USACE / NAVFAC / AFCESA UFGS-35 59 13.16 (August 2008) ---------------------------- Preparing Activity: NAVFAC Superseding UFGS-35 59 13.16 (April 2008) UNIFIED FACILITIES GUIDE SPECIFICATIONS References are in agreement with UMRL dated January 2009 SECTION 35 59 13.16 MARINE FENDERS 08/08 NOTE: This guide specification covers the requirements for marine fenders. This specification includes four different fender types. Each type is typically used for a different application. The author should choose the applicable fender types for the project. The subpart titles indicate the applicable fender type. The author should delete any subpart not applicable to the project. Edit this guide specification for project specific requirements by adding, deleting, or revising text. For bracketed items, choose applicable items(s) or insert appropriate information. Remove information and requirements not required in respective project, whether or not brackets are present. Comments and suggestions on this guide specification are welcome and should be directed to the technical proponent of the specification. A listing of technical proponents, including their organization designation and telephone number, is on the Internet. Recommended changes to a UFGS should be submitted as a Criteria Change Request (CCR). NOTE: Fender type should be selected based on the following considerations: 1. Performance, including energy, berthing angle, reaction, and hull pressure. 2. Geometry, including stand-off, dock configuration, vessel configuration, and tidal variation. 3. Configuration and construction, including corrosion resistance, netted vs not netted, magnetic permeability, buoyancy and portability. The following information shall be shown on the project drawings: 1. Location, size,and mounting elevation (if applicable) of each fender type. 2. Connection details to the waterfront structure. Include connection sizes, material type, embedment, plate sizes and hole sizes and locations, as applicable. PART 1 GENERAL 1.1 REFERENCES NOTE: This paragraph is used to list the publications cited in the text of the guide specification. The publications are referred to in the text by basic designation only and listed in this paragraph by organization, designation, date, and title. Use the Reference Wizard's Check Reference feature when you add a RID outside of the Section's Reference Article to automatically place the reference in the Reference Article. Do not use the Reference Wizard's Check Reference feature to update the issue dates, as this document is specific to the standards listed. This guide specification will be updated when the standards are updated. References not used in the text will automatically be deleted from this section of the project specification when you choose to reconcile references in the publish print process. The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AMERICAN BUREAU OF SHIPPING (ABS)ABS 2(1995) Building and Classing Steel VesselsAMERICAN WELDING SOCIETY (AWS)AWS D1.1/D1.1M(2008) Structural Welding Code - SteelASTM INTERNATIONAL (ASTM)ASTM A 123/A 123M(2008) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel ProductsASTM A 153/A 153M(2005) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel HardwareASTM A 307(2007b) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile StrengthASTM A 36/A 36M(2008) Standard Specification for Carbon Structural SteelASTM A 479/A 479M(2008) Standard Specification for Stainless Steel Bars and Shapes for Use in Boilers and Other Pressure VesselsASTM A 563(2007a) Standard Specification for Carbon and Alloy Steel NutsASTM B 695(2004) Standard Specification for Coatings of Zinc Mechanically Deposited on Iron and SteelASTM D 1052(2005) Measuring Rubber Deterioration-Cut Growth Using Ross Flexing ApparatusASTM D 1630(2006) Rubber Property - Abrasion Resistance (Footware Abrader)ASTM D 1667(2005) Flexible Cellular Materials - Poly (Vinyl Chloride) Foam (Closed-Cell)ASTM D 1894(2008) Static and Kinetic Coefficients of Friction of Plastic Film and SheetingASTM D 2000(2008) Standard Classification System for Rubber Products in Automotive ApplicationsASTM D 2240(2005) Standard Test Method for Rubber Property - Durometer HardnessASTM D 256(2006e1) Determining the Izod Pendulum Impact Resistance of PlasticsASTM D 3575(2008) Flexible Cellular Materials Made From Olefin PolymersASTM D 412(2006ae1e2) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - TensionASTM D 470(2005) Crosslinked Insulations and Jackets for Wire and CableASTM F 2192(2005) Standard Test Method for Determining and Reporting the Berthing Energy and Reaction of Marine FeedersASTM F 593(2002; R 2008) Stainless Steel Bolts, Hex Cap Screws, and StudsASTM F 594(2008) Standard Specification for Stainless Steel NutsASTM F 844(2007a) Washers, Steel, Plain (Flat), Unhardened for General UseINTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)ISO 17357(2002) High Pressure Floating Pneumatic Rubber FendersU.S. DEPARTMENT OF DEFENSE (DOD)MIL-PRF-907(Rev F) Antiseize Thread Compound, High TemperatureU.S. GENERAL SERVICES ADMINISTRATION (GSA)FS RR-C-271(Rev D; Am 1) Chains and Attachments, Welded and Weldless1.2 SYSTEM DESCRIPTION 1.2.1 Extruded Fenders NOTE: Extruded fender systems typically absorb a minimum amount of energy. Therefore, they are typically used at the wale elevation of fender pile systems. They have also been used as festoon fenders, rub strips and as an energy absorbing element in a separator. Extruded fenders are elements typically manufactured in a long length by an extrusion process. After manufacture, the elements are cut to length. These fender elements are typically used as fenders for small craft, rub strips on marine structures,and energy absorbing elements at the wale. Examples of extruded fender shapes are 'Side Mounted Hollow Bore', 'Cylindrical', 'D', 'Square', 'W' and 'Wing'. 