FLOATING DOCK SPECIFICATION

P246633 Marzo, 2005

 FLOATING DOCK
SPECIFICATION

INDICE

1 General .................................................................................................................................... 3

1.1 Description....................................................................................................................... 3
1.2 Main characteristics ......................................................................................................... 6
1.3 Classification and Rules................................................................................................... 6
1.4 Stability............................................................................................................................ 6

2 Hull .......................................................................................................................................... 7

2.1 Structure ........................................................................................................................... 7

2.2 Pontoon ............................................................................................................................ 7
2.3 Wing walls ....................................................................................................................... 7
2.4 Umbrella structure............................................................................................................ 7
2.5 Connecting Towers between Umbrella and Dock. .......................................................... 8

3 Equipment ............................................................................................................................ 10

3.1 Umbrella hoisting system .............................................................................................. 10

3.2 Working forms ............................................................................................................... 11
3.3 Concrete booms .............................................................................................................. 13
3.4 Mooring.......................................................................................................................... 17
3.5 Towing ........................................................................................................................... 18
3.6 Platforms, Stairs & Ladders........................................................................................... 18
3.7 Cathodic Protection........................................................................................................ 19
3.8 Painting .......................................................................................................................... 20
3.9 Rails & Stanchions......................................................................................................... 22
3.10 Grating ........................................................................................................................... 22
3.11 Control room preparation............................................................................................... 22

4 Systems .................................................................................................................................. 23

4.1 Ballast system ................................................................................................................ 23

4.2 Sounding and Vents of tanks ......................................................................................... 24

5 Electricity .............................................................................................................................. 25

5.1 Shore connection............................................................................................................ 25

5.2 Main switchboard........................................................................................................... 25
5.3 Battery and battery charger. ........................................................................................... 25
5.4 24 V c.c. Switchboard. ................................................................................................... 25
5.5 Control panels ................................................................................................................ 25
5.6 Electrical consumers ...................................................................................................... 26
5.7 Generating set ................................................................................................................ 26

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1 General

1.1 Description

The aim of the present document is to define the main cha racteristics of a floating dock
designed for construction of floating caissons, made of reinforced concrete.

The maximum dimensions of caissons to build are the following:

Length 58 m.
Beam 37 m.
Depth 35,5 m.
Weight 45000 Tm approx.

There will be the possibility of building another kind of caissons, according to the design of
dock.

The floating dock will operate in sheltered waters, protected from the sea, near a harbour.
Occasionally the floating dock will be towed in open waters from harbour to harbour.

To see the composition and distribution of dock elements see the preliminary General
arrangement drawing.

The floating dock comprises a central pontoon and two lateral walls having on top of each
side, a metallic structure of seven (7) towers connected between them. From these towers a
main horizontal frame (so-called umbrella) hangs on. This frame can slide using a motion
controlled system (hydraulic jacks).

Over the pontoon deck is constructed the floating caisson. When the caisson is completed
the caisson floats, after the dock have reached the necessary draught.

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Umbrella

25000
Dock

Figure 1.- Floating dock configuration (preliminary).

Basically the floating dock can be splitted in two different parts:

The dock
The sliding structure (umbrella)
The connecting towers between dock and umbrella

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Figure 2.- Umbrella and connecting towers.

The main equipment involved is:

o Forms and supporting elements
o Concrete mixing and pumping machines
o Pneumatic air system
o Hydraulic integrated system to lift and lower the so-called construction umbrella
that holds the block construction formers.
o Lighting system
o Ancillary hydraulic crane for handling material

There is an equipment for hydraulic lifting/lowering the umbrella for construction of high-rise
concrete caisson structures.

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1.2 Main characteristics

Except otherwise specified, the metric system will be used through this specification.

The following cha racteristics and dimensions are provisional and could be changed after a
final design is achieved.

Length b. p. 60 m.
Beam moulded (exterior) 49 m.
Beam (interior bulkheads of wing walls 39 m.
Depth of pontoon deck 5 m.
Depth of wing walls 31,1 m.
Halfbreadth of sides 5 m.
Scantling draught 29,1 m.

1.3 Classification and Rules

The dock is designed, classified and built to operate in sheltered waters. The classification
notation will be I 3/3 + Service Floating Dock /NP Sheltered Waters and navigation
Deep Sea/Occasionally.

