T RELL EBORG M A RINE A ND INFR A S T RUC T URE

Bollard

Installation and Maintenance Manual

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1
Bollard
Installation and
Maintenance Manual
Trelleborg has a range of seven bollard styles
to ensure the ideal solution for your
application.
Contents
All Trelleborg bollards are precision-engineered and
manufactured in a variety of metals, including Bollard Installation and
premium-grade spheroidal graphite ductile iron and Maintenance Manual
cast steel to offer unprecedented levels of service
life, as well as resistance to corrosion and impact. Loading, Unloading and Handling5
Storage7
We understand that safety is your number one
priority, and provide bespoke safety-critical bollards, Installation11
anchoring and fixing solutions to your exact
Inspection and Maintenance 23
specifications. This guide provides detailed and
specific information about the installation process. It
also includes maintenance and inspection
guidelines, which ensures the condition of the
bollards to be used for your mooring operation.

2
 A Smarter Approach
at every stage
A smarter approach to…

Consultation Concepts DESIGN Manufacture

Consultation from the earliest Conceptual design in your Concepts are taken to our Our entire product range
project phase to ensure the local office – with full Engineering Centers of is manufactured in-house,
optimum fender, mooring, knowledge of local standards Excellence where our team meaning we have full control
navigation and transfer and regulations, delivered in generates 3D CAD designs, over the design and quality of
solutions are specified, with your language – for optimized application-engineering everything we produce. Our
full technical support from port and vessel solutions. drawings, a bill of materials, strategically located, state-
our global offices. finite engineering analyses of-the-art facilities ensure
and calculations for both our our global, industry leading
fender systems and marine manufacturing capability.
technology solutions.

3
 TESTING INSTALLATION Support the future
Across our entire product Dedicated project Local support on a truly global Deploying the latest in smart
range, stringent testing management, from solution scale, with customer support technologies to enable fully
comes as standard at design right the way through teams all over the world. And automated, data-driven
every step in our in-house to on-site installation support. this service doesn’t stop after a decision making that
manufacturing process. We We design products and product is installed. You have our optimizes port and terminal
ensure that life-cycle and solutions that always consider full support throughout the entire efficiency. At Trelleborg, we’re
performance of our entire ease of installation and future lifetime of your project, including constantly evolving to provide
product range meets your maintenance requirements. customized training programs, the digital infrastructure our
specifications, and more. maintenance and on-site service industry increasingly needs.
and support.

When you choose Trelleborg you

ensure your expectations will be met,
because we deliver a truly end-to-end
service – retaining vigilance and full
control at every stage.

4
Loading, Unloading
and Handling

5
Loading, Unloading and Handling
Materials/Consumables Required Information
Bollards should be placed on a timber bolster to
Timber / rubber blocks
avoid damage.
Should be heavy-duty waterproof plastic
Tarpaulin
(Refer Storage section)
Refer to Appendix – 1.1 & 1.2:
Crane and rigging equipment
Bollard weight and total packing (gross) weight

❙ Lift a bollard from its neck for ease of placement ❙ All bollards should be laid on the ground only. If
on its base. they must be stacked, secure them to avoid tipping
them over.
❙ Do not open or dismantle the packing of the
bollards until ready for installation. ❙ Always handle bollards at ground level.

❙ To avoid paint damage, do not handle the bollards ❙ All the tabove points are also applicable to bollard
with unprotected lift forks or hooks. anchors.

❙ Never drag the bollards along the ground.

Caution Recommendations
❙ Never lift a bollard with direct steel contact. ❙ Before unloading the shipment, visually inspect the
container for signs of any damage incurred during
❙ Bollards should be handled carefully to avoid transportation. If significant damage is found, take
injuries. a photograph as evidence and send it to Trelleborg
❙ Do not handle bollards in areas with insufficient Marine Systems.
lighting to avoid damage to the bollards and the ❙ Bollards must be handled with protective lifting
surrounding premises. equipment to avoid damage.

