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

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

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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 RangeMinimum Tensile StrengthMinimum Elongation (Ultimate)Minimum Tear ResistanceMinimum Compressive Strength (50%)Maximum Compressive Set (Suffix B)
Standard Capacity55 kg/m³ to 68 kg/m³293 kPa95 %2.2 kN/m110 kPa17.2%
Low Reaction29 kg/m³ to 35 kg/m³200 kPa79 %1.5 kN/m80 kPa27%
High Capacity79 kg/m³ to 97 kg/m³546 kPa101 %4.2 kN/m168 kPa15.3%
Extra-High Capacity115 kg/m³to 141 kg/m³738 kPa120 %6.5 kN/m226 kPa11.5%
Super-High Capacity158 kg/m³ to 194 kg/m³1207 kPa120 %8.8 kN/m490 kPa13.5%
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 ItemTest MethodRequired Value
DensityAsTM d-3575  suffix w62 kg / cu m  (+/-10%)
Tensile strengthAsTM d-3575  suffix T289 kPa Min.
ElongationAsTM d-3575  suffix T95 % Min.
Tear resistanceAsTM d-3575  suffix g2.2 kN/m Min.
compressive strengthAsTM d-3575  suffix d
10% deflection27 kPa Min.
25% deflection48 kPa Min.
40% deflection77 kPa Min.
50% deflection110 kPa Min.
compression set averageAsTM d-3575  suffix b17.2 %
Thermal stabilityAsTM d-3575  suffix s<0.5 % change (24 hrs at 70 deg c)
water absorptionAsTM d-3575  suffix l<0.34 kg / sq m (skived)
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 ItemTest MethodRequired Value
Shore A durometer hardnessAsTM d-224075-95
Tensile strengthAsTM d-41213.8 MPa Min.
ElongationAsTM d-412300% Min.
Tear strengthAsTM d-62432.4 kN/m Min.
flex life (ross)AsTM d-1052100,000 cycles Min. break
Abrasion resistance (Nbs)AsTM d-1630100

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Test ItemTest MethodRequired Value
Nylon cord weightAsTM d-8850.280 g/m avg.
breaking strengthAsTM d-885231 N avg.
Elongation (ultimate)AsTM d-88516% 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 ItemTest MethodRequired Value
Tensile strengthAsTM d-41231.0 Mpa Min.
ElongationAsTM d-41216% Min.
Tear strengthAsTM d-62478.8 kN/m Min.

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Diameter x Length
Metric (mm) US (ft)
Low Reaction
Energy Reaction
Energy Reaction
High Capacity
Energy Reaction
Extra High Capacity
Energy Reaction
Super High
Energy Reaction
600 x 12002 x 495315891911628169392317214
600 x 18002 x 615882414731191462806438310514
600 x 24002 x 8201253420945271653968854313814
600 x 30002 x 102616043267573478350711369417119
700 x 1500N/A16802613334173492536834810419
900 x 15003 x 52512042200542628038311052013619
900 x 18003 x 632128532146927610040513755617319
900 x 24003 x 845182753029839114257419478721419
900 x 30003 x 105823596391125507183743251101926819
900 x 37003 x 1271288118480153623224912306125033619
900 x 43003 x 14843421405691827382661081363148139019
1000 x 1500N/A2810447173612258932912245015419
1000 x 2000N/A41152682548833012948317766020819
1200 x 18004 x 6491508124910632515547221264930825
1200 x 2000N/A551689128011836417353223772833625
1200 x 24004 x 87222212136915748022970331396139925
1200 x 30004 x 1096297160494207641304939416128649725
1200 x 37004 x 121193631986052587873761148515157561425
1200 x 49004 x 1616550427584135810945231597716218480325
1200 x 61004 x 202126463531076458140167020469172798100025
1350 x 2500N/A91251152418198543289794395108747525
1500 x 24005 x 8110267183445239578348845476115750725
1500 x 30005 x 101473572445963177744641134635154863832
1500 x 37005 x 121834463057433979655801410793193179032
1500 x 43005 x 1421953436589047511576931690948231392032
1500 x 49005 x 1625562242410365521348807197111042696105132
1500 x 55005 x 1829071048411836291539919224612583078118232
1800 x 37006 x 122444974078275291076773157010582153110332
1800 x 43006 x 1429660049410016411303938190412832602127732
1800 x 49006 x 16347707579117975215351100224215053065145132
1800 x 55006 x 18399814666135786517661265258017313527163432
1800 x 61006 x 20450918751153097619881428290919523977180832
2000 x 3500N/A2725074548455901099863160611802197124038
2000 x 4000N/A324603540100570213071026191014042613141338
2000 x 4500N/A374697624116181115091186220616223019159544
2100 x 43007 x 14396691660115285814991254218917162994161544
2100 x 49007 x 164678147781357101117661479258020233527184944
2100 x 55007 x 185379378951561116320281700296723274061207444
2100 x 61007 x 20608105910131766131622951924335426334591230744
2100 x 67007 x 22678118211291971146825622146374529375124253244
2400 x 37008 x 12432659720109493614231367208218702856185944
2400 x 43008 x 145047698391281109116641594243321823332216144
2400 x 49008 x 165969119941517129219711889288225843946246251
2400 x 55008 x 18689105111481753149322772182333229864555276451
2400 x 61008 x 20782119313031988169325842476377733885169306651
2400 x 67008 x 22875133514582224189528912770422637905783336851
2500 x 4000N/A4817188011197104115561522227420833112210751
2500 x 5500N/A720107312001788156023242280339731204649290251
2700 x 43009 x 1463485910561432137218592007271827463723268751
2700 x 49009 x 1672498212071637156921262293310931374257299951
2700 x 55009 x 18840114013991899182024692659360836384938331151
2700 x 61009 x 20956129815932162207228113028410641425623368351
2700 x 67009 x 221072145517872424232331543395460846466303405451
3000 x 490010 x 16879107314661788190523262785339838114648333151
3000 x 550010 x 181023124917062082221727053240395444355413376851
3000 x 6000N/A1111137718512295240629843517436148135967420664
3000 x 610010 x 201167142519462375253030873697451550596174413064
3000 x 670010 x 221311160121862669284234704153507156826939463664
3000 x 730010 x 241431174724552998309937814530553461997571507364
3300 x 4500N/A899101414981690194721972846321138954394341664
3300 x 6500N/A1453163924212731314735504600518962957101509064
3400 x 550011 x 181206133820092229261328963818423552245796442064
3400 x 610011 x 201380153022992549290333144370484959796632494964
3400 x 670011 x 221554172525902874336637374920545867337473547064
3400 x 730011 x 241695188128243132367340755368595273468149646864
Custom sizes available on request.[Units: kN, kJ, kg, mm]

Foam-filled fender pressure resistance test