Floating Foam Filed Closed Cell Pneumatic Fenders Nature Rubber CTN Type and Sling Type with Hose for Ports

Floating Foam Filed Closed Cell Pneumatic Fenders Nature Rubber CTN Type and Sling Type with Hose for Ports

Combining the high energy absorption of inflatable fenders with the buoyancy of closed-cell foam, these fenders come in two styles: CTN (Chain-Tire Network) and sling-type. They are commonly paired with hoses for collision protection during ship berthing in ports.

Product Description:

Material Advantages:

The main body is made of natural rubber, offering excellent elasticity and resistance to seawater corrosion. It is internally filled with 100% closed-cell foam, ensuring basic buoyancy and preventing sinking even if the outer rubber layer is damaged. An intermediate synthetic fabric reinforcement layer maintains stable internal air pressure and enhances impact resistance.
Standard initial working pressures are 50kPa or 80kPa, with custom pressures available upon request. Diameters typically range from 500 to 4500mm, with lengths from 1000 to 12000mm, accommodating vessels of various tonnages. Compliant with ISO 17357-1:2014 standards, select products also hold certifications from classification societies such as CCS and ABS.

The dedicated hoses primarily serve inflation and pressure relief operations. Constructed from high-pressure-resistant rubber, they withstand harsh environments like outdoor port settings and seawater corrosion. When connected to the fender's inflation valve, they enable rapid pressure adjustment with robust sealing to prevent air leakage.

Manufacturing Process:

Production Process for Natural Rubber Floating Inflatable Fenders with Closed-Cell Foam Filling (CTN Type/Sling Type)
This process strictly adheres to ISO 17357-1:2014 standards and specifications for rubber product vulcanization and foam filling. It centers on three core requirements: “sealing and anti-sinking, pressure-bearing and cushioning, and protective adaptability.” Specific steps are as follows:

### 1. Raw Material Preparation and Formula Mixing
- The primary rubber compound consists of a natural rubber and styrene-butadiene rubber blend, combined with additives including carbon black (for enhanced abrasion resistance), zinc oxide (vulcanization accelerator), anti-aging agents, and UV absorbers. These components are proportioned and fed into a closed-mill mixer, where they are thoroughly compounding for 30-40 minutes at 120-140°C to ensure uniform distribution.
- Closed-cell foam utilizes polyurethane (PU) closed-cell foam raw material. The foaming formula is pre-adjusted to control foam density between 30-50 kg/m³, ensuring buoyancy and anti-sinking performance meet standards after filling.
- The reinforcement layer utilizes high-strength polyester cord fabric, cut to dimensions matching the fender's length and circumference. It is pre-soaked in rubber adhesive to enhance bonding strength with the rubber layer.

### 2. Fender Body Molding (Rubber Layer + Reinforcement Layer)
- Employ a “wrap-molding + vulcanization curing” process: First, wrap inner tire rubber sheets around a custom cylindrical core mold. Then, layer polyester cord fabric (number of layers adjusted per fender diameter, typically 8-16 layers) with adhesive applied between each layer. Finally, cover with outer tire rubber sheets to ensure uniform overall thickness (Outer rubber thickness ≥15mm).
- The wound carcass is placed in a large vulcanization tank and cured at 150-160°C and 0.8-1.0MPa pressure for 4-6 hours. This fully cross-links and solidifies the rubber, forming an integrated sealed structure that prevents interlayer delamination.

### 3. Closed-Cell Foam Filling and Sealing
- After cooling the vulcanized fender body to room temperature, inject polyurethane closed-cell foam material through the reserved injection port. Slowly stir during injection to ensure uniform foam filling throughout the fender interior, eliminating voids and bubbles.
- After foam curing (24 hours at room temperature), the injection port is sealed using a hot vulcanization process. A gas tightness test is then conducted: pressurize to working pressure (50 kPa or 80 kPa), maintain pressure for 24 hours, and a leakage rate ≤3% is considered acceptable, eliminating air pressure leakage during use.