This class notation is according Bureau Veritas rules, but a similar notation according to
another Classification Society will be admitted.

The following international conventions are to be complied with:

InternationalConvention for the Safety of Life at Sea (SOLAS) 1978 and Amendments in
force. Consolidated edition 2001.

International convention on Load lines, 1966 including Protocol of 1988 and Amendments
in force.

International Tonnage Measurement of Ships 1969 and Amendments International

Convention of Prevention of Collision at Sea (1972) as amended by IMO Resolution A-464
(XII).

1.4 Stability

The dock will comply the stability criteria according to the Spanish requirement for this
kind of ships as far as applicable, in particular the Circular 12/90 de la Inspeccion General
de Buques sobre estabilidad de buques de carga y pasaje menores de 100 m.

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In all loading conditions GM, corrected by liquid surfaces, will be at least 1,0 m. as
required by Lloyds Register for this kind of naval docks.

2 Hull

2.1 Structure

For the construction of both the pontoon and the wing walls mild steel, class A will be
used, according to the Classification Society Rules. Minimum yielding stress to be 235
N/mm2 .

Welding is to be approved by Classification Society. Continuous welding is to be adopted

in the main structural elements and, always, inside ballast tanks.

There are two different zones by the structural point of view: the pontoon and the wing
wall.

2.2 Pontoon

Both ye deck and the bottom are longitudinally framed, with transversal bulkheads being
the boundaries of tanks. Every 2,50 m. there is a transversal girder, being this the span of
longitudinal stiffeners.

All constructive details will follow the good naval construction practice, according with the
Classification Society.

2.3 Wing walls

These are longitudinally reinforced in the upper part, where they collaborate to the
longitudinal strength of the dock. In way of the window existing in the wing walls, the
structure will be transversally framed, to stand up against the forces caused by the support,
lifting and descend of umbrella.

2.4 Umbrella structure

The umbrella is a truss steel structure, shaped to form the blocks including the internal cells
for stiffness.

It is a modular structure having 38.4 meters wide, 58 meters long and 3.3 m high. It has 24

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points to attach the climbing system (12 by side) and the estimated weight is about 420 ton.

This structure hangs from 24 points (12 by side). In addition and to avoid any excessive
movement due to wind effect, the umbrella shall be guided at four points (one per corner)
in both directions by means of shock absorbers.

Figure 3.- Umbrella structure.

There will have a central longitudinal platform to allow the installation of mobile concrete
booms on the top floor of the umbrella.

There shall also be two longitudinal platforms at both ends to allow the installation of
ancillary hydraulic cranes to manipulate steel bar for concrete caisson construction.

For both the booms and the cranes, it shall be required a system to allow the longitudinal
displacement, using a guiderail and the needed equipment.

In addition several transversal platforms/footbridges shall be foreseen for personnel access.

2.5 Connecting Towers between Umbrella and Dock.

The floating dock has fourteen (14) steel structural towers (seven by side) connected
between them by a master beam. There are two different types, four towers located at the
ends of the dock (narrow towers) and ten between them (wide towers).

The structure of each wide tower is a truss type of 4.4 x 5 m at the base and a height of

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about 25 m. Its weight is about 17 ton.

The structure of each narrow tower is a truss type of 4.4 x 3 m at the base and a height of
about 25 m. Its weight is about 16 ton.

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3 Equipment

3.1 Umbrella hoisting system

On both sides of the dock, 12 sets of stage- lifting hydraulic units operated by 3 high- flow
power sources and controlled by a synchronized PLC system operate the umbrella.

Controlled Movement

Due to the size of the concrete block and thus the umbrella, the risk of twisting and
therefore locking the umbrella between both dock walls is a serious thread to the process.
For that reason a fully PLC controlled synchronized hydraulic integrated system is
required.

Climbing elements

Along both sides of the dock huge but lightweight constructions hold the climbing stage
lifting steel notched plates, while the climbing stage lifting hydraulic units are fastened to
the umbrella deck. As mentioned before, 12 units along each side of the umbrella deck.
Each unit exists of an advanced hydraulic system including stroke and and proximity
sensoring technology.

