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Scope:                         Annual rolling maintenance programme for removal,
                                  refurbishment and installation of 8 no hydraulic
                                  cylinders and gimbals                                                        

FISHBOURNE & PORTSMOUTH FERRY PORTS -
LINKSPAN HYDRAULIC CYLINDER REPLACEMENTS

At Fishbourne and Portsmouth ferry port terminals, there are 4 no hydraulic
cylinders on gimbals located on each linkspan approach (2 on either side). Each
cylinder stands approximately 11 meters high and weighs approximately 9 tons.
The hydraulic cylinders move vertically in line with the daily tide levels, providing lift
control and correct height adjustment for the loading ramps - permitting vehicles to
safely embark and disembark the ferries.


Continuous use and daily operation of the cylinders and the associated gimbals,
combined with weather and tidal conditions, cause wear problems such as oil
leakages from the seals on the cylinders and excessive corrosion to a number of
the gimbal mechanisms.


Following an inspection, Shepcote Engineering (who maintain the hydraulic cylinders
for Wightlink) and Ekspan identified the need for an annual rolling programme of
major maintenance and refurbishment works to be carried out on 1 cylinder per
year. The duration for the works was programmed for eight years to accommodate
all 8 hydraulic cylinders and gimbals for structural servicing and replacement, at
both terminals.

Job Brief

Background Information

Project Team

Client:                          Wightlink Limited
Main Contractor:            Shepcote Engineering
Structural Consultants:    Ekspan
Start Date:                    2009
Completion Date:           Ongoing

Ekspan were employed by Shepcote Engineering to carry out the removal and replacement works for each of the 8 hydraulic cylinders on a rolling maintenance
contract. The scope of works included; manufacture of a new gimbal assembly and
clevis to enable the new unit to be fitted after removal of the first old cylinder assembly; design and manufacture of lifting clamps for safe removal and replacement of cylinder; removal of cylinder assembly and installation of 1 new unit. Refurbishment
of gimbal assembly included new bushes, application of paint system, fitting of new
bolts and fixings. The gimbal was prepared ready for attachment to the cylinder for
the following year’s replacement.


These works had to be undertaken sequentially, in agreement with Wightlink, during
specific night shift closures (Sat 22:00 - Sun 06:30), to avoid disruptions to ferry
crossings. The lift planning methodology for removal and re-installation had to be
precise, as the area around the leaking cylinders for maneuverability was very tight
and therefore great care had to be taken .


All operations during this contract were implemented successfully by Ekspan, on
time and with no disruption to ferry services, even with the challenges of working
with limited access and within confined spaces.

Ekspan's Workscope

Fishbourne Ferry Port - Condition of existing gimbal showing wear and corrosion

Portsmouth Ferry Port - Underside burning of bolts to
release cylinder ready for removal

Portsmouth Ferry Port - New gimbal installed

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