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HANDLING MANUAL No.

FD-04R1

MANUAL FOR YOKOHAMA

PNEUMATIC RUBBER
FENDERS

CONTENTS
Preface

1. SPECIAL PRECAUTIONS

2. PERFORMANCE

3. CONSTRUCTION

3-1 Outer Rubber

3-2 Synthetic-tire-cord-Layer

3-3 Inner Rubber

3-4 Bead Ring


3-5 Flange Opening

4. INFLATION

4-1 Small and medium-size

4-2 Large-size

5. UNPACKING, TRANSPORTING, AND STORING

5-1 Unpacking

5-2 Inflating the fender

5-3 Lifting the fender


5-4 Transporting by trailer or forklift

5-5 Avoiding direct sunlight

5-6 Avoiding other damage

5-7 Preventing rolling

5-8 Storing repair materials

6. INSTALLATION
6-1 For a quay / jetty

12

6-2 For a ship

7. PRECAUTIONS

18

8. INSPECTION AND MAINTENANCE

18

9. REPLACEMENT

18

10. SAFETY VALVE

19

10-1 Installation

10-2 Pressure checking

11. REPAIR

20

12. ACCESSORIES

21

12-1 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 accessories


13. GUARANTEE

01

22

Pr eface
This 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 main features of Yokohama Pneumatic


Rubber Fenders are:
1) High energy absorption and low reaction force
and surface pressure.
2) No decline in the rate of energy absorption when
obliquely compressed, under normal
circumstances, and uniform surface pressure for
any contact area.
3) Low reaction force to prevent damage from
repeated impacts against the hull of a ship,
a quay/jetty, or a mooring rope.
4) Ability to float and thus rise and fall with the ebb
and flow of tides and the movements of a ship.
5) Easy installation.
6) High standard of uniform quality in compression
performance with no deterioration of the rubber.

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.

SPECIAL PRECAUTIONS

This product is containing compressed air inside.


If the product gets burst, burst energy of
the compressed air will make people injured.
Therefore,
1) 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.
2) 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) Use within the maximum energy absorption


specification in Table 2-1 to avoid
rupturing the fender.
4) Avoid allowing the fender to come in contact with
surface protrusions or sharp-edged implements
at any time.
5) Cut or exposed reinforcement cords might result in
damage to the fender.
6) The fender must be lifted at its designated
lifting points. Failure to do so could result in
damage to the fender.

02

PERFORMANCE

Table2-1
(A-1) Pneumatic 50 Standard Sizes
Weight of Net Type (Type)
Guaranteed
Reaction Hull
Energy
Weight
Force Pressure Safety
Nominal Size Initial
Absorption
Approx.
Valve
of
Sling
Testing
Approx.
Weight
of
Net
at
GEA
at
GEA
Internal
(GEA)
Type
Setting Pressure Fender
Pressure
Body
Pressure
(Type )
Diameter
Weight Chain
Wire Synthetic

E
R
P
Length
Net
Net
Fiber Net
(mm mm)

(kPa)

(kNm)

(kN)

(kPa)

(kPa)

(kPa)

(kg)

(kg)

(kg)

(kg)

(kg)

5001000

50

64

132

200

22

110

30

20

32

6001000

50

74

126

200

25

120

30

22

36

7001500

50

17

137

135

200

45

150

40

37

55

10001500

50

32

182

122

200

73

200

80

51

89

10002000

50

45

257

132

200

88

220

140

57

104

12002000

50

63

297

126

200

131

320

190

68

147

13502500

50

102

427

130

200

200

350

200

229

15003000

50

153

579

132

200

250

530

350

279

17003000

50

191

639

128

200

290

580

440

320

20003500

50

308

875

128

200

405

960

640

459

25004000

50

663

1381

137

175

250

902

1240

910

1080

25005550

50

943

2019

148

175

250

1090

1850

1160

1320

33004500

50

1175

1884

130

175

250

1460

1710

1270

1840

33006500

50

1814

3015

146

175

250

1870

2570

1910

2250

330010600

50

3067

5257

158

175

250

2560

4660

3300

3060

45009000

50

4752

5747

146

175

250

3940

5390

3520

450012000

50

6473

7984

154

175

250

4790

6990

5190

(A-2) Pneumatic 50 Popular Non Standard Sizes


Weight of Net Type (Type)
Guaranteed
Reaction Hull
Energy
Weight
Force Pressure Safety
Nominal Size Initial
Absorption
Valve Testing Approx.
of Sling
Approx. Weight of Net
at GEA at GEA
Internal
(GEA)
Setting Pressure Fender
Type
Pressure
Body
Pressure
(Type
)
Diameter
Weight Chain
Wire Synthetic

