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ASSEMBLY GUIDE

B.P 53 – LES PRAIRIES DE GRAND’VILLE – 44250 SAINT BREVIN LES PINS FRANCE PHONE : 33 (0) 240 391 840 FAX : 33 (0) 240 270 247 For more details visit www.marinemegastore.com or call 0871 8732404

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THE seven steps

UNLOADING FLOATS ASSEMBLY FRAMES TURNOVER LAUNCHING FRAMES ASSEMBLY GUIDING RINGS AND ACCESSORIES INSTALLATION GANGWAYS INSTALLATION RESULT

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UNLOADING DOCKS AND FINGERS FRAMES UNLOADING Docks and fingers are delivered in trucks or containers. To facilitate the docks assembly, three steps are to be followed. More often than not, frames are already turned on the right side, ready to put on the ground for the floats installation. If it is not the case, it is necessary to do this during the unloading process.

1st step : Lifting points. Lifting points have to be balanced on the frame : - docks : place straps over the last crossbars as shown in the diagram below. - fingers : - use the rubber blocks and the extremity ring when placing the straps. - use 4 cleats (4 holes) positioned on the superior rail. (ÂŤ hammer head Âť bolts diameter 16mm length 40mm)

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2nd step : Lifting. Once the lifting points are positioned, it is possible to lift the frame with straps. An appropriate crane must be used with sufficient capacity to lift the frames and to carry them the distance to the launching area. Docks and fingers are unloaded the same way.

3rd step : Positioning for insertion of the floats.

To go faster, the frames are positioned on the ground upside down. In this configuration, floats can be easily and quickly inserted into the frame. Rubber blocks and fingers connecting pieces will be assembled after the turnover of the frames.

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GANGWAY UNLOADING Gangways are unloaded following a specific process: lifting points, lifting, storage.

1st step : Lifting points. Gangways are loaded on the right side, you do not have to turn them over. Lifting points are indicated directly on the upper handrails. As for the frame, the balance is very important.

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2nd step : Lifting. This is a delicate step as the truck has to move forward while the crane remains still. 1/ The crane lifts the gangway and keeps still 2/ The truck moves forward

1

2

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2

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3rd step : Storage. The storage of the gangway is very easy.

Next step will be the launching of the gangway with the dock which will receive it.

FLOATS UNLOADING AND STORAGE Floats are easier to unload. They are easy to maneuver and stock. When unloading, we recommend classifying the floats by type for easy installation on the frames. A drawing with floats sizes is furnished.

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FLOATS ASSEMBLY This is probably one of the most important step of the process. The positioning of the floats is calculated regarding the stability and the floatability required. So the positioning may vary and a layout drawing corresponding to your project is furnished.

Standard positioning of the floats for a 40 feet long dock :

Standard positioning of the floats for a 23 feet long finger :

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Floats are fitted into the extrusion on one side and bolted on the other side on an angle iron. They are maintained with small grooved extrusions, bolts and safety nuts.

Fitted into the extrusion

Installation methodology is the following : - floats insertion - drilling - bolting

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1/ Floats insertion.

Bolted on an angle iron

Fitted into the extrusion

2/ Drilling.

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3/ Bolting. You are now going to fix the floats on the frame. Once this operation done, the frames can be turned over.

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FRAMES TURN OVER When the floats are assembled, the docks are turned over and ready for the launching. The turn over process is as follow : 1/ Lifting points positioning (see 1st step page 3) 2/ Lifting 3/ Storage on the right side LIFTING TURNOVER STORAGE

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LAUNCHING Docks, fingers and gangways launching process can be divided in four steps. - straps positioning - lifting - launching - on site transport

Straps positioning : Next step is to strap the docks for the launching. A balance placement of the straps is necessary and they must be placed down the frame between the floats.

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Lifting : As for the unloading process, the balance positioning of the straps is vital for easy and safe handling.

Launching :

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On site transport: Once in water, the frame can be transported to its final destination. A small boat is enough for this. We recommend to attach the frame on the side of the boat.

DOCKS TRANSPORTATION

Accessories are laid down the frame and the cleats are pre-installed. The current should be considered at all times when maneuvering the frames. It is very important to anticipate this element.

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FINGERS TRANSPORTATION The fingers which are lighter are transported as shown :

GANGWAYS TRANSPORTATION In order to facilitate its installation, the gangway is transported on the same dock on which it will be fastened. As you can see, it is positioned 2/3 on the dock side, 1/3 outside the dock for an easiest handling when operating.

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FRAMES ASSEMBLY The frames are joined together using the connecting blocks. These blocks are inserted in gussets welded in the extremity crossbars of the docks. To fasten the blocks, we use vertical bolts length 100mm diameter 16 and security nuts. GUSSET

The reinforced rubber blocks and the stainless steel bolts must be greased before insertion.

Blocks are used to give to the main dock its elasticity and its strength. We use vertical bolting to avoid any snatching of the extremity crossbars.

