Durable 500H-3000H Cell Rubber Fender for Efficient Docking and Mooring WITH CCS ABS LR BV

Durable 500H-3000H Cell Rubber Fender for Efficient Docking and Mooring WITH CCS ABS LR BV

Product Description:

Material Advantages:

Main body made of rubber
The core adopts a compound formula of natural rubber and synthetic rubber (such as styrene-butadiene rubber and chloroprene rubber). Natural rubber ensures excellent elasticity and resilience, while synthetic rubber enhances weather resistance, seawater corrosion resistance and anti-aging ability.
Adding reinforcing agents such as carbon black, anti-tear agents and weather-resistant additives can enhance the tensile strength, tear strength and wear resistance of rubber, enabling it to withstand the impact and friction of ships during berthing as well as the erosion of the high-salt and humid Marine environment.
The hardness of the rubber is controlled at 55 to 65 degrees on the Shore A scale, taking into account both the buffering and energy absorption effects as well as structural stability, to avoid excessive deformation or excessive reaction force.
Internal reinforcement and structural materials
Some models are equipped with multiple layers of polyester or nylon cord fabric as the skeleton layer to enhance the tensile and deformation resistance of the fender, ensuring that the original structural shape can be maintained after long-term use.
The key force-bearing parts can be embedded with steel plates or fiber-reinforced composite materials to enhance the local load-bearing capacity and prevent local damage when the fender comes into contact with the wharf or the hull.
Surface and matching materials
The surface is often coated with ultra-high molecular weight polyethylene (UHMW-PE) wear-resistant plates to reduce the friction coefficient with the hull, prevent scratches on the hull surface, and at the same time reduce the wear of the fender itself.
Installation accessories (such as bolts, pressure plates, and connecting parts) are made of hot-dip galvanized steel or stainless steel, which have excellent resistance to seawater corrosion and ensure the stability of the connection between the fender and the wharf structure.

Manufacturing Process:

1.. Raw material preparation and formula optimization
Natural rubber, synthetic rubber (such as styrene-butadiene rubber/chloroprene rubber, etc.), carbon black reinforcing agent, antioxidant, vulcanizing agent and other raw materials are mixed in proportion, and then mixed at high temperature and high pressure in an internal mixer to produce a uniform rubber compound with weather resistance and wear resistance.
The rubber compound needs to undergo cooling and standing (curing) treatment to eliminate internal stress and ensure fluidity and adhesion during subsequent molding.
2. Enhance structural pretreatment
If polyester/nylon cord fabric is built-in, it needs to be cut in advance to the size suitable for the honeycomb structure, and the surface should be coated with rubber-specific adhesive to enhance the bonding strength with rubber.
The embedded steel plates need to undergo sandblasting for rust removal and acid washing for oil removal. After drying, they should be coated with anti-corrosion materials and adhesives to prevent seawater erosion and ensure a tight bond with the rubber.
3. Mold preparation and insert positioning
Customized honeycomb structure molds are adopted, and the inner walls of the molds are coated with mold release agents to ensure smooth demolding after molding and a smooth product surface.
The pre-treated curtain fabric, steel plates and other reinforcing parts are precisely placed into the mold at the designed positions, and the positioning devices are fixed to prevent displacement during the molding process.
4. Rubber compound filling and molding
The cured rubber compound is injected into the mold through an injection machine or calender to ensure that the compound fully fills each cavity of the honeycomb structure without any defects such as bubbles or material shortage.
Apply a certain pressure (15-30 mpa) to the mold to make the rubber compound closely adhere to the reinforcing parts and initially fix the shape of the product.
5. Vulcanization curing treatment
The mold is sent into the vulcanizing tank and the "medium-temperature long-duration" vulcanization process is adopted. The temperature is controlled at 145-155℃, and the vulcanization time is adjusted according to the thickness of the product (usually 8-12 hours).
During the vulcanization process, the temperature and pressure need to be monitored in real time to ensure that the rubber is fully cross-linked and cured, while also guaranteeing a firm bond between the reinforcing parts and the rubber.
6. Post-processing and finishing
After vulcanization is completed, demolding is carried out to remove the flash and burrs on the product edges. The surface is ground and polished to ensure that the dimensional accuracy meets the design standards (such as honeycomb pore size, overall length, width and height).
If UHMW-PE wear-resistant plates need to be installed, apply special glue to the fender surface, attach and fix the wear-resistant plates, and then apply pressure and let them stand to ensure a smooth bond without any loosening.
7. Accessory assembly and quality inspection
Install hot-dip galvanized steel or stainless steel connectors (bolts, pressure plates, etc.) to ensure that the accessories are firmly installed and precisely positioned.
Conduct multiple performance tests: including dimensional deviation measurement, rubber hardness (Shore A 55-65 degrees) test, tensile/tear strength test, honeycomb structure sealing performance test, and peel test of reinforcing part bonding strength. Only after passing the tests can the products be released from the factory.