### 4. Functional Component Installation (for CTN/Sling Types)
- **Universal Component Installation**: Weld stainless steel 316L lifting rings (for securing and suspension) to the end caps of the fender. Install copper inflation valves (with leak-proof seals) and pressure relief valves. Connect matching rubber hoses and test valve operation flexibility and sealing integrity.
- **CTN-Specific Process**: Cut and assemble used tires into protective netting. Secure the netting to the fender exterior using high-strength iron chains. Ensure tire surfaces adhere to the fender. Connect both ends to the lifting rings via shackles to prevent netting loosening or shifting.
- **Sling-Type Exclusive Process**: Custom polyester slings (load capacity ≥ 3 times the fender's self-weight) matching the fender length are thermally bonded to both ends. Rubber sleeves cover the sling surfaces to prevent abrasion of the fender body.

### 5. Surface Treatment and Quality Inspection
- Grind the fender's outer surface to remove burrs and excess material from vulcanization. For CTN-type fenders, inspect the secure connection between the tire net and chain links. For sling-type fenders, verify no loosening at sling attachment points.
- Core performance testing includes: - Hydrostatic burst testing (at 1.5 times working pressure) - Foam density verification (via ultrasonic testing) - Dimensional tolerance checks (diameter deviation ≤ ±5mm, length deviation ≤ ±10mm)
- Apply warning colors (e.g., orange, yellow) and affix reflective markings per port requirements. Certain products require certification from classification societies like CCS or ABS, with issuance of compliance reports.

### 6. Finished Product Packaging and Factory Acceptance
- After deflation, fenders are shrink-wrapped. CTN models require additional protective netting wrapped in woven bags to prevent transport abrasion.
- Conduct final inspection before shipment to verify: - Visual quality (no cracks or bulges) - Component integrity - Performance test data Apply compliance labels upon full compliance and arrange for dispatch.

Features:

Dual Protection Against Damage and Sinking: The natural rubber outer layer resists seawater and UV erosion, while closed-cell foam filling addresses the common issue of traditional inflatable fenders sinking after damage, significantly reducing the risk of port equipment loss.
Dual-Directional Protection for Fenders and Hulls: The CTN-type chain-tire net and sling-type reinforced rubber layer prevent damage to both fenders and hulls from different angles during collisions, reducing vessel repair and fender replacement costs.
Adaptable for multiple operational scenarios: Suitable for both collision prevention during vessel berthing at ports and as a buffer during ship-to-ship transfers. Its easy installation and adjustment accommodate various port facilities, including standard berths and inclined berths, enhancing port operational efficiency.

Technical Parameters:

Applications:

Yacht / Sailing Boat Protection: Suitable for various sizes of yachts and sailboats. When moored at the dock or when sailing and meeting, it buffers the impact force of collisions, protecting the paint finish and the structure of the boat.
Fishing Boat / Speedboat Use: Suitable for near-shore navigation and mooring in shallow waters. It resists the friction of rocks and shore walls, and is also suitable for the portable storage needs of small vessels.
Dock / Floating Platform Protection: As a fixed buffer device, it is installed at the edge of the dock or around the floating platform to prevent direct impact of ships when moored, reducing wear and tear.
Commercial Vessel Accessories: Suitable for ferries, sightseeing boats, etc. of commercial vessels. Multiple specifications are available for selection, and they can be used in batches to enhance the safety of navigation and docking.
Waterborne Work Platform Protection: Provides anti-collision protection for waterborne construction platforms and breeding floating platforms, resisting collisions caused by wind and waves, and ensuring the stability of the platforms.
Temporary Docking Buffer: For temporary mooring of outdoor water activities (such as kayaks, motorboats), it is inflated quickly for use to avoid direct contact between the boat and hard objects.

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.
Maintenance guidance: The manufacturer or professional organizations will provide customers with maintenance guidance, including regularly checking for deformation, rust, ; applying rust-preventive oil or corrosion inhibitors after cleaning; and lubricating .
 
 
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