Yokohama Fender Manual 2s4h4b

HANDLING MANUAL No.

FD-04R1

MANUAL FOR YOKOHAMA

PNEUMATIC RUBBER FENDERS

CONTENTS Preface

2

1. SPECIAL PRECAUTIONS

2

2. PERFORMANCE

3

3. CONSTRUCTION

5

3-1 Outer Rubber

 

3-2 Synthetic-tire-cord-Layer

 

3-3 Inner Rubber

 

3-4 Bead Ring 3-5 Flange Opening

4. INFLATION

    

 7

4-1 Small and medium-size

 

4-2 Large-size

 

5. UNPACKING, TRANSPORTING, AND STORING

9

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 : φ500mm ~ φ2,000mm)   12-2 Large-size (Size : φ2,500mm ~ φ4,500mm)

 

  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 company’s 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 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.

1

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 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

2

PERFORMANCE

Table2-1 (A-1) Pneumatic 50 Standard Sizes Weight of Net Type (TypeⅠ) 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 Ⅱ) 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)

500×1000

50

6

64

132

-

200

22

110

30

20

32

600×1000

50

8

74

126

-

200

25

120

30

22

36

700×1500

50

17

137

135

-

200

45

150

40

37

55

1000×1500

50

32

182

122

-

200

73

200

80

51

89

1000×2000

50

45

257

132

-

200

88

220

140

57

104

1200×2000

50

63

297

126

-

200

131

320

190

68

147

1350×2500

50

102

427

130

-

200

200

350

200

-

229

1500×3000

50

153

579

132

-

200

250

530

350

-

279

1700×3000

50

191

639

128

-

200

290

580

440

-

320

2000×3500

50

308

875

128

-

200

405

960

640

-

459

2500×4000

50

663

1381

137

175

250

902

1240

910

-

1080

2500×5550

50

943

2019

148

175

250

1090

1850

1160

-

1320

3300×4500

50

1175

1884

130

175

250

1460

1710

1270

-

1840

3300×6500

50

1814

3015

146

175

250

1870

2570

1910

-

2250

3300×10600

50

3067

5257

158

175

250

2560

4660

3300

-

3060

4500×9000

50

4752

5747

146

175

250

3940

5390

3520

-

-

4500×12000

50

6473

7984

154

175

250

4790

6990

5190

-

-

(A-2) Pneumatic 50 Popular Non Standard Sizes Weight of Net Type (TypeⅠ) 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 Ⅱ) 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)

400×1500

50

6

87

151

-

200

23

-

-

-

33

600×1200

50

10

93

132

-

200

28

-

-

-

39

800×1200

50

16

116

122

-

200

48

240

-

-

58

1200×1800

50

55

262

122

-

200

123

310

-

-

139

1350×3500

50

152

641

141

-

200

255

600

-

-

284

1500×2500

50

123

464

126

-

200

221

440

-

-

250

2000×3000

50

255

727

122

-

200

367

900

-

-

421

2000×4500

50

418

1188

137

-

200

480

1200

-

-

534

2500×7700

50

1350

2951

157

175

250

1370

3020

-

-

1600

3300×8600

50

2443

4138

154

175

250

2220

3710

-

-

2720

4500×6400

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 (TypeⅠ) 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 Ⅱ) 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)

500×1000

80

8

85

174

-

250

24

110

30

20

34

600×1000

80

11

98

166

-

250

27

120

30

22

38

700×1500

80

24

180

177

-

250

47

150

40

37

57

1000×1500

80

45

239

160

-

250

76

200

80

51

92

1000×2000

80

63

338

174

-

250

92

220

140

57

108

1200×2000

80

88

390

166

-

250

135

320

190

68

151

1350×2500

80

142

561

170

-

250

205

350

200

-

234

1500×3000

80

214

761

174

-

250

277

530

350

-

306

1700×3000

80

267

840

168

-

250

316

580

440

-

346

2000×3500

80

430

1150

168

-

250

413

970

690

-

467

2500×4000

80

925

1815

180

230

300

1010

1250

910

-

1190

2500×5550

80

1317

2653

195

230

300

1230

1860

1170

-

1460

3300×4500

80

1640

2476

171

230

300

1720

1720

1280

-

2090

3300×6500

80

2532

3961

191

230

300

2200

2580

1990

-

2570

3300×10600

80

4281

6907

208

230

300

3030

4660

3300

-

3520

4500×9000

80

6633

7551

192

230

300

4380

5440

3580

-

-

4500×12000

80

9037

10490

202

230

300

5330

7030

5230

-

-

(B-2) Pneumatic 80 Popular Non Standard Sizes Weight of Net Type (TypeⅠ) 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 Ⅱ) 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)

