Yokohama Fender Manual
24
PNEUMATIC RUBBER FENDERS FD-04R1 HANDLING MANUAL No. MANUAL FOR YOKOHAMA
description
Yokohama fenders catalog
Transcript of Yokohama Fender Manual
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PNEUMATIC RUBBER FENDERS
FD-04R1HANDLING MANUAL No.
MANUAL FOR YOKOHAMA
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01
Preface
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12. 13.
SPECIAL PRECAUTIONS
PERFORMANCE
CONSTRUCTION3-1 Outer Rubber3-2 Synthetic-tire-cord-Layer3-3 Inner Rubber3-4 Bead Ring3-5 Flange Opening
INFLATION4-1 Small and medium-size4-2 Large-size
UNPACKING, TRANSPORTING, AND STORING5-1 Unpacking5-2 Inflating the fender5-3 Lifting the fender5-4 Transporting by trailer or forklift5-5 Avoiding direct sunlight5-6 Avoiding other damage5-7 Preventing rolling5-8 Storing repair materials
INSTALLATION6-1 For a quay / jetty6-2 For a ship
PRECAUTIONS
INSPECTION AND MAINTENANCE
REPLACEMENT
SAFETY VALVE10-1 Installation10-2 Pressure checking
REPAIR
ACCESSORIES12-1 Small and medium-size (Size: 500mm ~ 2,000mm) 12-2 Large-size (Size: 2,500mm ~ 4,500mm) 12-3 Precautions for storage and use of accessoriesGUARANTEE
2
2
3
5
7
9
12
18
18
18
19
20
21
22
CONTENTS
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02
efacePrThis manual has been prepared to familiarize you with the specifications and procedures for operation, installation, maintenance, inspection, testing and repair of Yokohama Pneumatic Rubber Fenders. We hope that the manual will be useful and convenient so that you can use our fenders safely and satisfactorily.
Yokohama Pneumatic Rubber Fenders were developed utilizing the companys ninety years of research and development technology and expertise in related areas ranging from automobile tires to aircraft fuel cells. Since the first Yokohama Pneumatic Rubber Fender was introduced in1958, about more than 50,000 of these units have been in use around the world, receiving wide acclaim for their safe, dependable performance.
The major difference between conventional rubber fenders and Yokohama Pneumatic Rubber Fender is that conventional rubber fenders rely solely on the elasticity of rubber for job performance. Yokohama Pneumatic Rubber Fenders do more than that: they utilize the elasticity of air as the primary cushioning agent, thus giving superior performance and greater versatility.
The main features of Yokohama Pneumatic Rubber Fenders are:
1)
2)
3)
4)
5)6)
High energy absorption and low reaction force and surface pressure.No decline in the rate of energy absorption when obliquely compressed, under normal circumstances, and uniform surface pressure for any contact area.Low reaction force to prevent damage from repeated impacts against the hull of a ship, a quay/jetty, or a mooring rope.Ability to float and thus rise and fall with the ebb and flow of tides and the movements of a ship.Easy installation.High standard of uniform quality in compression performance with no deterioration of the rubber.
SPECIAL PRECAUTIONS1This product is containing compressed air inside. If the product gets burst, burst energy of the compressed air will make people injured.
Therefore,
1)
2)
Make sure that air pressure is not more than specified pressure, as there is a possibility of burst if the air pressure is higher than the specified pressure.Make sure that there are no damage on the product, as the damage will weaken pressure resistance strength of the product and make the product burst.
3)
4)
5)
6)
Use within the maximum energy absorption specification in Table 2-1 to avoid rupturing the fender.Avoid allowing the fender to come in contact with surface protrusions or sharp-edged implements at any time.Cut or exposed reinforcement cords might result in damage to the fender.The fender must be lifted at its designated lifting points. Failure to do so could result in damage to the fender.
