems Dubai Tel: +971 4 886 1825 tms.middleeast@trelleborg.com Trelleborg Marine Systems Docking & Mooring Group Middle East Tel: +971 4 8861825 mooringsales@trelleborg.com Trelleborg Marine Systems India Tel: +91 79 4001 3333 tms.india@trelleborg.com

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Trelleborg Marine Systems Docking & Mooring Group Europe Tel: +44 (0) 7624 462776 mooringsales@trelleborg.com SOUTH AMERICA Trelleborg Marine Systems Brazil Tel: +55 11 5035 1353 tms.brazil@trelleborg.com NORTH AMERICA & CANADA Trelleborg Marine Systems USA (Main Ofce) Tel: +1 540 723 2520 tms.americas@trelleborg.com Trelleborg Marine Systems USA (West Coast) Tel: +1 540 723 2520 tms.americas@trelleborg.com Trelleborg Marine Systems USA (East Coast) Tel: +1 540 723 2553 tms.americas@trelleborg.com Trelleborg Marine Systems USA (Gulf Coast and South East) Tel: +1 540 723 2553 tms.americas@trelleborg.com Trelleborg Marine Systems Docking & Mooring Group North America Tel: +1 720 299 5506 mooringsales@trelleborg.com

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