Nature Rubber Cylindrical Fender with Easy Installation Hose for Harbors and Ports/certificate ISO9001 2008, BV.CCS

Cylindrical  Rubber Fender
 
It is a classic high-pressure inflatable anti-collision protection structure used in port terminals and ship operations. It adopts an integrated vulcanization molding of a cylindrical structure, relying on the internal compressed air to achieve elastic buffering and energy absorption. With the advantages of uniform force distribution, flexible installation, and wide adaptability, it has become the core equipment for small and medium-sized terminals, ship berthing, temporary operation berths, and ship side protection. It also combines practicality and economy.

Product Description:

Material Advantages:
 
The overall structure is an integrated vulcanized design consisting of multiple layers of rubber composite and reinforced by high-strength cord fabric. There are no joint gaps, and the structure is sturdy with excellent air tightness, suitable for harsh marine conditions:
Outer layer: Made of natural rubber / nitrile rubber composite material, with additives for anti-aging and anti-ultraviolet protection, resistant to seawater corrosion, friction, and tearing, and some specifications can be customized with wear-resistant pattern coatings;
Middle layer: Multiple layers of high-strength polyester cord / nylon cord are axially and radially cross-wound to enhance the hull's tensile and impact resistance, preventing deformation and bulging under high pressure;
Inner layer: High air tightness butyl rubber to ensure long-term pressure retention, reducing the frequency of daily air replenishment and lowering maintenance costs;
Standard accessories: Standardly equipped with galvanized / stainless steel inflation valves, pressure gauges, and sealing gaskets. For large-sized products, they can be paired with lifting hooks, anti-collision panels, and fixed chains to meet different installation requirements.

 
Manufacturing Process:
 
The production process for cylindrical tugboat fenders strictly adheres to integrated molding standards for rubber products, focusing on core requirements of “structural integrity, compliant elasticity, and suitability for high-frequency tugboat operations.” Specific steps are as follows:
### 1. Raw Material Preparation and Compound Formulation
- Core raw materials include natural rubber (≥65% content), blended with styrene-butadiene rubber (enhancing elasticity and abrasion resistance), carbon black (strengthening structural integrity), zinc oxide (vulcanization accelerator), anti-aging agents, and UV absorbers. These are meticulously proportioned and fed into the internal mixer.
- Compound at 120-140°C for 30-40 minutes to ensure uniform blending. Subsequently, roll the compound into uniformly thick rubber sheets (thickness adjusted per fender diameter, typically 6-12mm) using an open mill, then cool to room temperature for later use.
### 2. Mold Design and Pre-Treatment
- Customize cylindrical steel molds according to fender specifications (diameter 100-400mm, length 500-2000mm). Polish the inner mold surface to ensure a smooth fender surface after molding.
- Preheat the mold to 80-100°C and evenly apply release agent to prevent adhesion between the cured fender and mold, while extending mold service life.
### 3. Molding and Vulcanization
- Cut calendered rubber sheets to match the mold cavity dimensions. Layer them around the cylindrical core mold, ensuring tight adhesion without wrinkles or voids.
- For diameters ≥200mm, embed 2-4 layers of polyester cord fabric reinforcement between rubber layers. Apply specialized adhesive between reinforcement and rubber layers to enhance tear resistance and pressure-bearing capacity.
- After closing the mold, place it into the vulcanization chamber. Vulcanize at 150-160°C and 0.8-1.0 MPa pressure for 3-5 hours to fully cross-link and cure the rubber, forming an integrated cylindrical structure.
### 4. Post-Processing and Precision Correction
- After vulcanization, allow the mold to cool below 80°C before opening. Remove the rough fender blank, trim excess material and flash along the mold line, and grind surface burrs to ensure a uniform cylindrical contour.
- Process both ends of the fender: install metal flanges or weld lifting rings (made of corrosion-resistant 316L stainless steel), drill mounting holes, and smooth hole walls to ensure component compatibility.
### 5. Performance Testing and Quality Control
- Visual Inspection: Verify fender surface is free of cracks, bulges, or missing rubber. Cylindrical dimensional deviation ≤ ±3mm, length deviation ≤ ±5mm.
- Core Performance Testing: Conduct hardness testing (Shore A 60-70HA), tensile strength testing (≥18MPa), and compression set testing (≤20%) to ensure elasticity and wear resistance meet standards.
- Conduct impact cushioning tests on samples to validate energy absorption capacity under collision scenarios during tugboat operations, meeting operational intensity requirements.
### 6. Finished Product Packaging and Shipment
- Surface Treatment: Apply warning colors (e.g., black, orange) as required. Select products may feature wear-resistant PE film adhesive coating.
- Packaging & Shipment: Packaged on wooden pallets or in woven bags to prevent deformation during transit. Includes product inspection reports and installation manuals for direct use by tugboat shipyards or repair facilities.

Features:

Uniform force distribution, excellent buffering effect: The contact area of the cylindrical body is large, when the ship docks, the force is dispersed, the counterforce is gentle, which can effectively protect the ship's steel plates and the dock's protective wall, avoiding scratches and damages caused by hard collisions;
Flexible installation, wide application scenarios: Supports various installation methods such as fixed on the side wall of the dock, suspended on the side of the ship body, and combined floating with floating buoys. No need for complex supports, can quickly adapt to small, medium, and large-sized docks, fishing ports, temporary operation areas, and various ship side protection;
Strong weather resistance, long service life: The rubber material can withstand extreme temperatures of -40℃ to +60℃, is resistant to seawater, acids, alkalis, and salt fog corrosion, and is resistant to aging and ozone. Under normal conditions, the service life can reach 7-9 years, and the outdoor maintenance is good;
Rich specifications, high cost performance: Standard specifications cover small, medium, and large tonnage requirements. It can be put into use after inflation. Daily maintenance only requires regular inspection of air pressure, and the gas replenishment operation is simple. Compared with other anti-collision facilities, the purchase and maintenance costs are lower;
Stable energy absorption, safe and reliable: It relies on the elastic deformation of internal compressed air to absorb energy, without the risk of bursting or sinking, the deformation recovery speed is fast, and it can continuously withstand the repeated impact of ship docking.

Technical Parameters:

Applications:

 
It is widely applied in small and medium-sized ports and docks (fish ports, passenger ports, general cargo docks), ship side protection (cargo ships, fishing boats, yachts, work vessels), ship-to-ship berthing operations (anchorage transfer, fleet grouping), temporary operation berths (engineering ships' docking, water construction areas), as well as inland river ports, lake ports, etc. It is the preferred equipment for small-tonnage anti-collision protection.

Support and Services:

After-sales consultation: We provide 24/7 customer service to answer customer questions , such as specification selection, usage methods, and maintenance points.
Regular follow-up visits: The manufacturer may conduct regular follow-up visits to customers to understand the usage and collect customer feedback in order to continuously improve product quality and service levels.
 
with its excellent quality and attentive service, builds a solid guarantee for your maritime career. Choosing us means choosing safety, efficiency, and worry - free operation. Embark on a new journey of navigation, starting from choosing our fender!
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