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03
Table2-1(A-1) Pneumatic 50 Standard Sizes
Diameter
Length
Nominal Size
(mm mm) 5001000
6001000
7001500
10001500
10002000
12002000
13502500
15003000
17003000
20003500
25004000
25005550
33004500
33006500
330010600
45009000
450012000
InitialInternalPressure
(kPa)50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
6
8
17
32
45
63
102
153
191
308
663
943
1175
1814
3067
4752
6473
64
74
137
182
257
297
427
579
639
875
1381
2019
1884
3015
5257
5747
7984
132
126
135
122
132
126
130
132
128
128
137
148
130
146
158
146
154
-
-
-
-
-
-
-
-
-
-
175
175
175
175
175
175
175
200
200
200
200
200
200
200
200
200
200
250
250
250
250
250
250
250
22
25
45
73
88
131
200
250
290
405
902
1090
1460
1870
2560
3940
4790
110
120
150
200
220
320
350
530
580
960
1240
1850
1710
2570
4660
5390
6990
30
30
40
80
140
190
200
350
440
640
910
1160
1270
1910
3300
3520
5190
20
22
37
51
57
68
-
-
-
-
-
-
-
-
-
-
-
32
36
55
89
104
147
229
279
320
459
1080
1320
1840
2250
3060
-
-
GuaranteedEnergy
Absorption(GEA)
ReactionForce
at GEA
HullPressureat GEA
SafetyValve
SettingPressure
TestingPressure
Approx.FenderBody
Weight ChainNet
Weight of Net Type (Type)
WireNet
Approx. Weight of Net
SyntheticFiber Net
Weightof Sling
Type(Type)
(kNm)E
(kN)R
(kPa)P
(kPa) (kPa) (kg) (kg) (kg) (kg) (kg)
(A-2) Pneumatic 50 Popular Non Standard Sizes
Diameter
Length
Nominal Size
(mm mm) 4001500
6001200
8001200
12001800
13503500
15002500
20003000
20004500
25007700
33008600
45006400
InitialInternalPressure
(kPa)50
50
50
50
50
50
50
50
50
50
50
6
10
16
55
152
123
255
418
1350
2443
3238
87
93
116
262
641
464
727
1188
2951
4138
3796
151
132
122
122
141
126
122
137
157
154
133
-
-
-
-
-
-
-
-
175
175
175
200
200
200
200
200
200
200
200
250
250
250
23
28
48
123
255
221
367
480
1370
2220
3400
-
-
240
310
600
440
900
1200
3020
3710
3900
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
33
39
58
139
284
250
421
534
1600
2720
-
GuaranteedEnergy
Absorption(GEA)
ReactionForce
at GEA
HullPressureat GEA
SafetyValve
SettingPressure
TestingPressure
Approx.FenderBody
Weight ChainNet
Weight of Net Type (Type)
WireNet
Approx. Weight of Net
SyntheticFiber Net
Weightof Sling
Type(Type)
(kNm)E
(kN)R
(kPa)P
(kPa) (kPa) (kg) (kg) (kg) (kg) (kg)
Note: 1.Figures on the table comply with requirements of ISO17357.2.Weight of fender body and net may vary 10%.3.Special size are available upon request.
PERFORMANCE2
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04
(B-2) Pneumatic 80 Popular Non Standard Sizes
Diameter
Length
Nominal Size
(mm mm) 4001500
6001200
8001200
12001800
13503500
15002500
20003000
20004500
25007700
33008600
45006400
InitialInternalPressure
(kPa)80
80
80
80
80
80
80
80
80
80
80
9
14
23
77
213
171
356
584
1884
3410
4518
114
122
153
344
842
610
955
1560
3876
5437
4988
199
174
160
160
185
166
160
179
206
202
174
-
-
-
-
-
-
-
-
230
230
230
250
250
250
250
250
250
250
250
300
300
300
24
30
50
127
261
244
375
488
1550
2620
3760
-
-
240
310
600
440
900
1210
3030
3710
3910
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
34
41
60
143
290
273
429
542
1780
3110
-
GuaranteedEnergy
Absorption(GEA)
ReactionForce
at GEA
HullPressureat GEA
SafetyValve
SettingPressure
TestingPressure
Approx.FenderBody
Weight ChainNet
Weight of Net Type (Type)
WireNet
Approx. Weight of Net
SyntheticFiber Net
Weightof Sling
Type(Type)
(kNm)E
(kN)R
(kPa)P
(kPa) (kPa) (kg) (kg) (kg) (kg) (kg)
(B-1) Pneumatic 80 Standard Sizes
Diameter
Length
Nominal Size
(mm mm) 5001000
6001000
7001500
10001500
10002000
12002000
13502500
15003000
17003000
20003500
25004000
25005550
33004500
33006500
330010600
45009000
450012000
InitialInternalPressure
(kPa)80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
8
11
24
45
63
88
142
214
267
430
925
1317
1640
2532
4281
6633
9037
85
98
180
239
338
390
561
761
840
1150
1815
2653
2476
3961
6907
7551
10490
174
166
177
160
174
166
170
174
168
168
180
195
171
191
208
192
202
-
-
-
-
-
-
-
-
-
-
230
230
230
230
230
230
230
250
250
250
250
250
250
250
250
250
250
300
300
300
300
300
300
300
24
27
47
76
92
135
205
277
316
413
1010
1230
1720
2200
3030
4380
5330
110
120
150
200
220
320
350
530
580
970
1250
1860
1720
2580
4660
5440
7030
30
30
40
80
140
190
200
350
440
690
910
1170
1280
1990
3300
3580
5230
20
22
37
51
57
68
-
-
-
-
-
-
-
-
-
-
-
34
38
57
92
108
151
234
306
346
467
1190
1460
2090
2570
3520
-
-
GuaranteedEnergy
Absorption(GEA)
ReactionForce
at GEA
HullPressureat GEA
SafetyValve
SettingPressure
TestingPressure
Approx.FenderBody
Weight ChainNet
Weight of Net Type (Type)
WireNet
Approx. Weight of Net
SyntheticFiber Net
Weightof Sling
Type(Type)
(kNm)E
(kN)R
(kPa)P
(kPa) (kPa) (kg) (kg) (kg) (kg) (kg)
Note: 1.Figures on the table comply with requirements of ISO17357.2.Weight of fender body and net may vary 10%.3.Special size are available upon request.
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05
CONSTRUCTION3
Outer Rubber3-1
There are two types of fenders : Type and Type .Type (Net type) fenders are covered with a chain net, wire net, or fiber net.Type (Sling type) fenders have an attachment eye on each end for lifting and installation.Basic body construction of these fenders consists of an outer rubber layer, cord layers and an inner rubber layer. All of these are vulcanized together. A steal ring and flange are placed at one or both ends of the fender.
The outer rubber layer protects the cord layers and inner rubber layer from abrasion and other external forces.