E
R
P
Length
Net
Net
Fiber Net
(mm mm)

(kPa)

(kNm)

(kN)

(kPa)

(kPa)

(kPa)

(kg)

(kg)

(kg)

(kg)

(kg)

4001500

50

87

151

200

23

33

6001200

50

10

93

132

200

28

39

8001200

50

16

116

122

200

48

240

58

12001800

50

55

262

122

200

123

310

139

13503500

50

152

641

141

200

255

600

284

15002500

50

123

464

126

200

221

440

250

20003000

50

255

727

122

200

367

900

421

20004500

50

418

1188

137

200

480

1200

534

25007700

50

1350

2951

157

175

250

1370

3020

1600

33008600

50

2443

4138

154

175

250

2220

3710

2720

45006400

50

3238

3796

133

175

250

3400

3900

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.
03

(B-1) Pneumatic 80 Standard Sizes


Weight of Net Type (Type)
Guaranteed
Reaction Hull
Energy
Weight
Force Pressure Safety
Nominal Size Initial
Absorption
Approx.
Valve
of
Sling
Testing
Approx.
Weight
of
Net
at
GEA
at
GEA
Internal
(GEA)
Setting Pressure Fender
Type
Pressure
Body
Pressure
(Type )
Diameter
Weight Chain
Wire Synthetic

E
R
P
Length
Net
Net
Fiber Net
(mm mm)

(kPa)

(kNm)

(kN)

(kPa)

(kPa)

(kPa)

(kg)

(kg)

(kg)

(kg)

(kg)

5001000

80

85

174

250

24

110

30

20

34

6001000

80

11

98

166

250

27

120

30

22

38

7001500

80

24

180

177

250

47

150

40

37

57

10001500

80

45

239

160

250

76

200

80

51

92

10002000

80

63

338

174

250

92

220

140

57

108

12002000

80

88

390

166

250

135

320

190

68

151

13502500

80

142

561

170

250

205

350

200

234

15003000

80

214

761

174

250

277

530

350

306

17003000

80

267

840

168

250

316

580

440

346

20003500

80

430

1150

168

250

413

970

690

467

25004000

80

925

1815

180

230

300

1010

1250

910

1190

25005550

80

1317

2653

195

230

300

1230

1860

1170

1460

33004500

80

1640

2476

171

230

300

1720

1720

1280

2090

33006500

80

2532

3961

191

230

300

2200

2580

1990

2570

330010600

80

4281

6907

208

230

300

3030

4660

3300

3520

45009000

80

6633

7551

192

230

300

4380

5440

3580

450012000

80

9037

10490

202

230

300

5330

7030

5230

(B-2) Pneumatic 80 Popular Non Standard Sizes


Weight of Net Type (Type)
Guaranteed
Reaction Hull
Energy
Weight
Force Pressure Safety
Nominal Size Initial
Absorption
Valve Testing Approx.
of Sling
Approx. Weight of Net
at GEA at GEA
Internal
(GEA)
Setting Pressure Fender
Type
Pressure
Body
Pressure
(Type
)
Diameter
Weight Chain
Wire Synthetic

E
R
P
Length
Net
Net
Fiber Net
(mm mm)

(kPa)

(kNm)

(kN)

(kPa)

(kPa)

(kPa)

(kg)

(kg)

(kg)

(kg)

(kg)

4001500

80

114

199

250

24

34

6001200

80

14

122

174

250

30

41

8001200

80

23

153

160

250

50

240

60

12001800

80

77

344

160

250

127

310

143

13503500

80

213

842

185

250

261

600

290

15002500

80

171

610

166

250

244

440

273

20003000

80

356

955

160

250

375

900

429

20004500

80

584

1560

179

250

488

1210

542

25007700

80

1884

3876

206

230

300

1550

3030

1780

33008600

80

3410

5437

202

230

300

2620

3710

3110

45006400

80

4518

4988

174

230

300

3760

3910

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.

04

CONSTRUCTION

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.

