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Road-transportable modular pontoons
Diving and ROV operations requiring surface-supplied or saturation diving systems and work-class ROVs, along with tools such as cranes, excavators, and pipe or cable laying systems (see photos below), as well as other heavy equipment, need surface support offering ample space. These operations sometimes occur in areas like rivers, natural lakes, artificial lakes with dams, congested port sections, or island lagoons isolated from the open sea by very shallow reefs, which are inaccessible to typical diving support vessels and barges used at sea. In such cases, road-transportable modular pontoons, which consist of floating platform sections designed for easy transport on standard trucks and assembly on-site into large floating structures, can provide an ideal solution.
It must also be considered that such pontoons can be used to create temporary jetties when operating in rivers or lakes with banks too shallow to allow small boats to approach, forcing personnel to jump into the water to embark and disembark, and preventing the transfer of large equipment. Regarding the historical origin of these technologies, it is worth noting that while the use of floating bridges dates back to antiquity, and perhaps earlier, the concept of using modular floating jetties to create entire port facilities dates back to World War II, when the British engineered and deployed temporary, portable harbors known as "Mulberry Harbours" for the D-Day landings on the Normandy coast (France) in June 1944 (see the picture below).
Current road-transportable modular pontoons, convenient for organizing diving and ROV operations in the aforementioned areas, can be made of steel and high-density polyethylene (plastic). Note that while anodized aluminum is still used in the construction of floats for some marina pontoons and small barges, it appears that this material is no longer employed in the design of road-transportable modular pontoons, except for frames supporting additional floors. Modular steel pontoons are typically composed of rectangular modules that are often compartmentalized into several sections. These compartments are frequently left empty, which allows for regular verification of their integrity. In some cases, they may be filled with closed-cell foam to reduce the risk of flooding in case of punctures or leaks. However, this advantage results in the inconvenience that the integrity of compartments cannot be visually checked from inside. The decision to leave compartments empty or fill them with foam depends on several factors, including the manufacturer's design, the intended use of the pontoon, and specific client requirements. These pontoons are provided with clamping systems allowing them to be assembled in various configurations to create large surface supports. These configurations can be customized to surround structures or be simple shapes like squares or rectangles. These clamping systems are usually specific to each manufacturer, so merging pontoons from two different manufacturers is not ordinarily possible. We can see these differences in the modules below from Poseidon Barge (https://www.poseidonbarge.com) and ETC Marine (https://www.ectmarine.com). The smaller modules are typically about 4 m (L) × 2 m (W) × 0.7 m (H), weigh between 1.2 and 2 tonnes, and have a load capacity of up to 10,000 kg/m², depending on the unit. The larger modules can typically be up to approximately 12 m (L) × 3 m (W) × 1.5 m (H), weigh around 11 tonnes, and have a load capacity of up to 10,000 kg/m². Barges designed with such modular pontoons can be anchored in various water bodies such as lakes, rivers, or ports using anchors or legs, depending on the operational depth. They can also be equipped with portable thrusters and dynamic positioning (DP) systems, allowing self-propulsion and positioning, such as illustrated below by Thrustmaster (https://www.thrustmaster.net), a well-known manufacturer of such equipment.
The concept of modular steel pontoon sections, which could be transported by truck and assembled into barges, ferries, or floating docks, dates back to at least the World War II era (1940s) and possibly earlier within military engineering circles. (Click on the photo below that shows such a unit to open the 1942 installation manual.)
These military-style modular pontoon units were then adapted into commercial barge platforms for the civil engineering, salvage, and dredging industries following the 2nd World War. In parallel, the concept of floating jetties has been widely reused to organize port facilities for small recreational boats and sometimes large vessels at more favorable costs than classical piers. However, please note that even though they can be considered an example of the use of this technology, the floating jetties used to create “Mulberry Harbours” could not have been transported by road due to their size. Therefore, this article focuses only on light units that can be carried by “normal” trucks, so as not to necessitate the organization of an exceptional convoy for their transfer, and that can be easily installed using a light crane. It must be considered that due to their size, exceptional convoys may not access difficult-to-reach areas.