Synthetic-tire-cord- Layer3-2
The reinforcement cord layers, which are made of synthetic-tire-cord, are arranged at ideal angles to hold the internal pressure and to distribute the stress evenly.
Inner Rubber3- 3
The inner rubber layer seals the air inside, utilizing a compound eguivalent to that of liner or tube of an automobile tire.
Fig.3-1Basic construction of floating type Pneumatic Rubber Fenders
TYPICAL CUT SECTIONOF FENDER WALL
outer rubber
cord layers
inner rubber flange opening
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06
Bead Ring3- 4
A steel ring is placed at one or both ends of the fender to hold the end of the reinforcement cord layers.
Flange Opening3-5
A steel flange to which air valves are attached is mounted on the fender to serve as flange opening.
Fig.3-2Construction of Flange Opening
Type
Type
Type
Type
Bead
ring
out
side
diam
eter
Bead
ring
out
side
diam
eter
Bead
ring
ou
tsid
e di
amet
er
Flan
ge o
peni
ngo
uts
ide
diam
eter
Bead
ring
out
side
diam
eter
Flan
ge o
peni
ngo
uts
ide
diam
eter
Flan
ge o
peni
ngo
uts
ide
daia
met
er
Bead ring
Bead ringCover plate
Mouth metal
Air charge valveAir valve
Air valve Air valve
Bushing
Bead ringAir valveHanging metal
Safety valve
Bead ring
Hanging metal
Mouth metal
Air charge valveAir valve
Safety valve
(Large size)
(Large size)
(Medium and small size)
(Medium and small size)
Flan
ge o
peni
ngo
uts
ide
diam
eter
Flan
ge o
peni
ngo
uts
ide
diam
eter
-
1 )
2 )3 )
4 )
5 )
6 )
7 )8 )
9 )
10)
11)
Remove the cap from the air valve at the flange opening and press the top of the air chuck at the end of the pressure gauge onto the valve of the fender to measure the air pressure and to see if additional air is necessary.Connect the air hose to the compressor.Turn on the compressor and open the compressor valve. The pressure of the compressor should be between 400 to 700 kPa.Press the air chuck at the end of the air hose onto the valve and air will automatically fill the fender.Before reaching the specified pressure, periodically check the air pressure in the fender to avoid overinflating. To make these checks remove the air chuck being used for inflation and apply the air chuck of the pressure gauge in the same manner as described in the above 1).Stop inflating the fender at the specified air pressure plus an additional 5kPa.Close the compressor valve.Use soapy water to check for leaks from the valve or the flange opening.Air from the compressor will have a high temperature but will decrease in temperature after inflating the fender. Therefore, check the pressure again one hour after inflating the fender. Lastly,check the pressure again once the fender is floating on the water.If the pressure is too high, release the air by pushing the head of the valve core or:a)
b)
Finally, close the valve cap firmly . Store the air hose without folding it tightly.
07
INFLATION4
Overinflation is very dangerous: Therefore, please follow the procedures below very closely.
CAUTION
Small and medium-size(See Fig.4-1)-Upto 2000 size 4-1
1 )
2 )3 )
4 )
5 )
6 )7 )
8 )
9 )
10)
Remove the cap of the small air valve and press the air chuck at the end of the pressure gauge onto the small air valve in order to check if inflation is necessary.Connect the air hose to a compressor.Slide the sleeve from the quick-disconnect joint to remove the dust plug, and remove the dust cap from .To connect to , slide the sleeve on back and push the quick-disconnect joint onto . Release sleeve.Turn on the compressor, and open the valve. Compressor pressure should be between 400 to 700 kPa.Open valve .Open valve next. Air will automatically fill the fender.Periodically check the internal air pressure so as not to overinflate by means of one of the following:a.
b.
Stop inflating when air pressure reaches the specified internal air pressure plus an additional 5kPa.Close valve and the compressor valve, and slide the sleeve of the quick-disconnect joint and remove the air hose.
11)
12)
13)
Use soapy water to check if air leaks from the valve , plugs and the small air valve .Check the pressure again one hour after inflation. The high temperature air from the compressor will decrease once in the fender, causing some pressure fluctuation. Lastly, check pressure again once the fender is floating on the water.Attach the dust cap to the plug and the dust plug to the quick-disconnect joint of the hose, and store the hose without folding.
Overinflation is very dangerous: Therefore, please follow the procedures below very closely.
CAUTION
The air remaining in the hose has some pressure.CAUTION
Large-size (See Fig. 4-2)-from 2500 size 4-2
Use the head of the valve cap to unscrew the valve core and release air.When the air pressure decreases to the specified point, stop the further release of air with your hand and quickly screw in the valve core with the head of the valve cap. Make sure the valve core is firmly in place after this procedure.
Measure the pressure using the pressure gauge
by pressing onto the small air valve in the flange opening explained in Paragraph 1). Inflation can continue while gauge is attached.Measure the pressure of gauge , closing valve
completely and opening valve . Any air leaking from the hose line will yield inaccurate measurement.
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08
Fig.4-1Inflation and Measuring Air Pressure
Fig.4-2Inflation and Measuring Air Pressure
Air hose
Air hose
Air hose
Sleeve
Dust plug
Dust cap
Pneumatic rubber
fender15m 5m
5m
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Unpacking5-1
09
1) Delivery conditionThe fender will be delivered in one of the following conditions:a) packed and deflated, and b) containerized and deflated. For the latter two conditions, unpack and inflate the fender within one week after receiving it.
