Views: 315 Author: NANJING TAIDUN Publish Time: 2026-10-02 Origin: Site
Content Menu
● Introduction: Why Safe Bollard Testing Matters for Global Maritime Operations
● What Is an In-Situ Bollard Tester? Technical Architecture
>> How the Testing Procedure Works
● The Problem with Traditional Bollard Testing: Why the Navy Needed a New Solution
>> Dangers of Tugboat-Based Testing
● Development Story: The NAVFAC EXWC Innovation
>> The Engineering Team Behind the Patent
>> Patent Details and Technology Transfer
● Comparative Analysis: In-Situ Tester vs. Traditional Methods
● Industry Context: Bollard Pull Testing Standards and Regulations
>> Classification Society Requirements
>> Norwegian Maritime Authority Procedures
● Added Value Section: Practical Implications for Port Authorities and Marine Procurement
>> Why This Patent Matters for Port Infrastructure Management
>> Procurement Considerations for Marine Equipment Suppliers
>> 1. What is the U.S. Navy's In-Situ Bollard Tester patent number?
>> 2. Why is the In-Situ Tester safer than tugboat testing?
>> 3. Can private companies license this technology?
>> 4. What types of bollards can be tested with this device?
>> 5. How does this relate to commercial bollard pull testing standards?
>> 6. What environmental conditions affect bollard pull testing?
>> 7. Why hasn't a standard bollard testing device existed before?
>> 8. What is the significance of this being the Navy's first patent of 2022?
● Conclusion: A New Standard for Mooring Hardware Integrity
The U.S. Navy maintains thousands of bollards worldwide, each designed to withstand hundreds of tons of pressure from mooring lines securing massive vessels . When a bollard degrades or fails, the consequences can be catastrophic—a ship's mooring line may snap the bollard, causing hull damage, operational delays, and serious safety risks to personnel .
For decades, the maritime industry relied on tugboat pull tests to verify bollard integrity. This method, while widely used, carried inherent dangers: the pulling force could create uplift on the bollard that didn't reflect real-world mooring angles, and the procedure itself posed risks to vessels and crews .
In January 2022, that changed. A team of engineers at the Naval Facilities Engineering and Expeditionary Warfare Center (NAVFAC EXWC) in Port Hueneme, California, secured U.S. Patent 11,215,541 for an innovative In-Situ Bollard Tester—the Navy's first patent of that year . This breakthrough device promises safer, more accurate, and more realistic testing of mooring hardware at its installed location.
This article examines the technology, its development, and what it means for port authorities, shipyards, and marine equipment suppliers evaluating mooring hardware testing solutions.
The patented In-Situ Bollard Tester represents a fundamental shift in how mooring hardware is evaluated. Unlike tugboat-based methods that rely on vessel propulsion and towline dynamics, this device applies controlled, measurable force directly to the bollard using a modular steel frame system .
According to the patent documentation, the device comprises:
- A rectangular frame: Made primarily of steel tubing, positioned around the bollard
- Adjustable struts: Attached to the wharf or pier surface for structural stability
- A cable and tensioner system: A hydraulic arm or winch that pulls the cable to apply force
- Adjustable cross members and lock pins: Position the cable at various angles to simulate real mooring conditions
The frame itself includes a pair of hanging columns, pair of jacks, and pair of legs, creating a stable platform that can be adapted to different bollard configurations and pier geometries .
The operational sequence is straightforward but technically precise:
1. Positioning: The frame is mounted onto the pier and around the bollard
2. Cable attachment: A cable is fastened around the bollard at the desired angle
3. Force application: The tensioner (hydraulic arm or winch) pulls the cable
4. Measurement: Force is applied at various load angles to test bollard integrity
Critical advantage: Unlike tugboat testing, which primarily applies horizontal force, the In-Situ Tester can replicate vertical mooring line angles that cause uplift—the very condition most likely to reveal degradation in aging bollards .
Before the In-Situ Tester, the standard approach involved connecting a tugboat to the bollard via a towline and applying pulling force through the vessel's propulsion system. While this method had the advantage of using available resources, it introduced multiple problems :
- Safety hazards: The high-tension towline and sudden failure potential endangered crews on both the tug and the dock
- Unrealistic loading conditions: Tugboat pulls primarily create horizontal forces, failing to replicate the vertical angle components present in actual mooring operations
- Uplift concerns: The geometry of tugboat pulling can induce uplift forces that may damage or weaken the bollard being tested
Perhaps the most significant deficiency in traditional testing was the absence of an accepted standard testing device and procedure. Different ports, operators, and naval facilities used varying methodologies, making it difficult to compare results or establish consistent pass/fail criteria.
The patent application explicitly acknowledges this gap: "There is, however, no accepted standard testing device and procedure. If a bollard is degraded, a ship's mooring line may break the bollard, resulting in damage to the ship and plausibly causing a dangerous situation for individuals involved" .
The In-Situ Bollard Tester emerged from a collaboration between NAVFAC EXWC professional engineer Gerritt Lang and five college interns participating in the PIPELINES program (Problem-based Initiatives for Powerful Engagement and Learning in Naval Engineering and Science) .
The team members credited on the patent include:
- Elaina Ryan
- Juan Carrillo
- Ricardo Contreras
- Zachary Harwood
- Benjamin Hulbert
This internship-driven innovation demonstrates how fresh perspectives combined with naval engineering expertise can produce practical solutions to long-standing operational challenges.
U.S. Patent 11,215,541, titled "In-Situ Bollard Tester," was assigned to the U.S. Navy on January 4, 2022 . The Navy typically receives over 250 patents annually, making this the first of 2022—a notable distinction for the Port Hueneme team .