Climbing Units

All 24 climbing units comprise two long stroke hydraulic double acting cylinders of 70 tons
capacity and two double acting hydraulic locking cylinders of 20 tons capacity. The long
stroke cylinders, used for the actual lifting and lowering process, include a magnetic stroke
sensoring system, which communicates the plungers position via a local manifold and
valving unit to the central PLC-system. The locking cylinders also include stroke sensors
that signal their position to the PLC-system where all data is processed and communicated
back to the pumps and 2/2-way valves that control all cylinders (96 in total) in all 24
climbing units. The locking cylinders are used to fix the climbing units during the climbing
process. The main PLC-system is operated via a touch screen with a graphical user
interface, continuously showing the actual stage of the process, including all parameters.
Overall lifting and lowing accuracy of the entire system is 0,01 mm.

Ancillary crane
Two hydraulic cranes type Palfinger or similar on top floor of Umbrella. Capacity 4
ton/12m, this crane shall be possible to use also as lifting appliance when lifting parts from
deck or loading materials onboard ship.

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Hydraulics
Hydraulic system with electrically driven hydraulic pumps to be installed. Pumps to be
installed top floor of Umbrella. Separate hydraulic system to be provided for ancillary
cranes. All hydraulic piping on exposed decks to be made of acid resistant pipes and
connections. System pressure preferably not to exceed 250 bar.

Final design of hydraulic system and components to be carried out in close co-operation
with owner.

3.2 Working forms

Working forms will be supplied by the shipowner.

General dimensions and basic array is included for the selected form type.

o Height 1.20 m
o Plate thickness 3 mm
o Total weight : Forms +Hanging supports+Platform 225kg/ml
o Strip (Tapering) 5-8 0/00
o Hanging supports length 1.50 m
o Hanging support clearance (free height) 0.7 m

The floating dock (umbrella included) could be adapted in order to use different working
forms as required.

The sliding speed shall be 20 cm/hour

The connecting elements between the umbrella and the working form shall be
adjustable in order to guarantee the horizontal plane of the forms.

Working form array caisson dimensions

Cell 4,00 3,80 3,50 3,30 3,00 m
diameter
Outer cells 111,06 0,00 64,70 119,68 108,90 Degrees
cutting angle
Length 57,30 56,60 56,10 56,60 56,60 m
Width 36,00 35,98 36,00 36,00 36,00 m

Concrete caisson wall thickness (distance between forms):

Outer cells minimum distance to longitudinal edge (both sides): 0,50 m

Outer cells minimum distance to transversal edge (both sides):: 0,40 m
Minimum distance between round shaped cells: 0,20 m

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Minimum distance between round-oval shaped cells: 0,20 m

PLANT OF TYPICAL CONCRETE CAISSON

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Figure 4.- Typical dimensions for 3.8 m diameter cell.

3.3 Concrete booms

To supply the concrete, three (3) booms sha ll be installed on the top part of the umbrella, these
booms shall be of stationary type, Putzmeister MXR-MX24-125 or equivalent and the total
amount of concrete shall be at least 90 m3 /h , this depends also in the human team to perform the
activity.

See Annex for Technical data.

Main Characterstics:

The booms shall be easily separated from the interface, they can reach up to 23.8 m and its
weight shall be less than 6.350 Kg without concrete, (6.800 kg with concrete on piping).

They shall have up to 4 articulated arms (Z deployment), swivel head and they must assure a
controlled discharge of concrete.

The pipeline diameter shall be 5 1/2", and the discharge hose will have a length of 4 m.

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The boom shall have a device to connect with the hydraulic system. This hydraulic system shall
comprise a tri-phase motor of 380V, 15 KW, 1480 rpm and a high pressure pump, 24 V control
box, 160 lt oil tank with a filter acting on the High pressure pump. All the electric control shall
comprise standard components located in a waterproof/watertight cabinet.

Figure 5.- Stationary boom MXR-(MX 24- T)

Accessories:

In addition to main components, each boom shall include the following accessories:

o Radio control
o 2 m length pillar with flanges to assembly, equipped to allow work.
o Working Platform with handrails, grid with required hole for stair access and four
attachment bolts.
o Rigid Base
o 2 m length stair, with protection and pipeline supports.