2) Packed and deflatedUnpack the fender and inflate it within one week after receiving it. If it is stored while deflated, the service life of the fender may be lessened.a)Loosen the wire clips fixing the wire or
cut the wire ropes around the fender.
b)
c)
Inflate the fender after clearing the area in order that the surface of the fender is not damaged with sharp protrusions or points. Inflate the fender slowly to avoid tangling the net.Adjust the air pressure as specified in Section 2 & 4 of this manual if you are to use the fender soon. If not, inflate to 20-30kPa.
UNPACKING, TRANSPORTING, AND STORING5
The ropes or bands may recoil with great force when loosen the wire clips or cut the wire.
CAUTION
d) Lift with a forklift or crane.Avoid rolling the fender because protruding objects nearby might damage the fender.
e) When storing the fender, brace it to keep it from rolling.
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10
3) Containerized and deflatedUnpack the fender and inflate it within one week after receiving it. If it is stored while deflated, the service life of the fender may be lessened.a)Lift the fender from the container using a bar as
shown below to keep the lifting force uniform.
b) Place the fender on the desired surface area in the same condition as it was loaded in the container (with tires on it).
c) Loosen the wire clips fixing the wire or cut the wire ropes surrounding the fender according to the numbers in the diagram. The deflated fender is tied as in the following figure. The fender and the tires are each bound separately by wires. Both are then bound together by another wire.
The wires may recoil with great force when loosen the wire clips or cut the wire.
CAUTION
d) Before inflating the fender, make sure that the flange opening, the ends of the fender, and the net are in the correct position, so that the net will not slip during inflation.
e)
f )
g)
Remove all wires, and inflate the fender slowly to prevent tangling of the net.Adjust the air pressure of the fender as specified in Section 2 & 4 of this manual if you use the fender soon. If not, inflate to 20-30kPa.When storing the fender, brace it securely to keep it from roling.
Wire slip
Tire Outer wire
Inner wire
Fender bodyEnd view
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Inflating the fender5-2
11
Inflate those fenders which arrived deflated condition as mentioned in 5-1.3) & 5-1. 4) within one week after receiving them. The air pressure should be under that specified in Table 2-1 in Section 1. If storing for long periods of time, keep the air pressure inside the fender around 20-30kPa.
Transporting by trailer or forklift5-4
After placing the fender on a trailer, make sure that the wheels of the trailer do not come in contact with the fender during transporting.When transporting by a forklift, avoid damaging the fender with the forks or by dragging it on the ground.
Avoiding direct sunlight5-5
Avoiding other damage5-6
Preventing rolling5-7
Storing repair materials5-8
Avoid exposing the fender to direct sunlight during storage. Cover the fender with a canvas.
Avoid getting oil or grease on the fender during storage. Avoid welding or excessive heat neat the fender. Clear the storage area of all sharp projections or pointed objects likely to damage the fender.
For storage, securely brace the fender with stoppers or rope to prevent it from roling.
Store in a dark, cool place.
Lifting the fender5-3
1)
2)
3)
a)
b)
When lifting a sling-type fender, attach wire or chain hooks to both ends of the fender body or to the shackles provided, and then lift slowly.Guy wire or guy chain can also be used for lifting.
When lifting a fender with the net and sling attached, lift by the ring or shackle fixed at the center of the sling.When lifting a fender with the net attached only, attach wire or chain to the shackles provided at both ends of the net, and then lift slowly.
-
For a quay/jetty6-1 For a ship6-2
12
INSTALLATION6Refer to Fig. 6-1, and 6-2 or 6-3 and the following points:1)
2)
3)
4)
5)
6)
Remove all protrusions such as frame hooks and steel framework to make the quay wall as flat and smooth as possible.Construct the quay wall as flat as possible to avoid deforming the fender unreasonably. If special characteristics of the quay prevent this, please contact us for proper installation.The ebb and flow of the tide may cause the fender to protrude above or below the quay wall. To prevent this, especially during deflection, see Fig. 6-3 for proper installation. If the fender still goes beyond these limits, please contact us.At both dolphins and ordinary quays/jetties, it is desirable to put the mooring position (anchor position) properly away from the fender.The guy rope or chain securing the fenders should be sufficiently long to allow for tidal variations.When installing a fender at an ordinary quay/jetty, at least two fenders must come in contact with the parallel body of the ship, one at each end of the parallel section.
Fender may be installed along the hull of a ship by the following two method: Fenders are rigged in a continuous string and in a pairs, as shown in Fig. 6-4 and Fig. 6-5. For either method, the following procedures should be taken.1)
2)
3)
4)
5)
6)
7)
When the fender is floating, the guy rope or chain should be long enough to avoid sudden stress on the guy ropes or chains.Attach the guy ropes to a secure part of the ship such as a bollard and not to weaker parts such as a handrail.It is desirable to use a crane or a derrick to hang the fenders. Lift up the specified portion as detailed in Section 5-4.Install the fenders away from scuppers and other protrusions.When two ships are moored side by side, at least two fenders must come in contact with the parallel bodies of each ship, one at each end.When waves are high or the contact area cannot be fixed, avoid rigging in a continuos string. Instead, place them at individual points along the ships hull.The guy lines should be sufficiently long to allow for tidal variations.
