Development for the Manufacturing of Concrete Pontoons


The concept of concrete floating pontoons has been around for many years and in order to improve and make advancements in concrete pontoons we obtained feed back from the marina operators we work with. The main concerns were the ongoing maintenance issues associated with the tightening of through bolts and the replacement of timber walers and galvanised mild steel components.

Traditional concrete pontoons require timber walers to connect the pontoons together and provide a surface for cleats and fender to attach to. The timber is held to the pontoons with galvanised steel through bolts which span the width of the pontoons. In order to reduce the periodic maintenance associated with bolt tightening and galvanised mild steel component replacement, Total Floating Systems have developed an aluminium waler system which eliminates the need for timber walers and galvanised steel through bolts.

Total Floating Systems have also perfected the process of casting holes into the end of concrete finger pontoons. The round ended finger pontoons are also a feature of Total Floating Systems product range and are popular for boat user as these minimise any damage to boats as they manoeuvre into the berth. At the time of pontoon installation the pile is driven within the hole of the pontoon via an anodised aluminium pile guide that eliminates the need for any galvanised mild steel components.

To secure finger pontoons in place traditional galvanised mild steel angle frames typically extend up to 1.5m into a berth space. Through the developments of the aluminium waler system Total Floating Systems can provide reduced angle frames that do not impinge as much into the berth space, but are still large enough to accommodate service pedestals. The angle frames are cast within the pontoons to produce a one piece concrete finger pontoon. With the use of the reduced angle frames urethane hinges have been developed to secure the concrete finger pontoon to the walkway. The hinges are fully UV protected and have been rigorously tested using a mechanical ram to simulate constant wave action.

Total Floating Systems have also made changes to the galvanised mild steel pile guides that bolt onto the timber walers and are often within the splash zone. The galvanising is prone to deteriorating over a number of years and although they may remain structurally sound for years, the surface rusting can be unattractive and the rust particles are possibly detrimental to the boat owners.

The galvanised coating process has been changed to an Aluminium Sprayed and Epoxy coated system and the contact points on the pile guide where the mild steel rubs against the tantalised pile has been replaced with stainless steel wearing plate. Under normal day to day conditions the lifetime of the pile guide is expected to last significantly longer than the equivalent galvanised guide.

Aluminium Walers
Aluminium Walers
Concrete Pontoon
Round Ended Pontoon
Pile End
Internal Pile Guide
Rubber Connecting Hinge
Rubber Connecting Hinge