What is Foam Filled Fender?

Jerryborg Marine uses heat-sealed foam for its fender core. The foam is fully enclosed and covered with a strong, reinforced polyurethane exterior. This feature makes the fender highly resistant to stress, allowing it to absorb large amounts of energy while operating at sea.

These foam-filled fenders have special insides to prevent overloading and manage docking pressure. They make mooring safer and simpler, even in rough weather.

They are available in various sizes, from 200mm to 4,500mm in diameter and 500mm to 10,600mm in length, and are designed to meet various maritime needs. They also come in different foam densities and shapes. Depending on the specific setup required, they can be installed using a two-point or four-point mounting system.

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Construction Parts of Foam Filled Fenders

Construction Parts of Foam Filled Fenders

Foam Core

The energy-absorbing foam core of our foam-filled fender shall be heat-laminated. Chipped or granulated particulate foam, as well as adhesives to bond the foam together, are not acceptable. Also, our foam core is 100% closed-cell foam. Each closed cell is completely enclosed, which prevents it from compressing or settling over time.

Nylon 6 filament reinforced and polyurethane elastomer skin.

The outer skin of our foam-filled fender is constructed of elastomer with filament reinforcing as specified. The polyurethane skin is reinforced with nylon 6 for extra strength. The reinforced skin’s tensile strength can reach 31Mpa, with tear strength around 78.8kN/m. The skin is thick enough to provide enough nylon wraps. They transfer shear forces from berthing and the rated reaction force.

Polyurea Spraying Coating

The surface of our foam-filled fenders will be sprayed with polyurea. Spraying polyurea can make them tough. It makes them resist chemicals, weather, and damage. It also keeps them flexible in extreme temperatures.

Advantages of Jerryborg Marine Foam Fenders

High energy absorption and low reaction force: Our foam fenders absorb impact well. They reduce the force returned to the vessel and protect it from berthing damage. This ensures safety and reduces repair costs.

Unsinkable even if the polyurethane skin is damaged: Featuring a closed-cell foam core, our floating foam-filled fenders remain buoyant and effective even when punctured. The foam core can still provide continuous protection.

Nylon 6 filament-reinforced polyurethane elastomer skin: The polyurethane skin is reinforced with nylon 6 for extra strength. Reinforced skin has a tensile strength of 31Mpa and a tear strength of 78.8kN/m. These traits ensure durability in harsh marine environments.

Strong and effective internal engineering structure: Unlike the foam sheet rolling production method, Our proven design of foam-filled fenders ensures high durability and consistent performance.

Easy to install and low maintenance costs: Our foam-filled fenders are easy to install and need little maintenance. They save money over their lifespan by cutting downtime and repair needs.

Available with chain and tyre net: You can equip the foam fender body with an optional chain and tyre net. This adds protection, spreads stress evenly, and extends the fender’s lifespan.

Standard range complemented by customized design service: Beyond our standard range, we offer custom design services to meet specific needs. They ensure your vessels get optimal protection tailored to unique requirements.

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Why Choose Jerryborg Marine Foam Filled Fender ?

1.Made with 100% Enclosed EVA Foam

This foam is built with tightly packed, fully sealed cells that don’t compress or change shape over time. The closed cell structure of EVA foam absorbs the hits well. It won’t get damaged, crushed, or lose shape easily. Since each cell is sealed, water can’t get in. So, the foam keeps its form and buoyancy, even if the outer polyurethane layer gets scratched.

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Density Range Minimum Tensile Strength Minimum Elongation (Ultimate) Minimum Tear Resistance Minimum Compressive Strength (50%) Maximum Compressive Set (Suffix B)
Standard Capacity 55 kg/m³ to 68 kg/m³ 293 kPa 95 % 2.2 kN/m 110 kPa 17.2%
Low Reaction 29 kg/m³ to 35 kg/m³ 200 kPa 79 % 1.5 kN/m 80 kPa 27%
High Capacity 79 kg/m³ to 97 kg/m³ 546 kPa 101 % 4.2 kN/m 168 kPa 15.3%
Extra-High Capacity 115 kg/m³to 141 kg/m³ 738 kPa 120 % 6.5 kN/m 226 kPa 11.5%
Super-High Capacity 158 kg/m³ to 194 kg/m³ 1207 kPa 120 % 8.8 kN/m 490 kPa 13.5%
The tests shown in this table are part of ASTM D-3575
Water Absorption: shall be less than 0.34 kg/m2 of cut surface
Working Temperature: -50 degrees C to 40 degrees C

2.Polyurethane Coating

The polyurethane layer is applied over the marine foam fender surface. It protects against corrosion, weather effects, abrasion, and other damaging factors. Polyurethane is suited for protecting fender skins and other marine and floating products. All thanks to its durable characteristics.