3-1 Outer Rubber

3 - 3 Inner Rubber
The inner rubber layer seals the air inside, utilizing a
compound eguivalent to that of liner or tube of
an automobile tire.

The outer rubber layer protects the cord layers and


inner rubber layer from abrasion and
other external forces.

3- 2 Synthetic-tire-cord- Layer
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.

Fig.3-1
Basic construction of floating
type Pneumatic Rubber Fenders
TYPICAL CUT SECTION
OF FENDER WALL

outer rubber
cord layers
inner rubber

05

flange opening

3 - 4 Bead Ring

3- 5 Flange Opening

A steel ring is placed at one or both ends of the fender


to hold the end of the reinforcement cord layers.

A steel flange to which air valves are attached is


mounted on the fender to serve as flange opening.

Fig.3-2
Construction of Flange Opening

Type

Type
Bead ring

Safety valve

Flange opening
outside diameter

Air valve

Bead ring
outside diameter

Air charge valve

Air valve
Bushing

(Large size)

Type

Flange opening
outside daiameter

Bead ring

Mouth metal
Flange opening
outside diameter

Bead ring outside diameter

Cover plate

Air valve

(Medium and small size)

Bead ring

Type

Safety valve

(Large size)

Flange opening
outside diameter

Air charge valve


Air valve

Bead ring outside diameter

Bead ring
Mouth metal
Flange opening
outside diameter

Bead ring outside diameter

Hanging metal
Air valve
Hanging metal

(Medium and small size)

06

INFLATION

Small and medium-size


4-1 (See Fig.4-1)-Upto 2000 size
CAUTION

Overinflation is very dangerous:


Therefore, please follow the procedures
below very closely.

1 ) 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.
2 ) Connect the air hose to the compressor.
3 ) Turn on the compressor and open
the compressor valve. The pressure of
the compressor should be between 400 to 700 kPa.
4 ) Press the air chuck at the end of the air hose
onto the valve and air will automatically
fill the fender.
5 ) 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).
6 ) Stop inflating the fender at the specified air
pressure plus an additional 5kPa.
7 ) Close the compressor valve.
8 ) Use soapy water to check for leaks from the valve
or the flange opening.
9 ) 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.
10) If the pressure is too high, release the air by
pushing the head of the valve core or:
a) Use the head of the valve cap to unscrew
the valve core and release air.
b) 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.
11) Finally, close the valve cap firmly . Store the air
hose without folding it tightly.

07

Large-size (See Fig. 4-2)-from


4-2 2500 size
CAUTION

Overinflation is very dangerous:


Therefore, please follow the procedures
below very closely.

1 ) 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.
2 ) Connect the air hose to a compressor.
3 ) Slide the sleeve from the quick-disconnect joint
to remove the dust plug, and remove the dust
cap from .
4 ) To connect to , slide the sleeve on back and
push the quick-disconnect joint onto .
Release sleeve.
5 ) Turn on the compressor, and open the valve.
Compressor pressure should be between
400 to 700 kPa.
6 ) Open valve .
7 ) Open valve next. Air will automatically
fill the fender.
8 ) Periodically check the internal air pressure so as
not to overinflate by means of one of the following:
a. 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.
b. Measure the pressure of gauge , closing valve
completely and opening valve .
Any air leaking from the hose line will yield
inaccurate measurement.
9 ) Stop inflating when air pressure reaches
the specified internal air pressure plus
an additional 5kPa.
10) Close valve and the compressor valve, and slide
the sleeve of the quick-disconnect joint and
remove the air hose.
CAUTION

The air remaining in


the hose has some pressure.

11) Use soapy water to check if air leaks from the valve
, plugs and the small air valve .
12) 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.
13) 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.

Fig.4-1
Inflation and Measuring Air Pressure

Air hose

Fig.4-2
Inflation and Measuring Air Pressure

Pneumatic rubber
fender
5m

15m

Air hose

Sleeve
Dust plug
Dust cap

Air hose

5m

08

UNPACKING, TRANSPORTING, AND STORING

5-1 Unpacking
1) Delivery condition
The 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.

d) Lift with a forklift or crane.


Avoid rolling the fender because protruding
objects nearby might damage the fender.

2) Packed and deflated


Unpack 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.

CAUTION

The ropes or bands may recoil with


great force when loosen the wire
clips or cut the wire.

e) When storing the fender, brace it to keep


it from rolling.

b) 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.
c) 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.