Commercialization pathway: The patent is available for licensing to private companies through technology transfer agreements, with TechLink (the Navy's national partnership intermediary) guiding interested parties through the process . This opens the door for marine equipment manufacturers, port service providers, and inspection firms to commercialize the technology.
| Testing Method | Safety Profile | Realism of Loading Conditions | Standardization Potential | Equipment Requirements |
|---|---|---|---|---|
| Tugboat Pull | High risk (towline failure, vessel movement) | Limited (primarily horizontal) | Low (variable procedures) | Tugboat, certified load cell, crew |
| In-Situ Bollard Tester | Low risk (controlled, stationary) | High (multi-angle including vertical) | High (repeatable device) | Portable frame, tensioner, load cell |
| Visual Inspection | Very low risk | None (surface only) | Moderate | Inspector only |
| Ultrasonic/NDT | Low risk | Indirect assessment | Moderate | Specialized equipment |
Bollard testing isn't limited to naval facilities—it's a regulated activity across commercial maritime operations. Bureau Veritas, for example, specifies detailed procedures for bollard pull trials used to certify tugboat performance .
Key requirements from BV rules include:
- Water depth: Minimum 4 times propeller immersion depth within a radius of 2 ship lengths
- Ship-to-shore distance: Minimum 50 times propeller diameter to avoid water circulation effects
- Environmental limits: Current speed < 0.5 knots (bow/side) or < 0.3 knots (stern); wind speed < 10 m/s; wave height < 0.5 m
The Norwegian Maritime Authority provides another benchmark for bollard pull testing, specifying :
- Towline length: ≥300 meters (150 meters for vessels under 40 meters)
- Water depth: ≥20 meters within 100-meter radius
- Load cell accuracy: ±2% at temperatures between -10°C and +40°C
- Measurement period: 10 minutes of stabilized bollard pull, recorded every 30 seconds
These standards apply to vessel bollard pull certification, not pier bollard testing. However, they establish the precision and rigor expected in critical mooring hardware assessment.
Port authorities worldwide manage aging infrastructure, including bollards installed decades ago. The In-Situ Tester offers a proactive maintenance tool that can:
1. Identify degradation before failure: Regular testing can detect weakening from corrosion, fatigue, or concrete deterioration
2. Prioritize replacement budgets: Data-driven assessment allows targeted investment in the most critical assets
3. Extend service life: Confirmed integrity enables confident continued use of bollards that might otherwise be replaced prematurely
For companies like NANJING TAIDUN MARINE EQUIPMENT ENGINEERING CO.,LTD that serve global port and marine clients, this technology signals important trends:
- Growing emphasis on testing and certification: Port operators increasingly require documented proof of mooring hardware integrity
- Opportunity for technology licensing: The Navy's technology transfer program opens possibilities for manufacturing and distributing testing equipment
- Integration with fender systems: Mooring hardware testing complements rubber fender selection—both are part of comprehensive berth protection strategies
A technical reference worth noting: The In-Situ Tester's load cell-based measurement approach aligns with the mooring bollard load testing procedures recommended by industry bodies, which emphasize calibrated load cells and controlled load application .
The patent is U.S. Patent 11,215,541, titled "In-Situ Bollard Tester," assigned to the U.S. Navy on January 4, 2022 .
Tugboat testing involves high-tension towlines and vessel movement, creating risks of line failure, crew injury, and unintended uplift forces on the bollard. The In-Situ Tester applies controlled hydraulic force from a stationary steel frame, eliminating these hazards .
Yes. The patent is available for commercialization through technology transfer agreements, with TechLink serving as the Navy's partnership intermediary to guide interested companies through the licensing process .
The tester is designed for in-situ testing of mooring bollards installed on piers and wharves. Its adjustable frame and cable positioning system accommodate various bollard geometries and pier configurations .
While the In-Situ Tester addresses pier bollard integrity, commercial bollard pull testing (for tugboat certification) follows standards like Bureau Veritas rules and Norwegian Maritime Authority procedures. Both aim to ensure safe mooring operations through rigorous, documented testing .
Key conditions include water depth (≥4× propeller immersion), current speed (<0.5 knots), wind speed (<10 m/s), and wave height (<0.5 m). Calm conditions ensure accurate and safe measurements .
The challenge lies in the diversity of bollard installations—varying sizes, materials, pier conditions, and loading angles. Developing a device that adapts to all these variables while maintaining measurement accuracy required the innovative frame design now patented by the Navy .
It highlights the high value placed on operational safety and readiness innovation within the Navy. The fact that an intern-driven project earned this distinction demonstrates the effectiveness of the PIPELINES program in generating practical solutions .
The U.S. Navy's In-Situ Bollard Tester represents a meaningful advance in maritime safety infrastructure. By replacing dangerous, imprecise tugboat testing with a controlled, repeatable device, the Navy has addressed a long-standing gap in mooring hardware assessment.
For port authorities, this technology offers a path toward data-driven maintenance of critical berthing infrastructure. For marine equipment suppliers, it signals growing demand for certified testing solutions and potential licensing opportunities. For the global maritime industry, it establishes a foundation for what could become a new standard in bollard integrity verification.
As the patent moves toward commercialization through technology transfer, stakeholders across the marine sector should monitor its availability and consider how proactive mooring hardware testing can enhance safety, reduce risk, and optimize infrastructure investment.
Ready to explore mooring hardware testing solutions for your port or vessel? Contact our engineering team to discuss your berth protection requirements, including rubber fenders, bollard assessment, and comprehensive marine equipment sourcing.
