ASSEMBLY PROCESS FOR

DOCKING-STATION
 I) Assembly the Docking Station

Step 01 :

Realize pre-assembly by mounting the guides ( upper parts ) on the pillars as planned.
Do not tighten up because the guides need to be adjusted later.

Step 02 :
Install the nuts on the threaded rods, follow the dimension of 100mm and let down the nuts
of the central rods of each plate.

10
0
m
m

Place washers and perforated plates, then cover the threaded rod by tube helping the
positioning of the pillar and protects the thread.
Step 03 :

Using a crane or forklift install the pillars on the anchorage starting with the pillar on the
back ( first line ).

Step 04 :

Adjusting the alignment of the pillar compared to the marking using the crane or forklift.
Make a mark on the centerline on the pillar.

YES NO

Step 05 :

Set the plates and adjust verticall and horizontall position with screws. The longitudinal plate
should follow the slope of the ground.
Step 06 :

Adjust the height of the pillars with the nuts, the height from the ground to above the guide
must be 1835 mm.

Step 07 :

Remove the protective tubes and put the machined washers, washers and nuts.

Step 08 :

Place the template to control the spacing between the two pillars.
The distance between one and the other guide of pillar must be 1221mm.
Check this with the weight suspended in the middle of template.
The weight should be centered relative to the guides.
Move one, the other or 2 guides in order to respect the balance. Use a tensionner.
Step 09 :

Proceed to tightening, for it unscrew the nuts one by one, put a few drops of Loctite 243 on
the thread and tighten the nut with key 55 by holding the lower nut. Then apply the torque
to 1800 Nm with hydraulic key.
 II) Realization of wire guidance grooves

Remarks :

- There must be no angle at 90 ° so that the wire is not "broken", drilled at 20mm
diameter at each angle over 40mm depth.

- Each joints connection, each slab joint, concrete seam, concrete crack and every 15m
make a hole (diameter: 20 mm / depth: 40 mm) and make a loop of wire.

- Le fond des tranchées doivent être plan

0 +/- 2mm

Step 01 :

Make the marking on the ground for the wire accordingly to the plan
Docking_conteneur_ATT_Lift. Use the setting docking bar and the centering metal weight
to determine the center between two pillars. Trace the path of the double wire on both
sides of the central line.
Step 02 :

Using a grooving machine, make the trenches following the marking on the ground.
The trenches must respect the plan, have a regular width of 3-4 mm for a wire diameter 2.5
mm and a regular depth of 20 mm.
Make measurements every 150 m to check the regularity and that the cutting disc has not
worn.

Step 03 :

Drill 20mm diameter and the depth of 40mm each trench angle and intersection with a slab
joint.

Step 04 :

Clean the grooves with compressed air and scraper so that inside there are no pebbles.
Sweep on the outside to keep out impurities back into the groove. The groove must be clean
inside.
 I) Installation of the guide wire

Instructions :

- it is recommended to install the wire soon after making grooves and cleaning them,
so we avoid dust and pebbles that can fall into the grooves

- It is preferable to use a wire having the total length of the circuit

- In the case of break or extend the wire must be welded and protected with
waterproof shrink tubing. Follow the instructions below.

- There must be no 90 ° angle so that the wire is not broken

- At each slab joint and drill holes make a loop in the hole provided

- The wire should not be tense, or force engaged in the groove

- Leave at least 2.5 m minimum wire at electrical box

Step 01 :

Unroll the wire being careful not to do spiral. Place the wire into the groove clean and dry (
groove should. The wire should not be stretched too much and he should lay into the
grooves itself.

Step 02 :

Place the foam seal in the groove, which must be fully inserted. Use a roll ( roll with holder)
to put the foam seal completely inside the groove. The wire must be full covered.

Next use compound (HIT-HY70 resin) to cover the foam and make it waterproof. Compound
can not have any contact with the wire.

The ends of the foam cut off in the holes ( joint holes, intersections and corners ) and put
inside loop of foam and compound to cover it
well.

Step 05 :

Cover the trench with com HIT-HY 70 using an applicator. Clean and dry the trench before.

Do not do it in the rain because there will not be adhesion.

Scrape surface to remove excess compound and have a clean finish.

Step 06 :

Connect the wire in the electrical box. Leave at least 2,5m reserve.

Mark the long and short loop.