09

3) Containerized and deflated


Unpack 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.

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.

CAUTION

The wires may recoil with great


force when loosen the wire clips or
cut the wire.
Wire slip
Tire

Outer wire

Inner wire

End view

b) Place the fender on the desired surface area in


the same condition as it was loaded in
the container (with tires on it).

Fender body

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) Remove all wires, and inflate the fender slowly


to prevent tangling of the net.
f ) 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.
g) When storing the fender, brace it securely to
keep it from roling.

10

5-2 Inflating the fender


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.

5-3 Lifting the fender


1) a) When lifting a fender with the net and
sling attached, lift by the ring or shackle fixed
at the center of the sling.
b) 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.
2) 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.
3) Guy wire or guy chain can also be used for lifting.

5-4 Transporting by trailer or forklift


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.

11

5 - 5 Avoiding direct sunlight


Avoid exposing the fender to direct sunlight
during storage. Cover the fender with a canvas.

5 - 6 Avoiding other damage


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.

5 - 7 Preventing rolling
For storage, securely brace the fender with stoppers
or rope to prevent it from roling.

5 - 8 Storing repair materials


Store in a dark, cool place.

INSTALLATION

6 -1 For a quay/jetty
Refer to Fig. 6-1, and 6-2 or 6-3 and
the following points:
1) Remove all protrusions such as frame hooks and
steel framework to make the quay wall as flat and
smooth as possible.
2) 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.
3) 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.
4) At both dolphins and ordinary quays/jetties, it is
desirable to put the mooring position
(anchor position) properly away from the fender.
5) The guy rope or chain securing the fenders should
be sufficiently long to allow for tidal variations.
6) 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.

6 - 2 For a ship
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) When the fender is floating, the guy rope or chain
should be long enough to avoid sudden stress on
the guy ropes or chains.
2) Attach the guy ropes to a secure part of the ship
such as a bollard and not to weaker parts
such as a handrail.
3) 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.
4) Install the fenders away from scuppers
and other protrusions.
5) 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.
6) 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.
7) The guy lines should be sufficiently long to allow
for tidal variations.

12

Fig.6-1 A)
Installation of Net-Type Pneumatic
Rubber Fender on Quay/Jetty

End
link

Rubber Sleeve

Table.6.A
Installation Recommendation for Chain net type ( Type) Small Sizes
Parts

Initial
Nominal Size
Dia.Length Type Pressure

Ring
Diameter

First
Shackle
Diameter

Swivel
Diameter

(mm)
(inch)

(mm)
(inch)

(mm)
(inch)

(mm)
(inch)

(mm)
(inch)

(mm)
(inch)

(mm)
(inch)

19
3/4
19
3/4
19
3/4
19
3/4
19
3/4
22
7/8
22
7/8
19
3/4
19
3/4
19
3/4
19
3/4
19
3/4
22
7/8
22
7/8

22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
25
1
25
1
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
25
1
25
1

19
3/4
19
3/4
19
3/4
19
3/4
19
3/4
22
7/8
22
7/8
19
3/4
19
3/4
19
3/4
19
3/4
19
3/4
22
7/8
22
7/8

22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8

16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
18
11/16
16
5/8
16
5/8
16
5/8
16
5/8
18
11/16
18
11/16
20
13/16

16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8

25
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1

(kPa)

(m)
0.5 1.0

50

0.6 1.0

50

0.7 1.5

50

1.0 1.5

50

1.0 2.0

50

1.2 2.0

50

1.35 2.5

50

0.5 1.0

80

0.6 1.0

80

0.7 1.5

80

1.0 1.5

80

1.0 2.0

80

1.2 2.0

80

1.35 2.5

80

Note: * The Ring and * The first shackle at each end of a fender are supplied.
Other equipment can be purchased upon request.