❙ Always lay components carefully on dry firm ground

supported by dunnage.

❙ Never drop the components or lay them directly

onto rocky or waterlogged ground.

6
Storage

7
Storage
2.1 StoRAGE TIMELINE FOR BOLLARD
❙ Store bollards in a safe area where they will not be exposed to damage.

❙ Place them carefully on dry ground over wood blocks to avoid paint damage.

❙ Do not stack bollards on top of each other if this can be avoided. If they must be stacked due to space
constraint, use appropriate racks.

❙ The above points are also applicable to bollard anchors.

❙ If you come across any fault or problem, report the matter to your regional Trelleborg office immediately for
further corrective action.

Caution Recommendation

❙ Get recommendations from Trelleborg if the ❙ Inspect stored bollards and their packaging at least
bollards are to be stored in temperatures below once a month for damage.
10°C.
❙ Every package should be clearly and visibly labeled.
❙ Before moving the packaging at any time, check
first for any signs of damage.

❙ Bollards should be recoated after 15 years of

storage.

❙ Bollards should be inspected every five years if

they are stored as per the above guidelines.

2.2 PACKAGING AND LABELLING

2.2.1 Packaging Caution

Bollards are usually packed in a closed box or fixed If bollards are removed from the packaging for
with wooden blocks. inspection, testing or any other purpose and are
subsequently to be returned to storage for a further
❙ The bollards should be covered with non- period, they must be repackaged and labeled in
transparent PE (polyethylene, double wrapping). accordance with section 2.2.2 and the date of the
❙ Avoid any direct contact between two bollards. repackaging must be recorded on the container.
❙ All bollards should be properly fastened in the
packaging.
❙ Check the weight of the package before lifting.
❙ All bollards must be packed in an upright position.
❙ Ensure the packaging is labeled with an orientation
arrow.
❙ The lifting provision should be indicated clearly on
the packaging with a symbol.
❙ The packaging should include a caution label
against fire.

8
Storage
2.2 PACKAGING AND LABELING
2.2.2 LABELING

Every package or container should be labelled on at least three sides with the below requisite information
and should be visible from the outside of the package without the need to break the seal.

Bollard type / Size

Bollard weight
Quantity / Package
In-box content
Total weight of package

2.3 INSPECTION AND RECORDING

Visual inspection must be made and recorded for
the following once a year.

❙ Surface penetration and / or scratches

❙ Cracked, chipped or peeling paint rust or corrosion

❙ Image on following page is for reference only.

9
10
Installation

Bollards must be installed correctly for a long and trouble-free service life. The type of installation depends
on the type of anchor used to fix the bollards as well as the type of structure on which the bollards are to be
installed. Bollards are mostly either recess mounted or surface mounted. The anchors required for each type
of installation are listed in the following page. If the type of installation you are planning is not listed, please
consult your regional Trelleborg office.

11
Installation
RECESS MOUNTED
The recess should be prepared in the required
dimensions. These dimensions are based on the
size of the base of the bollard. The base of the
bollard should be set in the recess with the required
grout thickness around the base, and the bollard
should be fixed with anchors. These can be either
cast-in anchors or epoxy / resin anchors.

SURFACE MOUNTED
Unlike recess-mounted installations, no preparation
is required for surface-mounted installations.
Grouting should be prepared depending on the
length, width and thickness. Grout should be used
to install the bollard with proper alignment so as to
utilize the maximum capacity of the bollard for a
long and trouble-free service life. The anchors can
be installed either with cast-in anchors or with epoxy
/ resin anchors.

CUSTOM MOUNTED
The bollard is surface-mounted on a steel structure.
The steel structure is designed by a jetty designer to
cater to the load of the designated capacity of the
bollard. Anchors for this type of application vary
depending on the structure of the steel on which the
bollard is to be installed. Trelleborg must review the
design and drawings of the structure on which the
bollard is to be installed.