-
Table.6.AInstallation Recommendation for Chain net type ( Type ) Small Sizes
13
Fig.6-1 A) Installation of Net-Type Pneumatic Rubber Fender on Quay/Jetty
Parts
Nominal SizeDia.Length
(m)
0.5 1.0
0.6 1.0
0.7 1.5
1.0 1.5
1.0 2.0
1.2 2.0
1.35 2.5
0.5 1.0
0.6 1.0
0.7 1.5
1.0 1.5
1.0 2.0
1.2 2.0
1.35 2.5
InitialPressure
(kPa)
50
50
50
50
50
50
50
80
80
80
80
80
80
80
227/8227/8227/8227/8227/8227/8227/8227/8227/8227/8227/8227/8227/8227/8
ShackleDiameter
(SB)(mm)(inch)
165/8165/8165/8165/8165/8165/818
11/16165/8165/8165/8165/818
11/1618
11/1620
13/16
Guy Rope(JIS-G3525)
(624-G)Diameter
(mm)(inch)
Type
RingDiameter
(mm)(inch)
193/4193/4193/4193/4193/4227/8227/8193/4193/4193/4193/4193/4227/8227/8
*
227/8227/8227/8227/8227/8251
251
227/8227/8227/8227/8227/8251
251
FirstShackleDiameter
(mm)(inch)
*
193/4193/4193/4193/4193/4227/8227/8193/4193/4193/4193/4193/4227/8227/8
SwivelDiameter
(mm)(inch)
165/8165/8165/8165/8165/8165/8165/8165/8165/8165/8165/8165/8165/8165/8
Guy Chain(SBC490)Diameter
(mm)(inch)
251
251
251
251
251
251
251
251
251
251
251
251
251
251
AnchorDiameter
(mm)(inch)
Note:* The Ring and * The first shackle at each end of a fender are supplied. Other equipment can be purchased upon request.
Endlink
Rubber Sleeve
-
14
Fig.6-1 B) Installation of Net-Type Pneumatic Rubber Fender on Quay/Jetty
Table.6.BInstallation Recommendation for Chain net type ( Type ) Medium and Large Size
Parts
Nominal SizeDia.Length
(m)
1.5 3.0
1.7 3.0
2.0 3.5
2.5 4.0
2.5 5.5
3.3 4.5
3.3 6.5
3.3 10.6
4.5 9.0
4.5 12.0
1.5 3.0
1.7 3.0
2.0 3.5
2.5 4.0
2.5 5.5
3.3 4.5
3.3 6.5
3.3 10.6
4.5 9.0
4.5 12.0
InitialPressure
(kPa)
50
50
50
50
50
50
50
50
50
50
80
80
80
80
80
80
80
80
80
80
Special Towing Ringpin Dia. 70 2-3/4
Special Towing Ringpin Dia. 70 2-3/4
Special Towing Ringpin Dia. 72 2-13/16
Special Towing Ringpin Dia. 70 2-3/4
Special Towing Ringpin Dia. 72 2-13/16
Special Towing Ringpin Dia. 90 3-9/16
2013/16
227/824
15/1630
1-3/1634
1-5/1634
1-5/1642
1-5/852
2-1/1654
2-1/865
2-9/1624
15/1624
15/1628
1-1/832
1-1/440
1-9/1638
1-1/246
1-13/1660
2-3/865
2-9/16753
Guy Rope(JIS-G3525)
(624-G)Diameter
(mm)(inch)
193/4193/4227/826132
1-1/430
1-3/1638
1-1/248
1-7/850258
2-5/1620
13/1620
13/1624
15/1630
1-3/1636
1-7/1634
1-5/1642
1-5/854
2-1/858
2-5/1668
2-11/16
Guy Chain(SBC490)Diameter
(mm)(inch)
Type
FirstShackleDiameter
(SB)(mm)(inch)
2415/16
2415/16
261
321-1/4
341-5/16
361-7/16
441-3/4
2415/16
2415/16
281-1/8
341-5/16
401-9/16
401-9/16
481-7/8
*
251
251
281-1/8
321-1/4
381-1/2
381-1/2
441-3/4
251
251
281-1/8
381-1/2
441-3/4
441-3/4
502
SwivelDiameter
(mm)(inch)
2415/16
2415/16
261
321-1/4
341-5/16
361-7/16
441-3/4
2415/16
2415/16
281-1/8
341-5/16
401-9/16
401-9/16
481-7/8
ShackleDiameter
(SB)(mm)(inch)
2415/16
2415/16
261
321-1/4
341-5/16
361-7/16
441-3/4
602-3/8
602-3/8
652-9/16
2415/16
2415/16
281-1/8
341-5/16
401-9/16
401-9/16
481-7/8
652-9/16
652-9/16
753
ShackleDiameter
(SB)(mm)(inch)
321-1/4
321-1/4
321-1/4
421-5/8
441-3/4
441-3/4
552-3/16
753
753
803-1/8
321-1/4
321-1/4
361-7/16
421+5/8
502
502
602-3/8
753
753
853-3/8
AnchorDiameter
(mm)(inch)
Note: * The first shackle at each end of a fender is supplied. Other equipment can be purchased upon request.