13

Guy Rope
Shackle
Guy Chain
(JIS-G3525)
Diameter
(SBC490)
(624-G)
(SB)
Diameter
Diameter

Anchor
Diameter

Fig.6-1 B)
Installation of Net-Type Pneumatic
Rubber Fender on Quay/Jetty

End link
Towing ring

Rubber Sleeve

Table.6.B
Installation Recommendation for Chain net type ( Type) Medium and Large Size
Parts

Initial
Nominal Size
Dia.Length Type Pressure

First
Shackle
Diameter
(SB)

Swivel
Diameter

(mm)
(inch)

(mm)
(inch)

24
15/16
24
15/16
26
1
32
1-1/4
34
1-5/16
36
1-7/16
44
1-3/4

24
15/16
24
15/16
28
1-1/8
34
1-5/16
40
1-9/16
40
1-9/16
48
1-7/8

(kPa)

(m)
1.5 3.0

50

1.7 3.0

50

2.0 3.5

50

2.5 4.0

50

2.5 5.5

50

3.3 4.5

50

3.3 6.5

50

3.3 10.6

50

4.5 9.0

50

4.5 12.0

50

1.5 3.0

80

1.7 3.0

80

2.0 3.5

80

2.5 4.0

80

2.5 5.5

80

3.3 4.5

80

3.3 6.5

80

3.3 10.6

80

4.5 9.0

80

4.5 12.0

80

Guy Rope
Shackle (JIS-G3525) Guy Chain
Diameter
(SBC490)
(624-G)
(SB)
Diameter
Diameter

Shackle
Diameter
(SB)

Anchor
Diameter

(mm)
(inch)

(mm)
(inch)

(mm)
(inch)

(mm)
(inch)

(mm)
(inch)

25
1
25
1
28
1-1/8
32
1-1/4
38
1-1/2
38
1-1/2
44
1-3/4

24
15/16
24
15/16
26
1
32
1-1/4
34
1-5/16
36
1-7/16
44
1-3/4

Special Towing Ring


pin Dia. 70 2-3/4
Special Towing Ring
pin Dia. 70 2-3/4
Special Towing Ring
pin Dia. 72 2-13/16
25
1
25
1
28
1-1/8
38
1-1/2
44
1-3/4
44
1-3/4
50
2

24
15/16
24
15/16
28
1-1/8
34
1-5/16
40
1-9/16
40
1-9/16
48
1-7/8

20
13/16
22
7/8
24
15/16
30
1-3/16
34
1-5/16
34
1-5/16
42
1-5/8
52
2-1/16
54
2-1/8
65
2-9/16
24
15/16
24
15/16
28
1-1/8
32
1-1/4
40
1-9/16
38
1-1/2
46
1-13/16
60
2-3/8
65
2-9/16
75
3

19
3/4
19
3/4
22
7/8
26
1
32
1-1/4
30
1-3/16
38
1-1/2
48
1-7/8
50
2
58
2-5/16
20
13/16
20
13/16
24
15/16
30
1-3/16
36
1-7/16
34
1-5/16
42
1-5/8
54
2-1/8
58
2-5/16
68
2-11/16

24
15/16
24
15/16
26
1
32
1-1/4
34
1-5/16
36
1-7/16
44
1-3/4
60
2-3/8
60
2-3/8
65
2-9/16
24
15/16
24
15/16
28
1-1/8
34
1-5/16
40
1-9/16
40
1-9/16
48
1-7/8
65
2-9/16
65
2-9/16
75
3

32
1-1/4
32
1-1/4
32
1-1/4
42
1-5/8
44
1-3/4
44
1-3/4
55
2-3/16
75
3
75
3
80
3-1/8
32
1-1/4
32
1-1/4
36
1-7/16
42
1+5/8
50
2
50
2
60
2-3/8
75
3
75
3
85
3-3/8

Special Towing Ring


pin Dia. 70 2-3/4
Special Towing Ring
pin Dia. 72 2-13/16
Special Towing Ring
pin Dia. 90 3-9/16

Note: * The first shackle at each end of a fender is supplied.


Other equipment can be purchased upon request.

14

Fig.6-2
Installation of Sling-Type Pneumatic
Rubber Fender on Quay/Jetty

Endlink

Table.6.C
Installation Recommendation for Sling type ( Type )
Parts

Nominal Size
Initial
Dia.Length Type Pressure
(m)

(kPa)

0.5 1.0

50

0.6 1.0

50

0.7 1.5

50

1.0 1.5

50

1.0 2.0

50

1.2 2.0

50

1.35 2.5

50

1.5 3.0

50

1.7 3.0

50

2.0 3.5

50

2.5 4.0

50

2.5 5.5

50

3.3 4.5

50

3.3 6.5

50

3.3 10.6

50

0.5 1.0

80

0.6 1.0

80

0.7 1.5

80

1.0 1.5

80

1.0 2.0

80

1.2 2.0

80

1.35 2.5

80

1.5 3.0

80

1.7 3.0

80

2.0 3.5

80

2.5 4.0

80

2.5 5.5

80

3.3 4.5

80

3.3 6.5

80

3.3 10.6

80

First
Shackle
Diameter
(SB)
(mm)
(inch)