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Description of the system:

1) MXR-SYSTEM

Pos.1 4-section arm assembly with concrete line 125mm dia. and 4m end horse.
Pos.2.1 Boom pedestal with quick-separating device, mounted hydraulic unit 15 kW 400 V
50 Hz (on request special voltage) and integrated hydraulic oil tank (160lts).
Pos.2.2 Electric control cabinet.
Pos 2.3 Electro- hydraulic control for all boom functions including climbing device.
Standard cable remote control with 40 cable. Special accessory-radio remote
control.

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2) WORKING RANGE

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3.4 Mooring

Following elements will be arranged for mooring procedure.

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3.4.1 Pontoon Deck

Four double mooring bitts ( two Portside and two Starboard) installed at the window
of the wing- wall.

Four mooring points. Four forward points and two aft points. Two forward points for
main towing operation and two more ( forward and aft) for emergency towing
operation.

3.4.2 Main Deck

Four double bitts, one for every corner ( two in Portside and two in Starboard).

Four mooring electrical winches ( continuous duty pulls) according to the rules
satisfying the environmental conditions of the operation.

Approximate data:

Continuous pull : 45 T.
Wire: 120 m.
Medium speed: 3 m/min.

3.5 Towing

The forward structure will arrange four towing eye-bolts. Two of them like main towing
operation and the other two like emergency towing operation. The eye-bolts will dimensioned by
a unitary load work maxima of 200 T. The shipyard will develop the rest of the adjacent elements
( chains, cables, rings, shackles, etc.)

3.6 Platforms, Stairs & Ladders

Platforms

Two braced platforms ( Portside & Starboard) on the top of the Lattice Columns.

Wide: 0.90 m
Weight: 150 Kg/m2

Stairs

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Two stair access towers, aft & forward ( one for every side) from Pontoon Deck to the Main
Deck. They will include rest intermediate platforms with their appropriate stanchions.

Wide (min): 0.75 m

Inclination ( max): 60o

Ladders

The structure will have two protected ladders of emergency opposite to the regular stairs arranged
mentioned.

All empty spaces and ballast tanks will be arranged vertical ladders.

Wide: 0.30 m
Step distance: 0.30 m

In general, platforms, stairs & ladders will be built following the criteria of the Shipyard and
satisfying all referring about security regulations.

3.7 Cathodic Protection

Cathodic protection will be required for ballast tanks and hull ( outer shell) and special attention
around Sea Chests. It will be considered sacrificial Zinc or Aluminium anode with a medium life
of 4 or 5 years.

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3.8 Painting

An appropriate painting schema will be applied to this kind of structures and work areas. Usually,
first performance is a blast cleaning treatment for all steel material used on the lattice and main
structure, ending this procedure with a final shop primer. Preliminary Painting Schema will be
the next one.

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PRELIMINARY PAINTING SCHEMA

AREA No. OF COATS KIND OF PAINT THICKNESS ()

1 Polyamide Epoxi 50
Underwater Outside Hull 1 Epoxi ( 100%) 200
Immersed areas
1 Safeguard Epoxi Tar-Free 75
1 Antifouling SPC Tin-Free 100
1 Antifouling SPC Tin-Free 100
1 Polyamide Epoxi 50
Outside Hull 1 Epoxi ( 100%) 150
Immersed / Non Immersed
areas 1 Epoxi ( 100%) 150
1 Polyurethane 50
1 Polyamide Epoxi 50
Umbrella & Towers 1 Epoxi ( 100%) 125
Steel Structure
Non Immersed areas 1 Epoxi ( 100%) 125
1 Polyurethane 50
1 Polyamide Epoxi 50
1 Epoxi ( 100%) 125
Deck
1 Epoxi ( 100%) 125
1 Non-Slip Polyamide Epoxi 120
1 Polyamide Epoxi 50
Machinery & Deck Cabins 1 Epoxi ( 100%) 150
Pipe lines, etc.
1 Polyamide Epoxi 150
1 Polyamide Epoxi 50
Ballast Tanks 1 Epoxi ( 100%) 150
1 Epoxi ( 100%) 150
1 Antifouling Epoxi ( 100%) 150
Empty areas & Internals
1 Epoxi ( 100%) 150

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3.9 Rails & Stanchions

Following the General Arrangement, Main deck, gangway, platforms in the towers and where are
arranged any type of stairs in the structure, will have stanchions. Preliminary, 1 meter of height (
according to the rules).