End linkTowing ring
Rubber Sleeve
-
15
Fig.6-2Installation of Sling-Type Pneumatic Rubber Fender on Quay/Jetty
Table.6.C Installation Recommendation for Sling type ( Type )
Parts
Nominal SizeDia.Length
(m)0.5 1.0
0.6 1.0
0.7 1.5
1.0 1.5
1.0 2.0
1.2 2.0
1.35 2.5
1.5 3.0
1.7 3.0
2.0 3.5
2.5 4.0
2.5 5.5
3.3 4.5
3.3 6.5
3.3 10.6
0.5 1.0
0.6 1.0
0.7 1.5
1.0 1.5
1.0 2.0
1.2 2.0
1.35 2.5
1.5 3.0
1.7 3.0
2.0 3.5
2.5 4.0
2.5 5.5
3.3 4.5
3.3 6.5
3.3 10.6
InitialPressure
(kPa)50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
165/8165/8165/8165/8165/8165/818
11/1620
13/16227/824
15/1630
1-3/1634
1-5/1634
1-5/1642
1-5/852
2-1/16165/8165/8165/8165/818
11/1618
11/1620
13/1624
15/1624
15/1628
1-1/832
1-1/440
1-9/1638
1-1/246
1-13/1660
2-3/8
Guy Rope(JIS-G3525)
(624-G)Diameter
(mm)(inch)
165/8165/8165/8165/8165/8165/8165/8193/4193/4227/826132
1-1/430
1-3/1638
1-1/248
1-7/8165/8165/8165/8165/8165/8165/8165/820
13/1620
13/1624
15/1630
1-3/1636
1-7/1634
1-5/1642
1-5/854
2-1/8
Guy Chain(SBC490)Diameter
(mm)(inch)
Type
FirstShackleDiameter
(SB)(mm)(inch)
165/8165/8165/8165/8165/8165/818
11/1618
11/1620
13/1620
13/162821-1/83221-1/436+32
1-7/16+1-1/4402
1-9/16
165/8165/8165/8165/8165/8165/818
11/1620
13/1620
13/16227/8
3021-3/16362
1-7/1636+34
1-7/16+1-5/164421-3/4
*
165/8165/8165/8193/4193/4193/4193/4227/8251
281-1/8
321-1/4
381-1/2
381-1/2
441-3/4
165/8165/8165/8193/4193/4193/4193/4251
251
281-1/8
381-1/2
441-3/4
441-3/4
502
Special Towing Ringpin Dia. 70 2-3/4
Special Towing Ringpin Dia. 70 2-3/4
SwivelDiameter
(mm)(inch)
227/8227/8227/8227/8227/8227/8227/824
15/1624
15/1626132
1-1/434
1-5/1636
1-7/1644
1-3/4
227/8227/8227/8227/8227/8227/8227/824
15/1624
15/1628
1-1/834
1-5/1640
1-9/1640
1-9/1648
1-7/8
ShackleDiameter
(SB)(mm)(inch)
227/8227/8227/8227/8227/8227/8227/824
15/1624
15/1626132
1-1/434
1-5/1636
1-7/1644
1-3/460
2-3/8227/8227/8227/8227/8227/8227/8227/824
15/1624
15/1628
1-1/834
1-5/1640
1-9/1640
1-9/1648
1-7/865
2-9/16
ShackleDiameter
(SB)(mm)(inch)
251
251
251
251
251
251
251
321-1/4
321-1/4
321-1/4
421-5/8
441-3/4
441-3/4
552-3/16
753
251
251
251
251
251
251
251
321-1/4
321-1/4
361-7/16
421-5/8
502
502
602-3/8
753
AnchorDiameter
(mm)(inch)
Note:* The first shackle at each end of a fender is supplied. Other equipment can be purchased upon request.
Rubber sleeve
Endlink
-
16
Fig.6-3Size and Sharp of Pneumatic Rubber Fender on Deflection
Table.6.DDimension of jetty for installation
Size Initial Pressure(kPa)50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
420
530
530
840
890
1060
1250
1410
1620
1920
2440
2460
3300
3360
3400
4660
4710
410
520
530
840
890
1060
1250
1400
1610
1910
2420
2450
3270
3330
3370
4640
4690
A(mm)
320
410
390
640
690
820
980
1110
1280
1520
1940
1960
2640
2700
2740
3760
3810
310
400
390
640
690
820
980
1100
1270
1510
1920
1950
2610
2670
2710
3740
3790
B(mm)
160
150
270
300
250
320
290
310
320
360
420
400
480
420
380
480
430
170
160
270
300
250
320
290
320
330
370
440
410
510
450
410
500
450
C(mm)
170
170
290
330
280
350
330
350
370
420
490
470
570
510
470
610
560
180
180
290
330
280
350
330
360
380
430
510
480
600
540
500
630
580
D(mm)
1300
1300
1950
1950
2600
2600
3250
3900
3900
4550
5200
7150
5850
8450
13780
11700
15600
1300
1300
1950
1950
2600
2600
3250
3900
3900
4550
5200
7150
5850
8450
13780
11700
15600
E(mm)
500 1000
600 1000
700 1500
1000 1500
1000 2000
1200 2000
1350 2500
1500 3000
1700 3000
2000 3500
2500 4000
2500 5500
3300 4500
3300 6500
3300 10600
4500 9000
4500 12000
500 1000
600 1000
700 1500
1000 1500
1000 2000
1200 2000
1350 2500
1500 3000
1700 3000
2000 3500
2500 4000
2500 5500
3300 4500
3300 6500
3300 10600
4500 9000
4500 12000
Note: Above figures are obtained using of weights of chain net type, and the difference between the figures for wire net type is small, therefore, the above figures may be used also for wire net type as well.Note: Above figures are only for chain net type, but the difference between the figures for wire net and chain net type is negligible. Therefore, the above figures may be used also for wire net type.