400×1500

80

9

114

199

-

250

24

-

-

-

34

600×1200

80

14

122

174

-

250

30

-

-

-

41

800×1200

80

23

153

160

-

250

50

240

-

-

60

1200×1800

80

77

344

160

-

250

127

310

-

-

143

1350×3500

80

213

842

185

-

250

261

600

-

-

290

1500×2500

80

171

610

166

-

250

244

440

-

-

273

2000×3000

80

356

955

160

-

250

375

900

-

-

429

2000×4500

80

584

1560

179

-

250

488

1210

-

-

542

2500×7700

80

1884

3876

206

230

300

1550

3030

-

-

1780

3300×8600

80

3410

5437

202

230

300

2620

3710

-

-

3110

4500×6400

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

3

CONSTRUCTION

There are two types of fenders : TypeⅠ and Type Ⅱ. TypeⅠ(Net type) fenders are covered with a chain net, wire net, or fiber net. Type Ⅱ (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

TypeⅠ

TypeⅠ Bead ring

Safety valve

Flange opening outside diameter

Air valve

Bead ring outside diameter

Air charge valve

Air valve Bushing

(Large size)

Type Ⅱ

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 Ⅱ

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

4

INFLATION

Small and medium-size 4-1 (See Fig.4-1)-Upto φ2000 size CAUTION

Overinflation is very dangerous: Therefore, please follow the procedures below very closely.

1 ) Remove the cap ② from the air valve ① at the flange opening and press the top of the air chuck ④ at the end of the pressure gauge ③ onto the valve of the fender to measure the air pressure and to see if additional air is necessary. 2 ) Connect the air hose ⑤ 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 ④ at the end of the air hose onto the valve ① 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 ⑥ or: a) Use the head of the valve cap ② to unscrew the valve core ⑥ 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 φ2500 size CAUTION

Overinflation is very dangerous: Therefore, please follow the procedures below very closely.

1 ) Remove the cap of the small air valve ① and press the air chuck ③ at the end of the pressure gauge ② onto the small air valve ① in order to check if inflation is necessary. 2 ) Connect the air hose ④ to a compressor. 3 ) Slide the sleeve from the quick-disconnect t ⑤ to remove the dust plug, and remove the dust cap from ⑥. 4 ) To connect ⑤ to ⑥, slide the sleeve on ⑤ back and push the quick-disconnect t ⑤ onto ⑥. Release sleeve. 5 ) Turn on the compressor, and open the valve. Compressor pressure should be between 400 to 700 kPa. 6 ) Open valve ⑦. 7 ) Open valve ⑧ 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 ② by pressing onto the small air valve ① in the flange opening explained in Paragraph 1). Inflation can continue while gauge is attached. b. Measure the pressure of gauge ⑨, closing valve ⑦ completely and opening valve ⑩. 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 ⑧ and the compressor valve, and slide the sleeve of the quick-disconnect t ⑤ 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 ⑧, plugs and the small air valve ①. 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 ⑥ and the dust plug to the quick-disconnect t ⑤ of the hose, and store the hose without folding.

Fig.4-1 Inflation and Measuring Air Pressure ③ ①

②

④

⑥ Air hose

⑤ Fig.4-2 Inflation and Measuring Air Pressure

Pneumatic rubber fender 5m

15m

①

②

③

⑧ ⑤

Air hose

Sleeve Dust plug Dust cap

⑨ Air hose

⑦

④

⑩

5m

08

5

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

① ②

Outer wire

Inner wire

③ 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 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.

6

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 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 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 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 with the parallel bodies of each ship, one at each end. 6) When waves are high or the area cannot be fixed, avoid rigging in a continuos string. Instead, place them at individual points along the ship’s 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

④

① ② ③

End link

⑥ ⑤

Rubber Sleeve

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

①*

②*

③

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

Ⅰ

50

0.6 × 1.0

Ⅰ

50

0.7 × 1.5

Ⅰ

50

1.0 × 1.5

Ⅰ

50

1.0 × 2.0

Ⅰ

50

1.2 × 2.0

Ⅰ

50

1.35 × 2.5

Ⅰ

50

0.5 × 1.0

Ⅰ

80

0.6 × 1.0

Ⅰ

80

0.7 × 1.5

Ⅰ

80

1.0 × 1.5

Ⅰ

80

1.0 × 2.0

Ⅰ

80

1.2 × 2.0

Ⅰ

80

1.35 × 2.5

Ⅰ

80

Note: ①* The Ring and ②* The first shackle at each end of a fender are supplied. Other equipment can be purchased upon request.