They will be compound for vertical flat bars ( 60X 20), handrails ( ND 42.2 X 3.5) and
intermediate rods ( ND 20).

Where in other areas are required, stairs dimensions could be modified.

3.10 Grating

Where are arranged, shall be Thielco (type double serrated and double anti slip) or approved
equivalent, thickness A5/30 above elevation +16 m and A5/50 30x5 (fully welded) DAS below
+16 m. Grating to be fastened with clamps or weld studs for (A5/30) or continuous angle iron
(A5/50), or approved equivalent. Grating floors shall have a 25 mm clearance from any vessel,
sheeting, column, etc, and a clearance of 10 mm from hand railing, baseplates etc. Grating shall
not be cut/adapted etc. after H.D. galvanizing.

3.11 Control room preparation

The distribution of the Control House will be following the kind of equipments to mounting and
Owners requirements in order to improve the control of the operations. The structural metallic
closing will be completed with a tight exterior door and naval panoramic windows. Top and
bulkheads of the Control House will arrange heat & acoustic insulation

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4 Systems

All the required systems will be installed, according to rules:

Ballast
Vents of tanks
Bilge
Fire fighting
Life saving
Ventilations of stores and rooms
Tank sounding
Mooring
Towing
Electric equipment

4.1 Ballast system

For all the operational conditions of dock is necessary to load or unload ballast from the
tanks showed in General Arrangement drawing. There are 16 tanks in pontoon and
another 4 in wing walls.

The ballast system will allow maintaining the desired draught and stability conditions for
a safe operation of dock

There will be four pump rooms in the pontoon, symmetrical. In each one a ballast pump to
be installed and a sea chest, with all the necessary valves manometers, filters and
accessories.

The pumps to be centrifugal, selfpriming, 1200 cubm/h capacity at 30 m. water column,

electrically driven, with a common foundation for both the motor and the pump. The
materials to be appropriated for sea water: casing and impeller of bronze, shaft of stainless
steel. The motor will have

Each pump will connected to another pump of the same side, allowing to work with the
tanks of this side in case of breakdown.

Valves of ballast system to be of butterfly type, hydraulically operated from control room,
in general.

Ballast pipes to be of GRP or galvanized mild steel

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4.2 Sounding and Vents of tanks

Each tank to be provided with vent pipe, going from below the pontoon deck and through
the wing wall up to the upper deck. The section of pipe to be 125 % of the corresponding
pump discharging pipe. Piping to be of GRP or galvanized mild steel.

A sounding pipe for each tank will be fitted. Piping to be DN 50 ASTM A106 Gr B XS,
galvanized., with the normal accessories fitted.

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5 Electricity

5.1 Shore connection

The dock shall be fitted with one Shore supply connection rated at 380 V, 1500 Kw, 50
Hz

5.2 Main switchboard.

The main switchboard will be located in the engine room, in the void spaces over the
tower tanks. This switchboard shall provide the control and distribution of the electrical
systems ( 380V 50 Hz. main consumers and 220V 50 Hz the low voltage)

5.3 Battery and battery charger.

Two battery groups will be fitted on board, for emergency lighting system and remote
operated valves
The batteries will be charged from the exterior by a transformer.

5.4 24 V c.c. Switchboard.

One 24 V continuous current shall be furnished and installed, shall provide emergency
distribution services

5.5 Control panels

The dock shall be fitted on board with the following control panels:

Lighting control panel

Umbrella elevation/descend system control panel
Draft indication, forward and aft, port and starboard sides
GM indication, heel and trim situation.
Remote Monitoring and Control System for Ballast Handling.

All functions of ballast handling will be carried out from Control Room.

Ballast monitoring from control room to be provided, with the

following possibilities:
Ballast pumps start, stop, and speed control
Ballast tank level/gauge indication: the four wing wall ballast tanks are
to be equipped with radar type sensing, Pontoon ballast tanks ullage

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(pressure sensing), with high and low level alarm.

Hydraulic remote valve control.
Ballast pumps running lights
Ballast pumps discharge pressure indicators.
Ballast remote controlled valves position (open/close)

5.6 Electrical consumers

Necessary lighting both for accommodation spaces as well as for deck spaces including working
lights to be installed. All apparatus installed on exposed decks to be of non-corrosive material.
Lighting equipment to be of approved type intended for use on board ships.
All electrical equipment installed on exposed decks to be IP-56.