E
tidal
rang
e
A B
H.W.L
State at 60% def.
Jetty/quayor dolphin
L.W.LDC
-
17
Fig.6-4Fenders Rigged in a Continuous string
Fig.6-5Fenders Rigged in Pairs
Small size fender
Guy rope Pneumatic rubber fenders
Tanker
Small size fender
Guy rope Pneumatic rubber fenders
Tanker
-
18
PRECAUTIONS71) 2 )
3)
4 )
5 )
6 )
Make sure the fenders air pressure is correct.Keep within the fenders maximum energy absorption limits. The energy of the fender must absorb depends on the speed of the vessel approaching for berthing and its weight. Please observe these factors when berthing in order to utilize the maximum energy absorption characteristics of the fender.It is advisable to adopt specific berthing procedures for each type of vessel and port in order not to exceed the fenders maximum energy absorption limits.Avoid contract with sharp protrusions when berthing.When the vessel is mooring, do not drop anything sharp edge or pointed object onto the fender.Special care should be taken in berthing for a ship having smaller free board than the top of the fender.
7 )
8 )
9 )
10)
11)
12)
Avoid securing the ships hawsers too tightly during offloading to prevent the fenders from rolling up the face of the quay. Loosen the ropes to ensure that the fenders are floating.When two or more fenders are used, periodical rotation of the fenders is recommended to lengthen their service life.When mooring, make sure that the parallel body of the ships hull comes in contract with at least two fenders.Oblique compression to the fenders should be limited max. ten degree when berthing.Avoid moving the ship while the fenders are under strong compression.Do not use fenders in extremely rough water such as during a typhoon.
INSPECTION AND MAINTENANCE81)
2 )
3 )
Check the air pressure of each fender at least once a year and, if possible, more frequently. If you make a spot check with your hand and the pressure seems less than normal, perform a gauge check referring to the description in 4-1 and 4-2 of this manual. If additional air is needed, fill the fender according the specifications shown in Table 2-1 in 2. PERFORMANCE. If the pressure is low, even considering the temperature factor, air might be leaking from the fender. In this case, check for leaks around the flange openings using soapy water. An air-leakage test should be done by making a gauge check of the specified pressure and repeating the check twenty-four hours later to determine if the pressure has dropped or not.If there is a cut or worn part on the fenders surface, repair according to the procedures given in Section 10 of this manual.When the metal fittings on the fender become rusty, remove the rust and coat the fittings with rustproof paint.
4 )
5 )
6 )
7 )
8 )
9 )
10)
Check the net and guys for rust and wear. Check the shackles for loss of pins, and the swivels to see if they are properly greased. Repair or replace accordingly.If the rubber sleeves on the net are loose or worn, the net could damage the fender. Fiber rope can be used to temporarily replace the rubber sleeves.Remove all protrusions from the quay-jetty wall and check periodically for any new protrusions that might appear.Check all anchors for wear, and repair by welding when necessary.Remove all sea moss or other marine life that has attached itself to the fender.To ensure proper rotation of the swivels, apply grease when necessary.Inspect and clean the safety valve every second year. Cleaning method detailed in Section11 of this manual.
REPLACEMENT91)
2 )
If over ten years have passed since the date of purchase.If the reinforcement cord layers are damaged beyond repair.
If one of the following conditions applies to your fenders, have them replaced.
3 )4 )
If the metal fittings are deformed beyond repair.If further use of the fender appears to be dangerous.
-
Pressure checking10-2
Installation10-1
SAFETY VALVEThe safety valve for the pneumatic rubber fender is specially designed to function in emergencies. If the internal air pressure of the fender goes up too rapidly, the safety valve will release the pressure and prevent the fender from bursting. Although the fender has a safety valve, this does not mean that it is safe to compress the fender beyond its maximum energy absorption capability.
When installing the safety valve, make sure that it is free from dust or foreign matter. Foreign substances like dust in the safety valve, especially the valve seat, will cause it to malfunction.
Tighten the bolts uniformly as follows:a.
b.
c.
1)
2)
3)
Set the assembled safety valve in a test tank with a capacity of 10 liters or more.Attach a pressure gauge to the test tank on the far side of the air supply point.Set pressure is recommended to check everytime when the net of the fender is replaced or every 3 years, whichever is the earlier.
Begin tightening the bolts symmetrically in the order shown in the diagram.The third and fourth bolts tightened should be those at right angles to one and two.Continue tightening the bolts in rotating to ensure uniform tightness.
19
10
5
8
7
6
43
2
1
-
If the damage is large and deep, please contact the nearest Yokohama Rubber Branch Office or representative.
