2*3.5M Foam Filled Fender with EVA Foam Core and Wear-resistant Polyurea 10-Year Lifespan for Ship Protection

2*3.5M Foam Filled Fender with EVA Foam Core and Wear-resistant Polyurea 10-Year Lifespan for Ship Protection

Product Description:

Material Advantages:

(Marine polyurethane foam-filled solid floating fenders) are mainly composed of the following materials:

Foam core material: Typically made of closed-cell EVA (ethylene-vinyl acetate copolymer) foam or closed-cell polyethylene foam. This foam is lightweight and highly elastic, capable of absorbing a large amount of impact energy under compression. Its closed-cell structure also gives it excellent hydrophobicity; even if the fender surface is damaged, it will not absorb water, thus ensuring the fender's buoyancy and preventing it from sinking.

Outer protective layer: Generally a polyurea coating. Polyurea is a new material with an adjustable high elastic modulus, possessing excellent wear resistance, impact resistance, corrosion resistance, water resistance, and UV protection. It effectively protects the internal foam core material, extending the fender's service life. Its smooth surface and low coefficient of friction minimize damage to the hull, and it is colorfast and non-foaming.

Reinforcing layer: Between the foam core material and the outer protective layer, there is usually a reinforcing layer made of nylon or fiber mesh. This layer increases the fender's strength and toughness, enabling it to better withstand external forces and preventing the outer protective layer from separating from the foam core material. End fittings: The two ends of the fender are usually equipped with hot-dip galvanized steel flanges or chain links, etc., to fix the fender to the dock or hull, which facilitates installation and use and has good corrosion resistance.

Manufacturing Process:

The core of the production process is "core material molding → structural reinforcement → outer layer protection → accessory assembly → inspection and shipment," with each step interconnected to ensure product strength, buoyancy, and weather resistance:

1. Raw Material Pretreatment and Preparation
The foam core material raw material (EVA or polyethylene granules) must be dried to remove moisture and prevent pores after molding.

The outer protective layer raw material (polyurea resin, curing agent) is mixed and stirred in a specific ratio to ensure uniform composition; the reinforcing layer (nylon fiber mesh) is cut to specifications matching the fender dimensions.

End accessories (hot-dip galvanized steel flanges, chain links) undergo surface cleaning to remove oil and impurities, ensuring sealing during subsequent assembly.

2. Foam Core Material Molding
The pretreated foam raw material is placed into a specialized mold and heated and pressurized through molding or injection molding processes to melt, foam, and solidify the material.

During the molding process, temperature (typically 80-120℃) and pressure are strictly controlled to ensure the foam forms a uniform closed-cell structure, guaranteeing buoyancy and elasticity.

After curing, demold the core material and trim the edges to remove excess material and ensure dimensional accuracy meets design requirements.

3. Reinforcing Layer Coating: Evenly wrap or cover the cut nylon fiber mesh onto the foam core material surface, ensuring a complete, wrinkle-free fit.

Some products have a special adhesive applied between the fiber mesh and the core material to enhance adhesion, prevent separation during subsequent use, and improve overall structural strength.

4. Outer Protective Layer (Polyurea) Spraying/Casting: Using high-pressure airless spraying equipment, evenly spray the mixed polyurea material onto the reinforcing layer surface to form a dense protective film.

During spraying, control the coating thickness (typically 3-5mm) to ensure no missed areas, pinholes, or other defects; some large fenders use a casting process to ensure uniform outer layer thickness.

After spraying, cure at room temperature (or accelerate curing at low temperature) to form a complete, wear-resistant, and corrosion-resistant protective structure.

5. End Fitting Assembly
Drill holes at both ends of the cured fender and secure the hot-dip galvanized steel flanges or chain links with bolts, adding sealing gaskets at the bolt connections.

Perform a secondary sealing treatment on the assembled parts by applying anti-corrosion sealant to prevent seawater from seeping into the interior and corroding the fittings or core material.

6. Finished Product Inspection and Finishing
Buoyancy Test: Submerge the fender in water to test its floating state, ensuring there are no issues such as sinking or tilting, and that the buoyancy meets design standards.

Strength Test: Simulate ship impact through impact testing to test the fender's elastic recovery capacity and structural integrity.

Appearance and Dimensional Inspection: Inspect the outer surface for scratches and damage, ensure dimensional deviations are within allowable limits, and verify the secure installation of fittings.

Defective products are repaired by grinding, repainting, or reassembling; qualified products are cleaned and labeled (with specifications, load-bearing capacity, and other parameters).

7. Packaging and Shipment
Wrap the finished fenders with stretch film to prevent scratches on the outer protective layer during transportation.

Package is prepared in batches according to order requirements or shipped unpackaged, with installation instructions and test reports provided.

Features:

Outstanding impact resistance and energy absorption performance
The interior is filled with high-density closed-cell EVA foam, combined with the outer layer of wear-resistant rubber. It can efficiently absorb the huge impact forces during ship berthing and mooring, and its buffering effect is superior to that of traditional inflatable protective planks. Moreover, it will not fail as a whole due to local damage.
No inflation maintenance, convenient to use
No need to be equipped with inflation equipment and pressure monitoring systems, completely avoiding the risks of air leakage and tire burst of inflatable protective planks; daily maintenance only requires simple cleaning, significantly reducing the operation and maintenance costs of the dock and the ship.
Strong weather resistance and corrosion resistance
The outer rubber is made with a seawater-resistant and ultraviolet-resistant formula, which can be used in harsh environments such as the ocean and ports for a long time. It can withstand salt fog, acid and alkali corrosion and temperature changes between high and low, and has a long service life.
Stable structure, wide adaptability
After foam filling, the shape of the protective planks is not prone to deformation, and it can be adapted to different tonnage ships (from speedboats to large cargo ships) and dock structures (vertical, inclined, floating docks); the installation method is flexible, supporting various schemes such as bolt fixation and chain suspension.

Technical Parameters:

Applications:

Ports and Terminals
As the core anti-collision facilities for wharf berths, bridge piers, and breakwaters, they protect the dock structure and the hulls of berthing vessels from collision damage. These are standard products for commercial ports, fishing ports, and yacht docks.
Ship Accessories
Installed on the sides of ships, they are used for side-by-side berthing of ships (such as for transfer operations) or for the contact buffering between ships and the dock. They are suitable for various types of ships, including cargo ships, oil tankers, ferries, and yachts.
Ocean Engineering
Applied to the anti-collision protection of offshore platforms, wind turbine foundations, and bridge piers of cross-sea bridges, etc., to resist the impact of passing ships and ocean waves.
Inland Waterway Transportation
Suitable for inland ports, locks, and ferry crossings, they meet the anti-collision requirements for berthing of inland vessels and adapt to the freshwater environment and complex navigation conditions of inland rivers.

Support and Services:

After-sales consultation: We provide 24/7 customer service to answer customer questions regarding anchor chain usage, 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.

Maintenance guidance: The manufacturer or professional organizations will provide customers with  maintenance guidance, including regularly checking for deformation, rust,; 

Any question please let us know ,our JinCheng maritime will provide you the best service with 7*24 hours ~