12
Installation
3.1 ANCHOR INSTALLATION
Refer to the general guidelines for anchor installation.

❙ Anchor installation should be carried out by qualified personnel and under the supervision of the person
responsible for technical matters of the site.

❙ Anchor installation should be in accordance with the manufacturer’s specifications and drawings.

❙ Use anchors which are supplied by the manufacturer or as per the approved drawings.

❙ Check the strength class of the concrete in which the anchor is to be installed.

❙ The concrete base must not have any significant voids.

❙ The anchorage depth must be marked.

❙ The edge distance and spacing should not be less than the specified values as per the bollard
manufacturer’s calculations.

❙ The anchor hole should be hammer-drilled with a diamond core drill bit.

❙ If the drill hole is aborted, the hole should be filled with mortar.

❙ For an overhead installation, piston plugs must be used. Embedded metal parts must be fixed during the
curing time, e.g. with wedges.

❙ For injection of the mortar in bore holes ≤250 mm, piston plugs must be used.

3.1.1 CAST-IN ANCHOR INSTALLATION

Anchors need to be installed at their designated

position before the concrete is poured. Steel
reinforcements have to be provided to the anchors.

Materials/Consumables Required Information

Reinforced concrete block With adequate compressive strength
Steel reinforcement bar Used to anchor template/Cage Hold Down Bolts
Equipment Required Information
Anchors Supplied by Trelleborg
Anchor bolt template Supplied by Trelleborg/Others
Spanner Suitable to the supplied anchor size
Recommended Personal Protective
Information
Equipment
General PPE As per site/plant requirements

13
Installation
3.1 ANCHOR INSTALLATION
3.1.1 CAST-IN ANCHOR INSTALLATION

Step 1. Mark embedment length on all anchors

used for each bollard.

Step 2. Use two anchor templates to locate and Step 1

align the anchors vertically straight.
(Ref. Fig. 5)
❙ As shown in the image, place one anchor
template on the head of the anchor and fix
another template below the marking of the
embedment length.

❙ Restrain the top template temporarily to

avoid any movement.

❙ Reinforce the anchors with steel bars as

per ACI318.11. The reinforcement design
can be carried out by a jetty designer. Step 2
Step 3. Start pouring the concrete as per the
instruction of the supervisor.

Caution :
In the case of a recess mounted bollard,
use a cover boundary to stop the concrete
being poured on the required recess for
the bollard.

Step 4. Provide enough time to cure the concrete.

Caution : Step 5
❙ Do not touch the anchors until the
desired curing time required for the
concrete has passed.

❙ Check the required protrusion height of

each anchor.

Step 5. After pouring, use the template to check

the final anchor locations as per the
relevant drawings.

14
Installation
3.1 ANCHOR INSTALLATION
3.1.2 EPOXY/RESIN ANCHOR INSTALLATION

Fully threaded anchors are used with resin/epoxy

bond materials to achieve a bond between the
anchors and the existing concrete. The detailed
procedure is as follows:

Step 1. Marking

❙ Clean the area first and use an anchor

template to mark the positions of the
holes on the jetty surface. Use a marker
pen to highlight the marked holes.

❙ Measure the distance from the jetty edge

to the first anchor as per the drawings.

❙ Clean the area again and measure each

distance to be verified with the bollard
drawing.

Step 2. Drilling / Coring Step 1

❙ Set the drilling machine in such a way
that the drill bit axis and the center of the
marking hole are aligned.

❙ Use a bubble gauge meter to verify that

the drill bit is perfectly vertical.

❙ Use a continuous flow of water to reduce

heat generation between the drill bit and
the concrete.

❙ Slowly drill the hole up to the required

depth.

Caution :
❙ Marking on the drill bit helps to Step 2
determine the depth of the hole. Diamond
coring is permissible when a diamond core
drilling machine and the corresponding
core bit are used.

❙ Verify that the depth and diameter of the

holes are within the tolerance ranges
mentioned in the relevant anchor layout
drawing.