20
The materials and instruments in the accessory box are available only for temporary repair of a fender.Adhesive is not included in repair kits. Please obtain TIP TOP SC2000 locally for adhesive.When and how to repair a fender are described below.1) If a fenders surface rubber is cut or peeled enough
to expose the reinforcement cord layer use the following five steps to repair it.a)
b)
c)
d)
e)
Buff the damaged rubber and a 100mm radius area around it immediately with sandpaper. Do not buff the exposed reinforcement cord. Please clean the exposed rubber, the buffed area and the exposed reinforcement cord with a solvent such as gasoline.Mix TIP TOP Cement SC2000 and 10% RF hardener, and apply one coat of the mixture onto buffed area. Allow this coat to dry completely until no longer tacky on back of finger.After that, apply a second coat of the cement to the same area.Cut a rubber patch roughly the same size of the buffed area and taper the edges. When the second application of cement has dried sufficiently, apply the patch over it.Use the hand roller provided in order to roll the patch onto the prepared surface, beginning from the center or the patch and working toward the edges to ensure that no air is between the patch and the surface rubber.
3)
4)
If the reinforcement cord layer is damaged, the better way to repair it is vulcanization by rubber company. However please contact the nearest Yokohama Rubber Branch Office or representative for an evaluation and assistance.It is structurally impossible to repair a cut within the area of approximately 300mm of the flange opening.
2) If the fender appears to be leaking, use the following steps to find and repair the leak.a)
b)
c)
d)
e)
f)
g)
Check the point of the leak by applying soapy water to the surface of the fender.Buff a 100-150mm radius area immediately around the hole with sandpaper, and clean the area with a solvent such as gasoline.Mix TIP TOP Cement SC2000 and 10% RF hardener together thoroughly.Hold the rubber plug with the jig as shown in the following figure, and after dipping the plug into the mixed cement, insert it into the hole.Pull out the jig, leaving only the plug in the hole. Check the leak again, and if is still leaking air, insert one or more plugs into the hole until the leaking stops.After the leak has been plugged completely, cut the plug(s) flush with the top of the surface rubber layer of the fender.Wash the buffed area with a solvent again, and apply the cement mixture.
h)
i)
When it has dried sufficiently, apply another coat of cement to the same area.Cut a rubber patch 100mm 100mm with tapered edges, and when the second coat of cement has dried sufficiently, apply the patch over the plugged hole.
j) Use the roller to roll on the patch, beginning from the center of the patch and working toward the edges to ensure that no air is between the patch and the surface rubber.
REPAIR11
Amber compound
Inner rubber
100
Reinforcement cord layer Outer rubber
Black compound
Rubber plugJig
Amber compound
Black compound100
100
-
Large-size(Size:2,500mm~4,500mm)12-2
ACCESSORIES
Small and medium-size(Size:500mm~2,000mm) 12-1
Installaction Tool Kit (Fig.12-1)1) 2)3)4)5)
Spare air valveBox spanner for removing air valveAir pressure gauge with air chuckAir filling hose with air chuck (10m)Valve core screw driver
1pc1pc1set1pc1pc
Repair Tool Kit (Fig.12-2)1)
2)
Repair materials:a. Rubber sheetb. Rubber plugRepair tools:a. Brushb. Sandpaperc. Tool for inserting plug (Jig)d. Hand roller
0.5m210pcs
1pc1sheet
1pc1pc
Both Kits IncludeManual for pneumatic rubber fender and Fender logbook.
21
12
Installaction Tool Kit (Fig.12-3)1) 2)3)4)5)
Spare air valveBox spanner for removing air valveAir pressure gauge with air chuckAir filling hose with one-touch joint (20m)Valve core screw driver
1pc1pc
1 set1 set1 set
Repair Tool Kit (Fig.12-4)1)
2)
Repair materials:Rubber sheetRepair tools:a. Brushb. Wire brushc. Sandpaperd. Hand roller
Both Kits IncludeManual for pneumatic rubber fender and Fender logbook.
0.5m2 2
2pcs1pc
2sheets1pc
Precautions for storage and use of accessories12-3
1) 2)
Store repair materials in a dark, cool place under 5. Do not use repair materials that are more than one year old.
Fig.12-1
Fig.12-2
Fig.12-3
Fig.12-4
-
242424242424242424424
GUARANTEE13We guarantee the quality of Yokohama Pneumatic Rubber Fenders for twelve(12) months from the date of installation or eighteen(18) months from the date of shipment, whichever comes earlier.
The guarantee shall cover any and all defects in materials, quality and workmanship caused in manufacturing. It shall not cover any damage which results from accidents or from failure to comply with the articles of this manual.
22
-
Head Office / Industrial Products Global Sales Department36-11 Shimbashi 5-chome, Minato-ku, Tokyo 105-8685 JAPAN +81-3-5400-4816 +81-3-5400-4830 [email protected]
Manufacturing Plant / Technical Department2-1 Oiwake, Hiratsuka, Kanagawa 254-8601 JAPAN
Sales Subsidiary / YOKOHAMA INDUSTRIAL PRODUCTS EUROPE GmbHMonschauer Str. 12 40549 Dusseldorf, Germany +49-211-5374-0570 +49-211-5374-0579 [email protected]
Sales Subsidiary / YH AMERICA, INC.105, Kuhlman Blvd., Versailles, KY 40383, U.S.A. +1-859-879-2858 +1-859-873-8943 [email protected]
Sales Subsidiary / YOKOHAMA INDUSTRIAL PRODUCTS ASIA-PACIFIC PTE.,LTD.1 Tampines Central 5, #07-10 CPF Tampines Building, Singapore 529508 +65-6587-7190 +65-6260-4394 [email protected]
THE YOKOHAMA RUBBER CO., LTD.
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