CONNECTING RUBBER BLOCK

The assembly is divided in three parts : 1/ Positioning 2/ Connecting rubber blocs insertion 3/ Bolting

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1/ Positioning : Docks are turned in their final configuration.

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2/ Connecting blocks insertion : Once the docks have been positioned, they are assembled. The process continues with the insertion of the rubber blocks in the gussets.

To make the insertion of the blocks easier, we recommend the use of a rope attached to two cleats.

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3/ Bolting : INSERTION OF THE BOLTS 16/100 IN THE BLOCKS :

BOLTING WITH THE USE OF A SOCKET WRENCH ON THE TOP:

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GUIDING RINGS & ACCESSORIES INSTALLATION GUIDING RINGS’ ASSEMBLY

LOADING OF THE GUIDING RING

INSTALLATION OF THE GUIDING RING

INSERTION OF THE «HAMMER HEAD » BOLTS IN THE SUPERIOR RAIL (diameter 16mm length 40mm, washers diameter 16mm)

INSERTION OF THE 4TH RUBBER ROLLER

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BOLTS INSERTION VIEW IN DETAIL

CENTRING OF A RUBBER ROLL

DETAIL OF THE LOWER RAIL ASSEMBLY (do not forget the diameter 16mm washers)

COMPLETED GUIDING RING WITH FOUR ROLLERS

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BEAM Docks are linked to the shoreline by aluminum beams, articulated on both sides so that the docks can move up and down with the tide. The size of a beam depends of its length but also of the mooring efforts on the dock. On the quay side, it is fixed in concrete with chemical rawplugs. On the dock side it is fixed with an interface (« hammer head » bolts). A layout drawing is furnished for this type of project."

H PROFILE ON QUAY SIDE Docks are linked to the quay by the use of an interface named “H guide”. This guide divided in two parts is bolted on the dock (« hammer head » bolts) and inserted in the H profile on the quay side. A layout drawing is furnished for this type of project.

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FINGERPIERS ASSEMBLY FINGERS INTERFACES POSITIONING OF THE INTERFACE

FINGERS INTERFACES

POSITIONED INTERFACE

Different interfaces can be used depending on the size and shape of the fingerpier. (2 holes bloc for a small fingerpier) Bolts diameter 16mm length 90mm and safety nuts. In this case , a detailed drawing is supplied. FIXATION DETAIL

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POSITIONING AND INSERTION OF THE FINGERPIERS

APPROACH

RECEIPT

PRESENTATION

POSITIONING

SUPPORT DURING THE POSITIONING

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INSERTION OF THE INTERFACE IN THE EXTRUSION

BOLTING

OF

INTERFACES AND CLEATS (“hammer

THE THE

head” bolts diameter 16mm length 40mm and safety nuts)

PRIMING OF THE LOWER « HAMMER HEAD » BOLTS

INSERTION OF THE LOWER « HAMMER HEAD » BOLTS (do not forget the diameter 16 washers)

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INSTALLATION OF OPTIONAL WATER AND ELECTRICAL BOLLARDS AND LINE CONDUITS Electrical and water bollards are fixed to the dock. On the back, they are maintained by “hammer head” bolts diameter 8mm in the extrusion and on the front, they are screwed in the decking.

Both lines are inserted in the frame in the technical conduit. We close this conduit by the use of an aluminum plate fitted into the extrusion on one side and screwed in the decking on the other side. (5 screws for a 10’ plate)

Networks are sheathed and attached under the gangway with pipe-collars. Then, they are inserted into the dock frame either by : - Placement directly inside the conduit. - Placement inside the conduit using a trap door. (as shown)

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GANGWAYS INSTALLATION The installation of the gangway is divided in four steps : -

presentation of the gangway lifting and positioning installation of the interface on the quay fastening of the gangway

PRESENTATION OF THE GANGWAY As describe previously, the gangway is transported on the dock to which it will be attached. When the dock is attached in the correct position, the gangway can then be installed.

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LIFTING AND POSITIONING The Gangway is lifted for positioning. This is a very important step as we are going to line the gangway up with the docks. It also determines where the interface between the gangway and the quay is going to be fixed.

LIFTING

PRESENTATION AND POSITIONING OF THE INTERFACE

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INSTALLATION OF THE INTERFACE Once the gangway is in its final position, the interfaces can be installed in the quay. In order to fix the interface, we use threaded shanks diameter 16mm and chemical rawplugs. Once the holes are made, the rawplugs are inserted and the threaded shanks are screwed up tight.

Drilling

Chemical rawplug

Bolting Threaded shank inserted

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FASTENING OF THE GANGWAY Last step is to connect the gangway to the interface. The axles are inserted into the cases are maintained with pins. On the dock side, the gangway rolls over aluminum rails.

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RESULT Installation is finished and the new docks are ready to receive the boats‌

BEFORE

AFTER

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Metalu Industries International-ASSEMBLY GUIDE  

B.P 53 – LES PRAIRIES DE GRAND’VILLE – 44250 SAINT BREVIN LES PINS - FRANCE PHONE : 33 (0) 240 391 840 FAX : 33 (0) 240 270 247 For more det...

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