13

④

⑤

⑥

Guy Rope Shackle Guy Chain (JIS-G3525) Diameter (SBC490) (6×24-G) (SB) Diameter Diameter

Anchor Diameter

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

End link Towing ring

⑤

①

④ ③ Rubber Sleeve

②

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

①*

②

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

Ⅰ

50

1.7 × 3.0

Ⅰ

50

2.0 × 3.5

Ⅰ

50

2.5 × 4.0

Ⅰ

50

2.5 × 5.5

Ⅰ

50

3.3 × 4.5

Ⅰ

50

3.3 × 6.5

Ⅰ

50

3.3 × 10.6

Ⅰ

50

4.5 × 9.0

Ⅰ

50

4.5 × 12.0

Ⅰ

50

1.5 × 3.0

Ⅰ

80

1.7 × 3.0

Ⅰ

80

2.0 × 3.5

Ⅰ

80

2.5 × 4.0

Ⅰ

80

2.5 × 5.5

Ⅰ

80

3.3 × 4.5

Ⅰ

80

3.3 × 6.5

Ⅰ

80

3.3 × 10.6

Ⅰ

80

4.5 × 9.0

Ⅰ

80

4.5 × 12.0

Ⅰ

80

③

⑤

⑥

Guy Rope Shackle (JIS-G3525) Guy Chain Diameter (SBC490) (6×24-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

④

Note: ①* 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

③ Endlink

⑤

① ④ Table.6.C Installation Recommendation for Sling type ( Type Ⅱ) Parts

①*

Nominal Size Initial Dia.×Length Type Pressure (m)

(kPa)

0.5 × 1.0

Ⅱ

50

0.6 × 1.0

Ⅱ

50

0.7 × 1.5

Ⅱ

50

1.0 × 1.5

Ⅱ

50

1.0 × 2.0

Ⅱ

50

1.2 × 2.0

Ⅱ

50

1.35 × 2.5

Ⅱ

50

1.5 × 3.0

Ⅱ

50

1.7 × 3.0

Ⅱ

50

2.0 × 3.5

Ⅱ

50

2.5 × 4.0

Ⅱ

50

2.5 × 5.5

Ⅱ

50

3.3 × 4.5

Ⅱ

50

3.3 × 6.5

Ⅱ

50

3.3 × 10.6

Ⅱ

50

0.5 × 1.0

Ⅱ

80

0.6 × 1.0

Ⅱ

80

0.7 × 1.5

Ⅱ

80

1.0 × 1.5

Ⅱ

80

1.0 × 2.0

Ⅱ

80

1.2 × 2.0

Ⅱ

80

1.35 × 2.5

Ⅱ

80

1.5 × 3.0

Ⅱ

80

1.7 × 3.0

Ⅱ

80

2.0 × 3.5

Ⅱ

80

2.5 × 4.0

Ⅱ

80

2.5 × 5.5

Ⅱ

80

3.3 × 4.5

Ⅱ

80

3.3 × 6.5

Ⅱ

80

3.3 × 10.6

Ⅱ

80

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

② Swivel Diameter (mm) (inch)

③

④

Guy Rope Shackle Guy Chain (JIS-G3525) Diameter (SBC490) (6×24-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 28×2 32 1-1/8 1-1/4 32×2 38 1-1/4 1-1/2 36+32 38 1-7/16+1-1/4 1-1/2 40×2 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 30×2 38 1-3/16 1-1/2 36×2 44 1-7/16 1-3/4 36+34 44 1-7/16+1-5/16 1-3/4 44×2 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: ①* The first shackle at each end of a fender is supplied. Other equipment can be purchased upon request. 15

Rubber sleeve

②

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

⑤

⑥

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

D

E

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

7

PRECAUTIONS

1 ) Make sure the fender’s air pressure is correct. 2 ) Keep within the fender’s 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 fender’s 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.

8

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 fender’s 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.

9

7 ) Avoid securing the ship’s 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 ship’s 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 ed 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.

1

7 5

3

4

8

6

2

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 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 fender’s 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

0

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 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:φ500mm~φ2,000mm)

Large-size 12-2 (Size : φ2,500mm~ φ4,500mm)

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 t (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 [email protected] Manufacturing Plant / Technical Department 2-1 Oiwake, Hiratsuka, Kanagawa 254-8601 JAPAN

Sales Subsidiary / YOKOHAMA INDUSTRIAL PRODUCTS EUROPE GmbH Monschauer Str. 12 40549 Dusseldorf, Phone +49-211-5374-0570 Fax +49-211-5374-0579 e-mail [email protected]   

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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