Swivel
Diameter
(mm)
(inch)

Guy Rope
Shackle
Guy Chain
(JIS-G3525)
Diameter
(SBC490)
(624-G)
(SB)
Diameter
Diameter
(mm)
(mm)
(mm)
(inch)
(inch)
(inch)

16
16
5/8
5/8
16
16
5/8
5/8
16
16
5/8
5/8
16
19
5/8
3/4
16
19
5/8
3/4
16
19
5/8
3/4
18
19
11/16
3/4
18
22
11/16
7/8
20
25
13/16
1
20
28
13/16
1-1/8
282
32
1-1/8
1-1/4
322
38
1-1/4
1-1/2
36+32
38
1-7/16+1-1/4
1-1/2
402
44
1-9/16
1-3/4
Special Towing Ring
pin Dia. 70 2-3/4
16
16
5/8
5/8
16
16
5/8
5/8
16
16
5/8
5/8
16
19
5/8
3/4
16
19
5/8
3/4
16
19
5/8
3/4
18
19
11/16
3/4
20
25
13/16
1
20
25
13/16
1
22
28
7/8
1-1/8
302
38
1-3/16
1-1/2
362
44
1-7/16
1-3/4
36+34
44
1-7/16+1-5/16
1-3/4
442
50
1-3/4
2
Special Towing Ring
pin Dia. 70 2-3/4

22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
24
15/16
24
15/16
26
1
32
1-1/4
34
1-5/16
36
1-7/16
44
1-3/4
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
24
15/16
24
15/16
28
1-1/8
34
1-5/16
40
1-9/16
40
1-9/16
48
1-7/8

16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
18
11/16
20
13/16
22
7/8
24
15/16
30
1-3/16
34
1-5/16
34
1-5/16
42
1-5/8
52
2-1/16
16
5/8
16
5/8
16
5/8
16
5/8
18
11/16
18
11/16
20
13/16
24
15/16
24
15/16
28
1-1/8
32
1-1/4
40
1-9/16
38
1-1/2
46
1-13/16
60
2-3/8

Note: * The first shackle at each end of a fender is supplied. Other equipment can be purchased upon request.
15

Rubber sleeve

16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
19
3/4
19
3/4
22
7/8
26
1
32
1-1/4
30
1-3/16
38
1-1/2
48
1-7/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
16
5/8
20
13/16
20
13/16
24
15/16
30
1-3/16
36
1-7/16
34
1-5/16
42
1-5/8
54
2-1/8

Shackle
Diameter
(SB)

Anchor
Diameter

(mm)
(inch)

(mm)
(inch)

22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
24
15/16
24
15/16
26
1
32
1-1/4
34
1-5/16
36
1-7/16
44
1-3/4
60
2-3/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
22
7/8
24
15/16
24
15/16
28
1-1/8
34
1-5/16
40
1-9/16
40
1-9/16
48
1-7/8
65
2-9/16

25
1
25
1
25
1
25
1
25
1
25
1
25
1
32
1-1/4
32
1-1/4
32
1-1/4
42
1-5/8
44
1-3/4
44
1-3/4
55
2-3/16
75
3
25
1
25
1
25
1
25
1
25
1
25
1
25
1
32
1-1/4
32
1-1/4
36
1-7/16
42
1-5/8
50
2
50
2
60
2-3/8
75
3

State at 60% def.