15
Installation
3.1 ANCHOR INSTALLATION
3.1.2 EPOXY/RESIN ANCHOR INSTALLATION
Step 2. Drilling / Coring

❙ Once the hole has been cored to the

desired depth and diameter, roughen the
surface of the core hole using a rotary
hammer drill bit.

(Roughing the surface of the hole is a

recommendation and not a requirement.)

Recommendation:

Proper core bit setting must be done so that the

base concrete can be secured. Step 3
Step 3. Cleaning

❙ Starting from the bottom surface of each

hole, use a pressurised water flow to clean
the holes.

❙ Run a flow of water continuously into the

holes until the water runs out clear.

❙ Brush two times with the specified brush

size (brush Ø ≥ bore hole Ø, see Table 7 in
Hilti manual) by inserting the steel brush
(Hilti HIT-RB or equivalent) to the back of
the hole (use an extension if needed) in a
twisting motion and removing it.

❙ The brush must produce natural

resistance as it enters the bore hole.

❙ Blow oil-free compressed air (with min.

6bar / 90 psi pressure) two times inside
the drilled hole, starting from the bottom
surface of the hole (use a nozzle extension
if needed) over the hole length until the
return air stream is free of noticeable dust
and water.

❙ Alternate the cleaning by water and air

two more times.

16
Installation
3.1 ANCHOR INSTALLATION
3.1.2 EPOXY/RESIN ANCHOR INSTALLATION
Step 4. Injection

❙ Insert foil pack in foil pack holder. Do not

use damaged foil packs and/or damaged
or unclean foil pack holders. Attach new
mixer prior to dispensing a new foil pack
(snug fit).

❙ Tightly attach Hilti(HIT-RE-M) or

equivalent mixer to foil pack manifold. Do
not modify the mixer in any way. Make
sure the mixing element is in the mixer.
Use only the mixer supplied with the
adhesive.

❙ Insert foil pack holder with foil pack into

HIT-dispenser. Push release trigger, retract
plunger and insert foil pack holder into the Step 4
appropriate Hilti dispenser.

❙ Discard initial adhesive. The foil pack

opens automatically as dispensing is
initiated. Depending on the size of the foil
pack an initial amount of adhesive must
be discarded.

❙ Discard quantities are 3 strokes for 330

ml foil pack, 4 strokes for 500 ml foil pack
and 65 ml for 1400 ml foil pack.

❙ Inject adhesive start from the bottom of

the bore hole without forming air voids.
Slowly withdraw the mixer with each
trigger pull.

❙ Continue filling the bore hole either up to

recommended amount of adhesive or until
hole fills 2/3 full.

❙ It is required to ensure that the annular

gap between the anchor and the concrete
is filled with adhesive along the
embedment length.

17
Installation
3.1 ANCHOR INSTALLATION
3.1.2 EPOXY / RESIN ANCHOR INSTALLATION
Step 5. Setting anchors

❙ Before use, clean each anchor with water ❙ After installing an anchor, the annular
and dry them completely with oil-free air. gap must be filled with epoxy / resin
Verify that the element is dry and free of adhesive. If the borehole is not filled along
oil and other contaminants. the embedment depth, the installation
should be rejected.
❙ Anchors must be twisted slowly and
inserted into the core, which is filled with ❙ Use an anchor template to stop the
epoxy / resin. movement of anchors right after
installation.
❙ Mark and set the element to the required
embedment depth until working time ❙ Leave anchors to cure for the curing time
TWORK has elapsed. The working time (TCURE) mentioned in Table 2.
TWORK is given in the table below.
Caution : Do not touch the anchors
during curing time.

Temperature in Maximum working Minimum curing time

anchorage base [°C] time(Twork) [minutes] (Tcure) [hours]
5 to 9 120 72
10 to 14 90 48
15 to 19 30 24
20 to 29 20 12
30 to 39 12 8
40 12 4
Note :

❙ Cover anchors with a suitable cap to avoid damage.