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Test Item Test Method Required Value
Density AsTM d-3575  suffix w 62 kg / cu m  (+/-10%)
Tensile strength AsTM d-3575  suffix T 289 kPa Min.
Elongation AsTM d-3575  suffix T 95 % Min.
Tear resistance AsTM d-3575  suffix g 2.2 kN/m Min.
compressive strength AsTM d-3575  suffix d
10% deflection 27 kPa Min.
25% deflection 48 kPa Min.
40% deflection 77 kPa Min.
50% deflection 110 kPa Min.
compression set average AsTM d-3575  suffix b 17.2 %
Thermal stability AsTM d-3575  suffix s <0.5 % change (24 hrs at 70 deg c)
water absorption AsTM d-3575  suffix l <0.34 kg / sq m (skived)
flammability fMVss302 Pass
PPP-c-1752b -54 deg c to 99 deg c

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3.Strengthening Techniques

We use a variety of reinforcement materials for our floating foam fenders. Those include metal or synthetic tyre cord fabrics, per construction guidelines. These reinforcement layers increase the strength of the fender. They also improve the grip of the polyurethane or SPUA coatings, making them more durable and effective.

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Test Item Test Method Required Value
Shore A durometer hardness AsTM d-2240 75-95
Tensile strength AsTM d-412 13.8 MPa Min.
Elongation AsTM d-412 300% Min.
Tear strength AsTM d-624 32.4 kN/m Min.
flex life (ross) AsTM d-1052 100,000 cycles Min. break
Abrasion resistance (Nbs) AsTM d-1630 100

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Test Item Test Method Required Value
Nylon cord weight AsTM d-885 0.280 g/m avg.
breaking strength AsTM d-885 231 N avg.
Elongation (ultimate) AsTM d-885 16% avg.

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4.Unique Designed Internal Structure

Our skilled engineers design specialized steel structures. These include axles for fenders and frames for buoys and floats. They tailor these structures to specific needs in our metalwork shop. Before starting production, our engineers perform stress analysis. This is done to refine and optimize the designs. It ensures the final products are of the highest quality.

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Foam filled Fender Dimensions and Performance

Test Item Test Method Required Value
Tensile strength AsTM d-412 31.0 Mpa Min.
Elongation AsTM d-412 16% Min.
Tear strength AsTM d-624 78.8 kN/m Min.

