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 Installation Guide – Solid Rubber Dock Bumper

 Tools & Materials Required

• Heavy-duty drill with masonry/steel bits (Ø16–Ø20mm depending on bolt size)
• Hammer drill for concrete or steel dock walls
• Anchor bolts / Expansion bolts (M16–M20 recommended, galvanized or stainless steel for marine use)
• Spanners / socket wrenches for tightening bolts
• Measuring tape & marker for alignment
• Level tool to ensure correct bumper positioning
• Protective gear (gloves, goggles, safety boots)

 Step 1 – Site Preparation

1. Identify the dock area or wall section where the bumper will be installed.
2. Ensure the surface is clean, dry, and free of loose debris (dust, grease, old paint).
3. For marine environments (ports, jetties in Kota Kinabalu, Bintulu, Muara, etc.), confirm the surface is corrosion-free and suitable for bolt anchoring.

 Step 2 – Positioning the Bumper

1. Hold the bumper against the wall in its intended mounting location.
2. Standard mounting height:
   • Dock walls → 400–600mm above ground (to match truck trailer bed height).
   • Marine jetties → aligned with the vessel’s contact point.
3. Use a measuring tape and level tool to align horizontally or vertically.
4. Mark bolt hole positions on the wall through the pre-drilled holes in the bumper.

 Step 3 – Drilling Holes

1. Using a hammer drill, drill holes into the wall at the marked positions.
2. Drill to the recommended depth:
   • Minimum embedment of 75–100mm for M16–M20 anchor bolts.
3. Ensure holes are straight and dust-free (blow out debris using compressed air).

 Step 4 – Mounting the Bumper

1. Align the bumper holes with the drilled wall holes.
2. Insert the anchor bolts through the bumper into the drilled holes.
3. Use a hammer (if necessary) to tap bolts fully into position.
4. Hand-tighten nuts to hold the bumper in place.

 Step 5 – Tightening & Securing

1. Use a spanner or impact wrench to tighten the bolts securely.
2. Ensure firm compression between bumper and wall (no gaps).
3. Avoid over-tightening, which may deform the rubber.

 Step 6 – Final Inspection

1. Check bumper alignment with dock edge / berthing point.
2. Confirm bolts are fully tightened and secure.
3. Perform a test with a vehicle (truck or forklift) to ensure correct impact alignment.
4. For marine applications, check periodically for bolt corrosion (especially in Muara, Sandakan, Tawau, Kuching Ports).

 Additional Installation Notes

• For concrete walls: Use heavy-duty expansion bolts or chemical anchor bolts.
• For steel frameworks: Use through-bolts with backing plates.
• For wooden docks (rare cases in rural Borneo towns): Pre-drill and secure with galvanized lag bolts.
• For high-impact zones: Use reinforced bumpers with internal steel plate.
• Custom installation: Larger bumpers (over 1000mm) may require welding brackets or bolted steel support frames.

# Estimated Installation Time

• Small bumper (Model 300 / 330): 20–30 minutes per unit.
• Larger bumper (Model 450 / 760): 30–45 minutes per unit.
• Full dock installation: 2–4 hours depending on quantity.

 Maintenance Tips After Installation

• Inspect every 3–6 months for wear, tear, or bolt loosening.
• Replace anchor bolts if corrosion is visible.
• Replace bumper when rubber is cracked, torn, or heavily compressed.