Also, note that some manufacturers claim that barges assembled with their modular steel pontoon sections can be used in open sea conditions. Regarding this point, I recall participating in the repair of an optical fiber cable between Dover (UK) and Calais (France), diving from such a barge, and completing the operations on time despite several days of rough weather. Providing the address of every manufacturer of this type of equipment would be a very long and nearly impossible task, considering that small shipyards produce them alongside established manufacturers. However, the directory below lists some well-known brands of such equipment designers, whose websites offer information to better understand their products: Damen: Damen Shipyards Group - Pontoon Division - P.O. Box 1 - 8260 AA Kampen, The Netherlands Website: https://www.damen.com/vessels/pontoons-and-barges/ modular-pontoons Email: info@damen.com Phone: +31 (0)38 385 8585
ECTMarine: Unit 4, The Mill Industrial Estate, Mill Road, Fareham, Hampshire PO16 0TH, United Kingdom Website: https://www.ectmarine.com Email: sales@ectmarine.com Phone: +44 (0)1329 288 121
Aqua Dock: Hereford House, Bath Parade, Cheltenham, Gloucestershire, GL53 7HU, United Kingdom Website: https://www.aqua-dock.co.uk Email: sales@aqua-dock.co.uk Phone: +44 (0)1242 216820
Flexifloat Systems PDM Bridge, LLC (Flexifloat) 1000 PDM Way - Point Pleasant, WV 25550, USA Website: https://www.flexifloat.com Email: info@flexifloat.com or sales@flexifloat.com Phone: +1 (304) 675-2361
Modular Pontoon Systems (MPS B.V.) Nijverheidsweg 12, 3641 RP Mijdrecht, Netherlands Website: https://mpsbv.com/ Email: info@mpsbv.com Phone: +31 (0)418 – 67 80 86
Poseidon Barge 5000 Hwy 308 (River Road) Belle Chasse, LA 70037, USA Website: https://www.poseidonbarge.com Email: info@poseidonbarge.com Phone: +1 (504) 656-9800
Weifang Dragon Machinery Technology No. 1688, Yuhe Road, Weifang City, Shandong Province, China 261000 Website: https://dragonsolution.en.made-in-china.com/ Email: sales@dragonfloat.com Phone: +86 536-227 2889
HDPE (High-Density Polyethylene) pontoons with UV stabilizers are popular due to their resistance to corrosion, ultraviolet rays, and impacts, providing good durability, low maintenance, and lifespans exceeding 15 years. They typically consist of square molded modules, each measuring about 0.5 m on each side and 0.4 m in height, joined using dedicated corner connectors or pin-and-nut systems." Installing them is straightforward and usually requires no specialized staff or heavy equipment, as the modules (weighing around 7 to 10 kg) can be hand-carried and transported in small vehicles over rough or unprepared roads. They are widely used for floating working platforms and jetties deployable on natural or unprepared shorelines. Their load capacity is generally around 350 kg/m², with some systems designed to support up to 750 kg/m² when configured in double layers. They are therefore unsuitable for heavy loads, although many suppliers offer steel or aluminum subframes and flooring to distribute weight more evenly.
Similar to steel modular pontoons, there are many manufacturers of HDPE (High-Density Polyethylene) pontoons with UV stabilizers. However, the market is highly fragmented, with companies frequently appearing or disappearing, making it impractical to maintain a complete and current list. Many of these manufacturers focus exclusively on the marina and leisure market, and although their products could technically be adapted for mobile work units, their legal acceptance for such use is uncertain. To avoid recommending potentially non-compliant products, I have limited my selection to manufacturers who explicitly describe this application in their product specifications.
National Pontoon Ltd: Unit 4, Mill Lane Industrial Estate, Wimborne, Dorset BH21 2JW, United Kingdom Website: https://www.nationalpontoon.co.uk Email: sales@nationalpontoon.co.uk Phone: +44 (0)1202 849400
Pontoonworks Ltd: Unit 4, Mill Lane Industrial Estate, Mill Lane, Wimborne, Dorset BH21 2JW, UK Website: https://www.pontoonworks.co.uk Email: sales@pontoonworks.co.uk Phone: +44 (0)1202 849400
It must be taken into account that a few manufacturers offer large- dimension high-density polyethylene (HDPE) modules. One example is Perebo, a company headquartered in Germany that provides units with the following typical dimensions: 5 m (L) x 2.5 m (W) x 1.2 m (H). These modules are assembled similarly to steel models and can withstand a load capacity of up to approximately 400 kg/m². The weight of these units is not mentioned. Perebo contact: Industriestraße 1 49439 Steinfeld, Germany Website: https://www.perebo.com Email: info@perebo.com Phone: +49 (0) 5492 980-0
Note that HDPE (High-Density Polyethylene) pontoons are also used as floating supports for activities such as fish farms and solar farms as a result of their reasonable costs and ease of transportation, installation, and maintenance.