Plymouth CATS

For this project, we were tasked with the refurbishment of bespoke Plymouth CAT ship berthing fender systems, used in conjunction with timber piling secured to the quay wall. To address deterioration and extend service life, we designed and manufactured galvanised steel clamps to restore structural integrity to splitting timber piles, ensuring long-term performance in the marine environment.

Developing a suitable design that addressed both the client’s budget constraints and the condition of the degrading timber piles proved challenging, particularly within the project timescale and site-specific working constraints.

Installation of the clamping units presented challenges due to below-water-level access. Through detailed planning, round-the-clock working, and close coordination with diving contractors, the works were successfully completed within the required timeframe while managing tidal movements.

The design solution comprised 8m-long folded steel plate sections with welded gussets for structural integrity, bolted back-to-back to form a clamp-like structure. All components were manufactured in-house and hot-dip galvanised to provide a durable marine-grade coating. Smaller clamp sections were also fabricated and installed along the length of the fender system below the waterline.

Through detailed planning and the use of heavy marine equipment, including multi-cat work barges and plant machinery, we completed the works on schedule, preparing the site for the installation of the newly refurbished Plymouth CAT berthing fenders from our contractor’s shipyard.

Using the ship lift to remove the berthing fenders allowed us to carry out a complete overhaul to a high standard. Each fender was surveyed and discussed with the client to determine the required works. All ancillary items were removed, new marine-grade paint systems applied, and replacement components installed where necessary. Upon completion, each fender was lifted back into the water and reinstalled alongside our newly installed piling-sleeve timber piles along the quay edge.