1.2.2 Molded Fenders NOTE: Molded fenders are typically mounted to the vertical face of a marine structure. These systems are used to berth ships of similar size and hull curvature. Therefore, they are usually found in commercial ports. Molded fenders are elements manufactured by the molded process. They typically have embedded metal plates cast into the molds. The fender elements are typically used as fenders for medium to large, flat sided vessels. The elements can be used as stand-alone fenders, combined with multiple fenders and a face panel, and energy absorbing elements at the wale. They include the shear fenders which absorb energy by deflecting parallel to the attachment plane. Examples of molded fender shapes are 'Arch Fender', 'Circle', 'Circular Dock', 'Fender Bars', 'Hexagonal', and the 'buckling fender' types, such as 'MV', 'V Leg' and 'V Section'. 1.2.3 Foam-Filled Fenders NOTE: Foam-filled fenders are typically used at berths that support ships of various sizes and with a variety of hull curvatures. Due to the wide variety of ship types that berth at Naval facilities, the foam-filled fenders are typically the fender of choice. Foam-Filled fenders are fenders typically manufactured by wrapping closed cell foam with a nylon reinforcement embedded in a polyurethane coating. The fenders typically used for fendering have an internal chain, though fenders having an external chain/tire netting have also been used. The fenders are typically used for berthing of medium to large vessels; vessels with considerable hull curvature; and at berths that support various ship types and sizes. The fenders can be used as stand-alone fenders, fendering between ships, or between a ship and a berthing structure. 1.2.4 Pneumatic and Hydro-pneumatic Fenders NOTE: Pneumatic fenders are inflated with air and float on the surface of the water to serve as a protective buffer for ships. Hydro-pneumatic fenders are similar, but contain water in addition to the pressurized air, with a counterweight at one end so the fender is partially submerged and are specifically designed for the berthing of submarines. Pneumatic and hydro-pneumatic fenders are constructed of an inner rubber layer, reinforcing cord layers and an outer rubber layer that form a synthetic-cord-rubber sheet, which forms a cylindrical air-bag with hemispherical heads at each end,which can be inflated with air. These fenders can be used as stand-alone fenders, fendering between ships, or between a ship and a berthing structure. In hydro-pneumatic fenders, the upper hemispherical head has a top plate that allows internal placement of water and air into the bag, and the lower hemispherical head has a bottom plate that provides a connection location for the counterweight. The air-bag typically has a long cylindrical shape and is counter-weighted to float vertically. Hydro-pneumatic fenders are typically used as fenders for submarines, acting as buffers between submarines and berthing structures and as separators between submarines. Hydro-pneumatic fenders can be used in combination with foam-filled fenders or pneumatic fenders to support both ships and submarines at the same berth, if designed appropriately. 1.3 SUBMITTALS NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL PROCEDURES and edit the following list to reflect only the submittals required for the project. Submittals should be kept to the minimum required for adequate quality control. A “G” following a submittal item indicates that the submittal requires Government approval. Some submittals are already marked with a “G”. Only delete an existing “G” if the submittal item is not complex and can be reviewed through the Contractor’s Quality Control system. Only add a “G” if the submittal is sufficiently important or complex in context of the project. For submittals requiring Government approval on Army projects, a code of up to three characters within the submittal tags may be used following the "G" designation to indicate the approving authority. Codes for Army projects using the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO" for District Office (Engineering Division or other organization in the District Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project Office. Codes following the "G" typically are not used for Navy, Air Force, and NASA projects. Choose the first bracketed item for Navy, Air Force and NASA projects, or choose the second bracketed item for Army projects. Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES: _{SD-02 Shop Drawings Panels G SD-03 Product Data Stainless Steel Hardware G Galvanized Steel Hardware G} Include Manufacturer's product data for all fender hardware, including bolts, anchor bolts, inserts, nuts, washers, chains, turnbuckles, dimensions, material specifications, working loads and ultimate loads, as applicable. For anchor bolts and inserts, include methods and materials for installation. _{Restraint Chains G Facing G} EXTRUDED FENDERS, MOLDED FENDERS _{Extruded fender G Molded fender G} Include dimensions, material specifications, and method of manufacture. FOAM-FILLED FENDERS Resilient, _{foam-filled marine fenders G} Prior to fabrication, copies of the manufacturer's catalog data including reaction, energy and percent compression curves, dimensions material specifications, and method of manufacture shall be submitted for approval. Include dimensions, material specifications, and method of manufacture. PNEUMATIC AND HYDRO-PNEUMATIC FENDERS Resilient, _{pneumatic fenders G} Resilient, _{hydro-pneumatic fenders G} Prior to fabrication, copies of the manufacturer's catalog data, performance curves per ISO 17357 , dimensions, material specifications, and method of manufacture shall be submitted for approval. _{SD-05 Design Data} NOTE: Performance requirements: the rated energy of the fender shall be no less than the calculated berthing energy and the rated fender reaction shall not exceed the allowable load on the structure supporting it. The maximum reaction divided by the corresponding contact area, shall be less than or equal to the maximum specified hull pressure for fender panels. Deflected standoff at specified energy must be greater than or equal to minimum specified standoff. The undeflected standoff, including nets if any, shall not be greater than any specified undeflected standoff. Fender design load shall be less than the rated reaction of the fender. Static shear force shall use the minimum static coefficient of friction. Dynamic shear force for foam-filled, pneumatic and hydro-pneumatic shall be the rated reaction times the difference between the coefficient of friction between the structure and fender and the coefficient between the fender and vessel times a factor of safety of 1.5. Dynamic shear force for rubber fenders for slicing surfaces shall be twice the maximum published dynamic coefficient of friction. For UHMW against steel, use 0.20 or the maximum published for the coefficient of friction. The ultimate elastomeric elongation shall be at least three times the maximum elongation anticipated at maximum design conditions. The bond strength of the elastomer to its substrate shall be greater than the elastomer's tensile strength at the ultimate elongation. Structural components shall be sized with a design load that does not exceed 80 percent of yield. Panel loads shall be based on the greater of: 1. Horizontal line contact applied at center of the footprint of the fender element against the panel. 2. Vertical line contact applied at the vertical center of the footprint of the fender element against the panel. 3. Simultaneous horizontal line contacts at top and bottom edge of the front face of the panel. Design factor for attachment points, restraints and nets shall be based on 1.5 times the dynamic shear. The end attachment load shall not exceed 80 percent of yield. Restraints shall be sized such that the load applied to the weakest component does not exceed 50 percent of its breaking strength. A weak link, preferably a shackle, swivel or other readily replaceable, cost effective component shall be designed to fail fist. Concrete embedments shall have a breaking load at least 1.25 times the breaking load of the weakest component attached to them. Mechanical hardware, such as fasteners shall be sized with a design working load that does not exceed 60 percent of the lower of the yield or breaking load. Foam-filled, pneumatic and hydro-pneumatic fenders should have at least 50% of the contact dimension in bearing on the supporting structure, or as recommended by the manufacturer. The contact surface for all floating fenders when not under load, should have low abrasion characteristics. Typically UHMWPE or plastic is used to face concrete or composite elements in the wear area. EXTRUDED FENDERS, MOLDED FENDERS Design data for _{rubber fenders G} Submit rated performance data (RPD) and published performance curves per ASTM F 2192. FOAM-FILLED FENDERS Design data for _{foam filled marine fenders G} Submit rated performance data (RPD) and published performance curves per ASTM F 2192. PNEUMATIC AND HYDRO-PNEUMATIC FENDERS Design data for _{pneumatic fenders G} Design data for _{hydro-pneumatic fenders G} Submit rated performance data (RPD) and published performance curves per ISO 17357. _{SD-06 Test Reports} EXTRUDED FENDERS, MOLDED FENDERS _{Ozone Resistance G Low Temperature Impact Resistance G Water Absorption G Heat Resistance G} Tests shall have been performed on the specified fender within 5 years of submittal of the reports for approval. Test reports shall be accompanied by notarized certificates from the manufacturer certifying that the tested material is of the same type, quality, manufacture and make as that proposed to be supplied. FOAM-FILLED FENDERS _{Fender cyclic-compression test G Fender sustained-load test G Fender pull-through test G Skin thickness core test G} Submit copies of reports of tests specified herein. The tests shall have been performed within three years of submittal of the reports for approval. Also, submit reports for tests specified in referenced documents which are applicable to the particular material furnished for use. PNEUMATIC AND HYDRO-PNEUMATIC FENDERS _{Prototype fender performance confirmation G} NOTE: Prototype fender performance confirmation includes the following tests: (1) performance; 2) angular compression; (3) durability; (4) compression recovery; and (5) puncture resistance. _{Material test of rubber G Dimensional inspection G Air-leakage test G