The electrical consumers are the following:

Umbrella and its equipment.

Concrete distribution System
Lighting system
Ballast system
Mooring system
Signal and control system.

5.7 Generating set

One generating set, 1200 KW, shall be installed to supply the consumers.

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Annex

A) TECHNICAL DATA SHEET MX 24Z

Mass (kg)
With concrete in pipeline: 6787 Out of order: 5898

Load moments (KNm)

Position of arm Arm-side arm-inclination

Pump operation with concrete en pipeline

446 0,0

Boom operation without concrete in pipeline

19 90,0

Boom not operation without concrete in pipeline,

position for climbing 19 90,0

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Torque moments (KNm)

With concrete in pipeline: 60 Out of order: 7

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Wind loads
Wind loads by pump operation
Pump operation is allowed only till wind force 8: (wind velocity 20 m/s preasure q 0.250
KN/m2)
Wind loads boom not operation (high wind in accordance with DIN 1055

Wind load W (KN)

Q Impact pressure (KN/ m2)

W= q * A * C A wind exposed area (m2)
C Aerodynamic force factor for boom
Impact pressure q((KN/m2)
Absolute altitude 0-8 8-20 20-100 Above 100
q((KN/m2) 0,5 0,8 1,1 1,3

Wind exposed area (m2)

Position of arm Win exposed area Center of gravity distance xs of wind

exposed surface
I Arm side 6,2 Xs I- 6.1
II Arm side 6,2 Xs II- 0.3
I/II Counterbalance side Xs I- -

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B) COLUMNS WITH QUICK-SEPARATING

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C) WORKING PLATFORM

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D) CRUCIFORM BASE

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MAIN EQUIPMENT AND MATERIAL LIST

Remarks
Quantity Units Description

3350 ton Pontoon and lateral walls

units Ballast pumps

units Power unit

Steel NEN-EN 10025 Grade S355J2/J4G3 for the
420 ton
Umbrella tucture
Steel NEN-EN 10025 Grade S355J2/J4G3 for the
234 ton
towers structure

Grid (type double serrated and double anti slip) or Handrails along the grating
approved equivalent, thickness A5/30 above elevation perimeter.
+16 m and A5/50 30x5 (fully welded) DAS below +16
1800 m2
m. Grating to be fastened with clamps or weld studs for
(A5/30) or continuous angle iron (A5/50), or approved
equivalent.

TBD Stairs

Accessories to be
included:
o Radio control
o 2 m length pillar with
flanges to assembly,
equipped to allow
work.
o Working Platform
with handrails, grid
PUTZMEISTER MXR-MX24-125 or equivalent. This with required hole for
hydraulic system shall comprise a tri-phase motor of stair access and four
3 units 380V, 15 KW, 1480 rpm and a high pressure pump, 24 attachment bolts.
V control box, 160 lt oil tank with a filter acting on the
o Rigid Base
High pressure pump
o 2 m length stair, with
protection and
pipeline supports

CONCRETE PUMPS
AND THE PIPELINE
TO THE BOOMS TO BE
PROVIDED BY
SHIPOWNER

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PALFINGER or similar on top floor of Umbrella.

2 units
Capacity 4 ton/12m

5.7.1.1.1.1.1.1.1 Working forms To be supplied by shipowner

o Height 1.20 m
o Plate thickness 3 mm
382 ton o Total weight : Forms +Hanging supports+Platform
225kg/ml
o Strip (Tapering) 5-8 0/00
o Hanging supports length 1.50 m
o Hanging support clearance (free height)
0.7 m

Hoisting system for Umbrella. All 24 climbing units

comprise two long stroke hydraulic double acting
24 set cylinders of 70 tons capacity and two double acting
hydraulic locking cylinders of 20 tons capacity (or any
other system of 140 tns capacity in each climbing unit)

72 ton Hoisting and guiding bars for hydraulic system. Steel

NEN-EN 10025 Grade S355J2/J4G3

24 Units Rotary joints for hoisting bars

3 units Longitudinal displacement system for concrete booms

5.7.1.1.1.1.1.1.11
25.7.1.1.1.1.1.1.10
Units Longitudinal displacement system for ancillary cranes

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