❙ Check that the protrusion length is outside of the concrete structure.
❙ Cover the area, marking with the word “Caution”.
❙ Ensure all anchors are straight and level.

18
Installation
3.2 GROUTING AND BOLLARD PLACEMENT
Grouting is needed to provide a flat surface on a deck to align the bollard horizontally. Cement-based grout is
made of water and cement in a ratio recommended by the grout manufacturers. Use the grout
manufacturer’s data sheet for each stage of grouting. Grout should be non-shrink grout with a minimum
strength of 60 MPa.
❙ Adequately roughen the surface of the concrete
deck.
❙ Use pressurized air flow to remove all debris.
❙ The base flange of the bollard should be aligned,
shimmed and cleaned of all grease, dirt, loose rust
and scale.
❙ Use removable shims to leave a gap between the
bollard base flange and the concrete surface.
❙ Shims must be corrosion free if using non-
removable shims.
❙ Check the alignment of the bollards by using a
bubble meter.
❙ Use boundary forms to isolate the area for
grouting.
❙ It should be sturdy and caulked oiled approximately
15 mm around the edge of the base of the bollard.
❙ Follow the grout manufacturer’s procedure for
filling the grout.
❙ Place the grout at least 5 mm (1/4”) above the
bottom of the base flange of the bollard to ensure
the complete filling of the void.
❙ Cover immediately with wet rags or curing
compound.
❙ Provide a 45° angle to the grout periphery prior to
the curing of the grout.
❙ All cement-based grouts should be cured according
to the guidelines of the grout manufacturer.
❙ Lift the bollard as per the handling procedure
mentioned in Section 1 and place it in its
designated position.

19
Installation
3.3 TORQUEING TO ANCHORS
After the grout is fully cured and the bollard is placed, fix the anchor with the Hex Nut/Hex Bolt as per the
drawing. Use the torque value as tabulated below to fasten the anchors.

% Utilization
Pretension Torque
Ton Bolt Size Bolt Tensile of Proof
Type of Bollard force Requirement
Capacity (Metric) Area Stress
(kN) (N.m)
(Gr. 8.8)
Tee Bollard 10 M20 245 25 120 16%
15 M24 352 30 216 13%
22.5 M30 560 45 270 13%
30 M30 560 60 360 17%
50 M36 816 100 720 19%
80 M42 1,120 130 1,092 18%
100 M42 1,120 140 1,176 20%
125 M48 1,473 175 1,680 19%
150 M48 1,473 210 2,016 22%
200 M56 2,029 240 2,688 18%
250 M64 2,675 300 3,840 18%
300 M64 2,675 300 3,840 18%

Horn Bollard 15 M24 352 35 168 16%

30 M30 560 60 360 17%
50 M36 816 100 720 19%
80 M42 1,120 130 1,092 18%
100 M42 1,120 140 1,176 20%
125 M48 1,473 170 1,632 18%
150 M48 1,473 210 2,016 22%
200 M56 2,029 240 2,688 18%
250 M64 2,675 300 3,840 18%

Kidney Bollard 15 M24 352 40 192 18%

30 M30 560 80 480 22%
50 M36 816 120 864 23%
80 M42 1,120 150 1,260 21%
100 M42 1,120 140 1,176 20%
125 M48 1,473 170 1,632 18%
150 M48 1,473 210 2,016 22%
200 M56 2,029 280 3,136 22%

20
Installation
3.3 TORQUEING TO ANCHORS

% Utilization
Pretension Torque
Ton Bolt Size Bolt Tensile of Proof
Type of Bollard force Requirement
Capacity (Metric) Area Stress
(kN) (N.m)
(Gr. 8.8)
Cleat Bollard 15 M20 245 100 720 64%
20 M24 352 125 900 55%
25 M24 352 155 744 69%
30 M24 352 155 744 69%
35 M30 560 160 960 45%

