Cylindrical Tugboat Rubber Fender/certificate ISO9001 2008, BV.CCS

Cylindrical Tugboat Rubber Fender
 
Cylindrical tugboat fenders are protective equipment specifically designed for towing operations. With their simple structure and strong adaptability, they serve as core protective components for docking, pushing, and rescue operations. The following details their key features, material composition, adaptability advantages, and application scenarios:
 

Product Description:

Material Advantages:
 
1. Core Structure and Material Advantages
Streamlined and Efficient Structural Design: Features an integrated cylindrical structure with common diameters ranging from 100-400mm and lengths from 500-2000mm. The smooth, protrusion-free surface ensures even force distribution upon contact with vessels, preventing localized stress concentration. Equipped with metal flanges or lifting rings at both ends for easy installation and secure mounting, adaptable to various positions including tugboat bows, sterns, and sides.
Material Strength and Wear Resistance: The core material is natural rubber, blended with styrene-butadiene rubber to enhance elasticity. Additives including carbon black, anti-aging agents, and UV absorbers provide resistance to seawater corrosion and friction wear. Shore hardness is controlled at 60-70HA, ensuring effective cushioning while maintaining dimensional stability. Large-sized models incorporate multi-layer polyester cord reinforcement with tensile strength ≥18MPa, delivering outstanding tear resistance to withstand instantaneous impacts during tugboat operations.
 
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:

Energy-absorbing rapid rebound: The cylindrical structure deforms in all directions under pressure, achieving over 25% higher energy absorption efficiency than flat fenders of the same size. It effectively cushions collision forces between tugboats, towed vessels, and docks, protecting structural integrity on both sides. With a rebound rate exceeding 92%, it rapidly restores its original shape after operation, enabling uninterrupted continuous work.
Adapted for Tugboat Operations: Compact and lightweight (individual unit ≤80kg), it imposes no additional load on tugs. Flexible installation allows single-unit deployment or multiple units arranged side-by-side, accommodating the confined side spaces and complex operational postures of tugboats.
Exceptional Durability: The rubber surface exhibits superior abrasion resistance, withstanding friction and scratches from sand, stones, and hull surfaces. It maintains performance for 5-8 years in high-salinity, high-humidity marine environments without frequent replacement, reducing maintenance costs.
Easy Installation and Maintenance: Installation is achieved through bolting or rope securing, eliminating the need for complex construction tools. The smooth surface resists fouling and marine organism growth, requiring only periodic visual inspections and fastener checks for minimal maintenance.

Technical Parameters:

Applications:

 
Tugboat Berthing Protection: Installed along the tugboat's hull, it provides cushioning and collision protection when the tugboat docks alongside piers, supply vessels, or other ships, preventing damage to the paintwork and structural integrity of both the tugboat and the berthing vessel.
Bow-Pushing Operations: Cylindrical fenders mounted on the tugboat's bow distribute thrust forces during the pushing of large vessels, floating structures, or offshore installations. This prevents localized overpressure damage to the pushed object while protecting the tugboat's bow structure.
Maritime Rescue Protection: During rescue operations for stranded or out-of-control vessels, fenders cushion impacts between the tugboat and distressed ships. This provides safety protection for rescue personnel and prevents secondary damage.

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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