Features:

Durable Cell Rubber Fender (Durable honeycomb rubber fender) has significant advantages in terms of protection performance, stability and adaptability through the collaborative design of structure and material. The core product features are as follows, which meet the core requirements of efficient berthing and mooring of ships:
1. Excellent energy absorption and impact resistance
This type of fend has an extremely high energy-absorbing weight ratio. The honeycomb structure combined with high-density rubber material of 1.2-1.5g /cm³ can efficiently absorb the huge impact force when ships berth, while maintaining a low reaction force, significantly reducing stress damage to the hull and wharf structure. Moreover, it also has excellent shear resistance. When used in combination with the front panel and ultra-high molecular weight polyethylene gasket, it can further reduce the impact of shear force and prevent the fender from being damaged in complex force scenarios such as diagonal collisions. The hardness of its rubber is controlled at 60-80 degrees on the Shore A scale, the elongation at break is ≥400%, and the compression set is ≤35%. Even if it is subjected to repeated impacts for a long time, it can quickly rebound and is not prone to permanent deformation.
2. The structure is stable and highly durable
It mostly adopts an integral structure similar to a drum. The circular shape makes the pressure distribution uniform when it is subjected to force. Compared with ordinary fenders, it can effectively disperse the impact energy from multiple directions. Even after long-term use, it can still maintain its original structural shape, and its stability far exceeds that of traditional block fenders. The material adopts a rubber formula with strong weather resistance, which can resist the erosion of high salt and ultraviolet rays in the Marine environment. Some super honeycomb fenders have been tested to achieve stable service for several decades. At the same time, the ultra-high molecular weight polyethylene wear-resistant plate matched on the surface can not only reduce the friction loss with the hull but also prevent the hull from being scratched, indirectly extending the service life of the fender itself.
3. Easy to install and maintain, and widely adaptable
The installation method is flexible, supporting two mainstream installation modes: bolt fixation and welding. It can be selected according to the needs of different installation scenarios such as docks and offshore platforms, and the connection is firm and stable after installation. This type of fenders can be customized in size, with outer diameters ranging from 650 millimeters to 3000 millimeters. They can also be adapted to ships of different tonnages such as large cargo ships, oil tankers, and ferries, as well as various scenarios including container terminals, oil and gas terminals, and passenger terminals. In addition, its maintenance requirements are extremely low. The high-quality rubber material and stable structure reduce the frequency of frequent inspections and replacements, which can help users such as ports lower their long-term operating costs.
4. Outstanding security compatibility
When subjected to force, the pressure on the hull is relatively small. When paired with low-friction panels, it can reduce damage to the hull shell during the sliding process of the ship's berthing. It is especially suitable for ships such as cruise ships and LNG carriers that have high requirements for surface protection of the hull. At the same time, it is compatible with a wide temperature range of -25℃ to 80℃ and can still play a normal protective role in extreme weather conditions such as storms and cold waves. Moreover, most of the products have passed multiple authoritative industry certifications such as ISO 9001, CCS, and BV, and the quality and usage safety are strictly guaranteed.

Technical Parameters:

Applications:

The application scenarios of durable honeycomb rubber fenders revolve around "high-impact protection, weather resistance and durability, and adaptability to diverse berthing needs", covering various port, ship and Marine engineering scenarios, as follows:

1. Core areas of various ports and terminals
- Container terminal: It is suitable for the frequent berthing of container ships, can absorb the concentrated impact force of large ships berthing, and protect the quay walls and the fixed structure of containers on the hull.
- Oil and gas terminals (LNG terminals, crude oil terminals) : They have strong oil resistance and corrosion resistance, which can meet the safety protection requirements for dangerous goods vessels berthing and avoid the risk of leakage caused by collisions.
- Bulk cargo terminals (coal, ore, and grain terminals) : They can withstand the impact of heavy vessel berthing, as well as the dust and humid environment of the terminals, reducing maintenance frequency.
- Passenger terminals/roll-on/roll-off terminals: The low reaction force design can protect the hull shells of passenger ships and roll-on/roll-off ships from scratches or structural damage, ensuring passenger safety.

2. Special ships and Marine engineering facilities
- Specifically designed for large vessels: Suitable for oil tankers, LNG carriers, large cargo ships and other vessels with large tonnage and strong impact force during berthing, providing efficient buffering.
- Offshore platforms: It is used for the protection of boarding points on drilling platforms and wind power platforms, resisting the impact of berthing on supply ships and workboats, and adapting to the harsh Marine environment of high salt and strong winds.
- Barges and special vessels: Suitable for temporary or long-term berthing of engineering barges, crane vessels and other operation vessels, taking into account both structural stability and anti-deformation capacity.

3. Complex berthing environment scenarios
- Special structure wharfs such as high-pile wharfs and caisson wharfs: Flexible installation, adaptable to different quay wall shapes of wharfs, and capable of filling the protection requirements of structural gaps.
For ports with large tidal fluctuations: The rubber material is resistant to immersion and aging, and can adapt to the long-term alternating dry and wet environment, maintaining stable protective performance.
Berths in busy waterways: In scenarios with frequent berthing, the strong durability feature can reduce the frequency of fender replacement and lower operating costs.

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.

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