Double Bitt Bollard 20 M20 245 30 216 19%

30 M22 303 40 288 21%
50 M30 560 60 432 17%
75 M36 816 75 540 14%
100 M42 1,120 100 720 14%
125 M42 1,120 120 864 17%
150 M48 1,473 150 1,080 16%
200 M56 2,029 190 1,368 15%

Single Bitt Bollard 15 M24 352 30 216 13%

30 M30 560 60 432 17%
50 M36 816 85 612 16%
75 M42 1,120 120 864 17%
100 M48 1,473 150 1,080 16%
150 M56 2,029 210 1,512 16%
200 M56 2,029 240 1,728 18%

Pillar Bollard 10 M20 245 30 216 19%

15 M24 352 40 288 18%
30 M36 816 80 576 15%
50 M36 816 80 576 15%
75 M42 1,120 110 792 15%
100 M48 1,473 140 1,008 15%
150 M56 2,029 190 1,368 15%
200 M64 2,675 240 1,728 14%

21
22
Inspection and
Maintenance

Bollards supplied are maintenance free. However, inspection is required every three months or when they are
subjected to abnormal actions such as being knocked by other equipment or used for other applications.
Relevant corrective action should be taken based on the findings to ensure the correct maintenance of the
bollards. The table on the right can be used as a guideline for the inspection process.

23
Bollard Inspection and Maintenance Guidelines
Visual
S/No Inspection Type Corrective Action Remarks
Observations
1 Examine for visual Check the relevant If less than the minimum
damage such as surface required minimum requirement is found, check
penetration and / or dimensions as per the the design calculations with
scratches on the surface manufacturer’s drawing. the manufacturer of the
of the bollard. bollard.

2 Examine the condition of Inspect for cracks, Make the necessary repairs
the paint on the bollard chipping and / or as per the Paint Repair or
for cracks, chips and/or peeling. Touch-up procedure, or
peeling. contact the manufacturer
for guidelines.

3 Examine for surface rust Inspect for surface Make the necessary repairs
or corrosion in the paint. pitting or cracks. as per the Paint Repair or
Touch-up procedure.

4 Inspect the barrel Compare the inspected If found to be less than the
thickness as per the thickness with the minimum required, check
bollard product drawing. manufacturing drawing the design calculation with
of the bollard. the bollard manufacturer.

5 Inspect all dimensions Compare all dimensions Provide an inspection report

as per the product with the manufacturing to the manufacturer of
drawing of the bollard. drawing of the bollard. bollard to examine.

6 Inspect to see if any Check with a torque If bolts are found to

anchor bolts have wrench for the desired have loosened, tighten
loosened. value of torque. the anchor bolt with the
required torque value.

7 Inspect for damage or Visually inspect threads If any damage is found,

deformation of anchor for any wear or damage. provide the manufacturer
bolts. with a detailed explanation
of the damage for further
examination.

8 Examine the coating Visually inspect the Apply Zinc coating to the
system of the anchor fasteners’ HDG coating. desired DFT as per the
bolts and other bollard manufacturer’s
fasteners. advice.
The site operator or owner may carry out general maintenance or repairs to the equipment supplied, as
outlined in this manual. For any major repairs, please consult the bollard manufacturers, otherwise the
warranty will be void.

24
Disclaimer
Trelleborg AB has made every effort to ensure that
the technical specifications and product descriptions
in this catalog are correct.

The responsibility or liability for errors and omissions

cannot be accepted for any reason whatsoever.
Customers are advised to request a detailed
specification and certified 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
specification changes without prior notice. All
dimensions, material properties and performance
values quoted are subject to normal production and
testing tolerances. This catalog 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 catalog 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.

BC-DAM-v1.0-EN, 2018

25
For a smarter approach to
your next project,
get in touch today.
Email: marine_infra@trelleborg.com

26
 Trelleborg is a world leader in engineered polymer solutions
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