A
B

Fig.6-3
Size and Sharp of
Pneumatic Rubber
Fender on Deflection

Jetty/quay
or dolphin
C

tidal range

H.W.L

L.W.L

Table.6.D
Dimension of jetty for installation
Size

Initial Pressure
(kPa)

A
(mm)

B
(mm)

C
(mm)

D
(mm)

E
(mm)

500 1000

50

420

320

160

170

1300

600 1000

50

530

410

150

170

1300

700 1500

50

530

390

270

290

1950

1000 1500

50

840

640

300

330

1950

1000 2000

50

890

690

250

280

2600

1200 2000

50

1060

820

320

350

2600

1350 2500

50

1250

980

290

330

3250

1500 3000

50

1410

1110

310

350

3900

1700 3000

50

1620

1280

320

370

3900

2000 3500

50

1920

1520

360

420

4550

2500 4000

50

2440

1940

420

490

5200

2500 5500

50

2460

1960

400

470

7150

3300 4500

50

3300

2640

480

570

5850

3300 6500

50

3360

2700

420

510

8450

3300 10600

50

3400

2740

380

470

13780

4500 9000

50

4660

3760

480

610

11700

4500 12000

50

4710

3810

430

560

15600

500 1000

80

410

310

170

180

1300

600 1000

80

520

400

160

180

1300

700 1500

80

530

390

270

290

1950

1000 1500

80

840

640

300

330

1950

1000 2000

80

890

690

250

280

2600

1200 2000

80

1060

820

320

350

2600

1350 2500

80

1250

980

290

330

3250

1500 3000

80

1400

1100

320

360

3900

1700 3000

80

1610

1270

330

380

3900

2000 3500

80

1910

1510

370

430

4550

2500 4000

80

2420

1920

440

510

5200

2500 5500

80

2450

1950

410

480

7150

3300 4500

80

3270

2610

510

600

5850

3300 6500

80

3330

2670

450

540

8450

3300 10600

80

3370

2710

410

500

13780

4500 9000

80

4640

3740

500

630

11700

4500 12000

80

4690

3790

450

580

15600

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.
16

Fig.6-4
Fenders Rigged in a Continuous string

Small size fender

Tanker

Guy rope

Pneumatic rubber fenders

Fig.6-5
Fenders Rigged in Pairs

Small size fender

Tanker

Guy rope

17

Pneumatic rubber fenders

PRECAUTIONS

1 ) Make sure the fenders air pressure is correct.


2 ) 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.
3 ) 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.
4 ) Avoid contract with sharp protrusions
when berthing.
5 ) When the vessel is mooring, do not drop anything
sharp edge or pointed object onto the fender.
6 ) Special care should be taken in berthing for a ship
having smaller free board than the top
of the fender.

INSPECTION AND MAINTENANCE

1 ) 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.
2 ) If there is a cut or worn part on the fenders surface,
repair according to the procedures given in Section
10 of this manual.
3 ) When the metal fittings on the fender become rusty,
remove the rust and coat the fittings with
rustproof paint.

7 ) 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.
8 ) When two or more fenders are used, periodical
rotation of the fenders is recommended to lengthen
their service life.
9 ) When mooring, make sure that the parallel body of
the ships hull comes in contract with at
least two fenders.
10) Oblique compression to the fenders should be
limited max. ten degree when berthing.
11) Avoid moving the ship while the fenders are under
strong compression.
12) Do not use fenders in extremely rough water such
as during a typhoon.

4 ) 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.
5 ) 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.
6 ) Remove all protrusions from the quay-jetty wall and
check periodically for any new protrusions that
might appear.
7 ) Check all anchors for wear, and repair by welding
when necessary.
8 ) Remove all sea moss or other marine life that has
attached itself to the fender.
9 ) To ensure proper rotation of the swivels, apply
grease when necessary.
10) Inspect and clean the safety valve every
second year. Cleaning method detailed in
Section11 of this manual.

REPLACEMENT

If one of the following conditions applies to


your fenders, have them replaced.
1 ) If over ten years have passed since
the date of purchase.
2 ) If the reinforcement cord layers are damaged
beyond repair.

3 ) If the metal fittings are deformed beyond repair.


4 ) If further use of the fender appears
to be dangerous.

18

10 SAFETY VALVE
The 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.

10-1 Installation
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. Begin tightening the bolts symmetrically in the order
shown in the diagram.
b. The third and fourth bolts tightened should be those
at right angles to one and two.
c. Continue tightening the bolts in rotating to ensure
uniform tightness.

7
5

19

10-2 Pressure checking


1) Set the assembled safety valve in a test tank with
a capacity of 10 liters or more.
2) Attach a pressure gauge to the test tank on the far
side of the air supply point.
3) Set pressure is recommended to check everytime
when the net of the fender is replaced or
every 3 years, whichever is the earlier.

