The Ultimate Guide to Mooring Bollard Installation & Maintenance

For port operators and contractors, the arrival of the bollards is just the beginning. The most robust bollard in the world is useless if it’s installed incorrectly.

I have seen projects delayed by weeks because anchor bolts¹ were misaligned by a few millimeters. I’ve seen expensive cast iron bodies crack because of poor grouting.

This guide covers the critical steps of installation and maintenance to ensure your mooring system lasts for decades², not just until the warranty expires.

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The Golden Rule of Pre-Installation: Use Templates

The biggest nightmare on a quay wall construction site is discovering that the pre-cast anchor bolts do not match the holes in the bollard.

Do not rely on drawings alone. We always manufacture a steel or plywood anchor bolt template³ that matches the exact bolt pattern of the bollards. We ship this to the contractor before the bollards arrive (or with the anchor cages) so they can use it during the concrete pouring phase.

Why is this non-negotiable?

• Concrete shifts during pouring.
• Manual measurements have tolerances.
• A physical template locks the bolts in the correct position relative to each other.

If you are a buyer, insist that your supplier provides these templates. It is a small cost that saves thousands in remedial work.

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Supplier Verification: Trust but Verify

Before you even pay the final balance to your supplier, you need to perform a critical check.

The "Photo Verification" Protocol Request that the supplier aligns the actual manufactured bollard with the anchor cage or template in their factory and sends you photos.

• Check the spacing: Use a tape measure in the photo to verify the distance between hole centers.
• Check the fit: Ensure the bolts slide easily through the holes without forcing.

If a supplier refuses to do this or sends blurry photos, be very suspicious. Catching a misalignment in the factory is a simple fix. Catching it on the construction site is a disaster.

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Step-by-Step Installation Process

Step 1: Surface Preparation & Positioning⁴

The concrete surface must be chipped to remove laitance (the weak, milky layer on top of concrete) to ensure good bonding for the grout. The bollard is then lifted into place over the protruding anchor bolts.

Step 2: The Critical Grouting Phase

This is where many installations fail. The gap between the underside of the bollard and the concrete deck must be filled with high-strength, non-shrink grout⁵.

• Purpose: It transfers the load uniformly from the bollard to the foundation.
• Risk: If there are air voids (bubbles) in the grout, the bollard will have "soft spots" support. Under heavy load, the cast iron can crack because it's bridging a gap rather than being supported.

Step 3: Bolt Tensioning

Bolts should be tightened in a star pattern⁶ (like changing a car tire) to ensure even pressure. They must be torqued to the specific value recommended by the manufacturer. Over-tightening can strip threads; under-tightening leads to fatigue failure.

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Common Installation "Crimes"

The "Cut and Bend" Technique When bolts don't align, lazy contractors might cut off a bolt or heat and bend it to fit.

• The Result: The steel structure is compromised. The bollard effectively has fewer anchors than designed. This is a severe safety violation.

Galvanic Corrosion Ignorance⁷ If you are using stainless steel anchors with a cast iron bollard, you effectively have a battery. In a saltwater environment, the less noble metal (cast iron) will corrode rapidly.

• The Fix: Use isolation washers and sleeves⁸ to break the electrical contact between dissimilar metals.

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Maintenance: It’s Not "Fit and Forget"

Mooring bollards are tough, but they live in a brutal environment.

Annual Inspection Checklist⁹:

1. Coating Damage: Look for deep scratches or peeling paint. Touch up immediately to prevent rust spread.
2. Bolt Tightness: Bolts can loosen over time due to vibration and settlement. Re-torque them annually.
3. Wear Patterns: Check the back of the bollard where ropes rub. Excessive grooves can damage expensive mooring lines.

By following these protocols—especially the use of templates and factory verification—you ensure that your mooring infrastructure is as safe on Day 1000 as it is on Day 1.

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