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Diameter x Length
Metric (mm) US (ft)		 Low Reaction
Energy Reaction		 Standard
Energy Reaction		 High Capacity
Energy Reaction		 Extra High Capacity
Energy Reaction		 Super High
Capacity
Energy Reaction		 Weight
STD		 Chain
Size
600 x 1200 2 x 4 9 53 15 89 19 116 28 169 39 231 72 14
600 x 1800 2 x 6 15 88 24 147 31 191 46 280 64 383 105 14
600 x 2400 2 x 8 20 125 34 209 45 271 65 396 88 543 138 14
600 x 3000 2 x 10 26 160 43 267 57 347 83 507 113 694 171 19
700 x 1500 N/A 16 80 26 133 34 173 49 253 68 348 104 19
900 x 1500 3 x 5 25 120 42 200 54 262 80 383 110 520 136 19
900 x 1800 3 x 6 32 128 53 214 69 276 100 405 137 556 173 19
900 x 2400 3 x 8 45 182 75 302 98 391 142 574 194 787 214 19
900 x 3000 3 x 10 58 235 96 391 125 507 183 743 251 1019 268 19
900 x 3700 3 x 12 71 288 118 480 153 623 224 912 306 1250 336 19
900 x 4300 3 x 14 84 342 140 569 182 738 266 1081 363 1481 390 19
1000 x 1500 N/A 28 104 47 173 61 225 89 329 122 450 154 19
1000 x 2000 N/A 41 152 68 254 88 330 129 483 177 660 208 19
1200 x 1800 4 x 6 49 150 81 249 106 325 155 472 212 649 308 25
1200 x 2000 N/A 55 168 91 280 118 364 173 532 237 728 336 25
1200 x 2400 4 x 8 72 222 121 369 157 480 229 703 313 961 399 25
1200 x 3000 4 x 10 96 297 160 494 207 641 304 939 416 1286 497 25
1200 x 3700 4 x 12 119 363 198 605 258 787 376 1148 515 1575 614 25
1200 x 4900 4 x 16 165 504 275 841 358 1094 523 1597 716 2184 803 25
1200 x 6100 4 x 20 212 646 353 1076 458 1401 670 2046 917 2798 1000 25
1350 x 2500 N/A 91 251 152 418 198 543 289 794 395 1087 475 25
1500 x 2400 5 x 8 110 267 183 445 239 578 348 845 476 1157 507 25
1500 x 3000 5 x 10 147 357 244 596 317 774 464 1134 635 1548 638 32
1500 x 3700 5 x 12 183 446 305 743 397 965 580 1410 793 1931 790 32
1500 x 4300 5 x 14 219 534 365 890 475 1157 693 1690 948 2313 920 32
1500 x 4900 5 x 16 255 622 424 1036 552 1348 807 1971 1104 2696 1051 32
1500 x 5500 5 x 18 290 710 484 1183 629 1539 919 2246 1258 3078 1182 32
1800 x 3700 6 x 12 244 497 407 827 529 1076 773 1570 1058 2153 1103 32
1800 x 4300 6 x 14 296 600 494 1001 641 1303 938 1904 1283 2602 1277 32
1800 x 4900 6 x 16 347 707 579 1179 752 1535 1100 2242 1505 3065 1451 32
1800 x 5500 6 x 18 399 814 666 1357 865 1766 1265 2580 1731 3527 1634 32
1800 x 6100 6 x 20 450 918 751 1530 976 1988 1428 2909 1952 3977 1808 32
2000 x 3500 N/A 272 507 454 845 590 1099 863 1606 1180 2197 1240 38
2000 x 4000 N/A 324 603 540 1005 702 1307 1026 1910 1404 2613 1413 38
2000 x 4500 N/A 374 697 624 1161 811 1509 1186 2206 1622 3019 1595 44
2100 x 4300 7 x 14 396 691 660 1152 858 1499 1254 2189 1716 2994 1615 44
2100 x 4900 7 x 16 467 814 778 1357 1011 1766 1479 2580 2023 3527 1849 44
2100 x 5500 7 x 18 537 937 895 1561 1163 2028 1700 2967 2327 4061 2074 44
2100 x 6100 7 x 20 608 1059 1013 1766 1316 2295 1924 3354 2633 4591 2307 44
2100 x 6700 7 x 22 678 1182 1129 1971 1468 2562 2146 3745 2937 5124 2532 44
2400 x 3700 8 x 12 432 659 720 1094 936 1423 1367 2082 1870 2856 1859 44
2400 x 4300 8 x 14 504 769 839 1281 1091 1664 1594 2433 2182 3332 2161 44
2400 x 4900 8 x 16 596 911 994 1517 1292 1971 1889 2882 2584 3946 2462 51
2400 x 5500 8 x 18 689 1051 1148 1753 1493 2277 2182 3332 2986 4555 2764 51
2400 x 6100 8 x 20 782 1193 1303 1988 1693 2584 2476 3777 3388 5169 3066 51
2400 x 6700 8 x 22 875 1335 1458 2224 1895 2891 2770 4226 3790 5783 3368 51
2500 x 4000 N/A 481 718 801 1197 1041 1556 1522 2274 2083 3112 2107 51
2500 x 5500 N/A 720 1073 1200 1788 1560 2324 2280 3397 3120 4649 2902 51
2700 x 4300 9 x 14 634 859 1056 1432 1372 1859 2007 2718 2746 3723 2687 51
2700 x 4900 9 x 16 724 982 1207 1637 1569 2126 2293 3109 3137 4257 2999 51
2700 x 5500 9 x 18 840 1140 1399 1899 1820 2469 2659 3608 3638 4938 3311 51
2700 x 6100 9 x 20 956 1298 1593 2162 2072 2811 3028 4106 4142 5623 3683 51
2700 x 6700 9 x 22 1072 1455 1787 2424 2323 3154 3395 4608 4646 6303 4054 51
3000 x 4900 10 x 16 879 1073 1466 1788 1905 2326 2785 3398 3811 4648 3331 51
3000 x 5500 10 x 18 1023 1249 1706 2082 2217 2705 3240 3954 4435 5413 3768 51
3000 x 6000 N/A 1111 1377 1851 2295 2406 2984 3517 4361 4813 5967 4206 64
3000 x 6100 10 x 20 1167 1425 1946 2375 2530 3087 3697 4515 5059 6174 4130 64
3000 x 6700 10 x 22 1311 1601 2186 2669 2842 3470 4153 5071 5682 6939 4636 64
3000 x 7300 10 x 24 1431 1747 2455 2998 3099 3781 4530 5534 6199 7571 5073 64
3300 x 4500 N/A 899 1014 1498 1690 1947 2197 2846 3211 3895 4394 3416 64
3300 x 6500 N/A 1453 1639 2421 2731 3147 3550 4600 5189 6295 7101 5090 64
3400 x 5500 11 x 18 1206 1338 2009 2229 2613 2896 3818 4235 5224 5796 4420 64
3400 x 6100 11 x 20 1380 1530 2299 2549 2903 3314 4370 4849 5979 6632 4949 64
3400 x 6700 11 x 22 1554 1725 2590 2874 3366 3737 4920 5458 6733 7473 5470 64
3400 x 7300 11 x 24 1695 1881 2824 3132 3673 4075 5368 5952 7346 8149 6468 64
Custom sizes available on request. [Units： kN, kJ, kg, mm]

Foam-filled fender pressure resistance test