11 REPAIR
If the damage is large and deep, please contact the nearest Yokohama Rubber Branch Office
or representative.
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) 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.
b) 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.
c) After that, apply a second coat of the cement to
the same area.
d) 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.
e) 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.
Black
compound

Amber
compound

100

Inner rubber

Reinforcement
cord layer

2) If the fender appears to be leaking, use the following


steps to find and repair the leak.
a) Check the point of the leak by applying soapy
water to the surface of the fender.
b) Buff a 100-150mm radius area immediately
around the hole with sandpaper, and clean
the area with a solvent such as gasoline.
c) Mix TIP TOP Cement SC2000 and 10% RF
hardener together thoroughly.
d) 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.
e) 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.
f) After the leak has been plugged completely, cut
the plug(s) flush with the top of the surface rubber
layer of the fender.
g) Wash the buffed area with a solvent again, and
apply the cement mixture.

Jig

Rubber plug

h) When it has dried sufficiently, apply another coat


of cement to the same area.
i) 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.
Black compound
100

Outer rubber
10

Amber compound

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.
3) 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.
4) It is structurally impossible to repair a cut within
the area of approximately 300mm of the flange opening.
20

12 ACCESSORIES
Small and medium-size
12-1 (Size:500mm~2,000mm)

Large-size
12-2 (Size : 2,500mm~ 4,500mm)

Installaction Tool Kit (Fig.12-1)


1) Spare air valve
2) Box spanner for removing air valve
3) Air pressure gauge with air chuck
4) Air filling hose with air chuck (10m)
5) Valve core screw driver

Installaction Tool Kit (Fig.12-3)


1) Spare air valve
2) Box spanner for removing air valve
3) Air pressure gauge with air chuck
4) Air filling hose with one-touch joint (20m)
5) Valve core screw driver

Repair Tool Kit (Fig.12-2)


1) Repair materials:
a. Rubber sheet
b. Rubber plug
2) Repair tools:
a. Brush
b. Sandpaper
c. Tool for inserting plug (Jig)
d. Hand roller
Both Kits Include
Manual for pneumatic rubber fender and
Fender logbook.

1pc
1pc
1set
1pc
1pc

0.5 m2
10pcs
1pc
1sheet
1pc
1pc

Repair Tool Kit (Fig.12-4)


1) Repair materials:
Rubber sheet
2) Repair tools:
a. Brush
b. Wire brush
c. Sandpaper
d. Hand roller

1pc
1pc
1 set
1 set
1 set

0.5 m2 2
2pcs
1pc
2sheets
1pc

Both Kits Include


Manual for pneumatic rubber fender and
Fender logbook.

Precautions for storage and


12-3 use of accessories
1) Store repair materials in a dark, cool place under 5.
2) Do not use repair materials that are more than
one year old.

21

Fig.12-1

Fig.12-3

Fig.12-2

Fig.12-4

13

GUARANTEE

We 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
24
4

THE YOKOHAMA RUBBER CO., LTD.


Head Office / Industrial Products Global Sales Department
36-11 Shimbashi 5-chome, Minato-ku, Tokyo 105-8685 JAPAN
Phone +81-3-5400-4816 Fax +81-3-5400-4830
e-mail marine.s@yrc.co.jp
Manufacturing Plant / Technical Department
2-1 Oiwake, Hiratsuka, Kanagawa 254-8601 JAPAN

Sales Subsidiary /
YOKOHAMA INDUSTRIAL PRODUCTS EUROPE GmbH
Monschauer Str. 12 40549 Dusseldorf, Germany
Phone +49-211-5374-0570 Fax +49-211-5374-0579
e-mail marine.s@yrc.co.jp
Sales Subsidiary / YH AMERICA, INC.
105, Kuhlman Blvd., Versailles, KY 40383, U.S.A.
Phone +1-859-879-2858 Fax +1-859-873-8943
e-mail marine.s@yrc.co.jp
Sales Subsidiary /
YOKOHAMA INDUSTRIAL PRODUCTS ASIA-PACIFIC PTE.,LTD.
1 Tampines Central 5, #07-10 CPF Tampines Building, Singapore 529508
Phone +65-6587-7190
Fax +65-6260-4394

e-mail marine.s@yrc.co.jp

Website

www.yrc.co.jp/english/mb/industrial/index.html

2013 THE YOKOHAMA RUBBER CO.,LTD. 2013 07 DPL SPC YRC

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