Port of Felixstowe – Torsion Arm Fender Supply

Project Overview:

Case Study: Port of Felixstowe – RoRo Berths 3 & 4
Project: RoRo Berth 3 & 4 Upgrade
Location: Port of Felixstowe
Date: Completed 2020

The Challenge: Mission-Critical Delivery in a Global Crisis

The upgrade of Ro-Ro Berths 3 and 4 at the Port of Felixstowe was a high-stakes project aimed at increasing the capacity of the Dooley Terminal. However, the project coincided with the height of the COVID-19 pandemic, a period that crippled global logistics and the construction industry. The challenge was to maintain a rigorous design and manufacturing schedule to ensure the port’s operational expansion remained on track despite unprecedented supply chain uncertainty.

The DockGuard Solution

DockGuard worked closely with McLaughlin & Harvey to provide a high-performance, multi-system fendering solution. Our scope included the detailed design, manufacture, and testing of a diverse range of fenders engineered specifically for the dynamic berthing requirements of modern Ro-Ro vessels.

Key System Components:

21 DGL Leg Fender Systems: Supplied as DGL1250 conventional leg systems, providing robust, high-energy protection across the main berths.

4 DCN Torsion Arm Systems: These specialized systems utilized DCN1200 Double Cone configurations integrated with torsion arm mechanics to manage the heavy, off-center impacts typical of ferry operations.

Advanced Frontal Panels: Each system featured watertight, closed-box steel panels fitted with low-friction UHMW-PE facing pads to protect vessel hulls.

Mooring Equipment: To complement the fenders, we supplied 100T Staghorn Mooring Bollards, each secured with high-grade M48 fixings.

Engineering Excellence: The Torsion Arm Advantage

The hallmark of the Felixstowe upgrade was the deployment of the Double Cone Torsion Arm fender systems. Unlike standard fenders, the torsion arm provides superior stability during berthing, ensuring the frontal panel remains parallel to the ship’s hull even under extreme angular loads. This reduces the risk of panel damage and ensures uniform energy absorption, which is critical for the rapid-turnaround environment of a Ro-Ro terminal.

Project Outcome

Despite the severe restrictions imposed by the pandemic, DockGuard managed the entire supply chain with clinical precision. While the original quotation estimated an 18-week lead time, we successfully delivered all 25 fender systems to the site within just 16 weeks. This rapid turnaround allowed the Port of Felixstowe to proceed with its infrastructure upgrades without delay, reinforcing our reputation for reliability during even the most challenging global conditions.