Hydrostatic-pressure test G Pressure Relief Valve Test Design Proof G} Submit copies of reports of tests specified herein. Also, submit reports for tests specified in referenced documents which are applicable to the particular material furnished for use. _{SD-07 Certificates Stainless Steel Hardware G Galvanized Steel Hardware G} Submit certificates of compliance certifying that materials meet the requirements specified herein. In addition, when the coating is shop applied, submit certificates of conformance or compliance certifying that surface preparation, coverage, and thickness meet the requirements specified. _{Pneumatic fenders G} Submit certificates of compliance certifying that materials meet the requirements specified herein. _{Hydro-pneumaticfenders G} Submit certificates of compliance certifying that materials meet the requirements specified herein. _{SD-08 Manufacturer's Instructions Installation Instructions} Provide installation instructions for each fender type. _{SD-10 Operation and Maintenance Data Fender Manual} Provide fender manual for each fender type. 1.4 DELIVERY, HANDLING AND STORAGE Fenders shall be undamaged when delivered and shall be handled and stored so as to prevent damage, such as bending or abrading end fittings, cutting of rubber, or damage to coating of hardware. Protect fenders from exposure to damaging liquids, oils, greases and extended exposure to sunlight. 1.4.1 Rejection Fenders that are delivered to the site in a damaged condition or that are not in conformance with this specification are subject to rejection. Any rejected materials shall be replaced with suitable materials, at no additional cost to the Government. 1.4.2 Fender Marking Unless otherwise specified, all fenders shall be identified in readable characters at least 1 in.25 mm high, either directly or on corrosion- and sunlight resistant permanently attached tags. The markings shall include the following: a. full or abbreviated manufacturer name, b. fender size model or part number designation, c. fender serial number, d. ASTM designation (including type, grade and class) or ISO number and year, as applicable, e. initial or rated internal pressure (pneumatic and hydro-pneumatic fenders only, f. rated performance (energy and reaction), and g. type of reinforcement layer (pneumatic and hydro-pneumatic fenders only,) and h. other information as the purchase specification or contract requires. 1.4.3 Fender Instructions and Manual Provide _{installation instructions} and a _{fender manual} describing maintenance requirements for each fender type. 1.4.4 Handling Coated Material Store, handle and place coated material in a manner that will minimize damage to the coating and will not reduce its effective protective value. Repair damaged surfaces as directed and per the Manufacturer's recommendations. Handle coated work which is flexible in a manner that will prevent flexing sufficient to crack coating, especially when temperature is below 40 degrees F. Do not place coated surfaces on strips or skids until coating has hardened thoroughly. Wide fabric slings used for lifting, and strips, slings, blocks, skids, cradles, and other supports shall provide ample bearing areas. In transporting, fasten and protect coated materials in a manner that will prevent movement and preclude chafing and rubbing, and when unloading, do not dump or drop. Place coated material in position carefully on suitably prepared beds and with a minimum of handling. 1.5 QUALITY ASSURANCE 1.5.1 Extruded Fenders, Molded Fenders Fender elements shall be molded of rubber, homogeneous and free from any defects, impurities, pores or cracks. Where internal plates are used, the rubber shall be bonded to integral steel mounting plates. The plates shall be fully encased in rubber to a minimum thickness of 1/16 inch1.6 mm. 1.5.2 Elastomer Skin The elastomer skin of the fender shall be free from cracks, burrs, warpage, checks, chipped or blistered surfaces, and shall have a smooth surface. 1.5.3 Foam Core The foam core shall be homogeneous and of one piece fabricated construction and shall not be in chip or granular form. The foam core shall not contain scraps, strips, or sheets of foam either rolled or stuffed into the required shape unless pieces are bonded together in layers of uniform patterns to form a homogeneous, one piece core. Homogeneous foam rings of adequate thickness to insure performance of the fender are acceptable provided the Contractor can show a minimum 5-year performance of similar fenders. 1.5.4 Steel Fabrication The steel used in fabrication shall be free from kinks, sharp bends, and other conditions which would be detrimental to the finished product. Manufacturing processes shall not reduce the strength of the steel to a value less than intended by the design. Manufacturing processes shall be done neatly and accurately. Make bends by controlled means to insure uniformity of size and shape. 1.5.5 Welding AWS D1.1/D1.1M. Welds shall be of sufficient size and shape to develop the full strength of the parts connected by the welds. Welds shall transmit stress without permanent deformation or failure when the parts connected by the weld are subjected to proof and service loadings. 1.6 FOAM-FILLED FENDERS, PNEUMATIC AND HYDRO-PNEUMATIC FENDERS - WARRANTY NOTE: The warranty requirements in this guide specification have been approved by a Level I Contracting Officer in accordance with the requirements of NAVFAC P-68. The paragraphs in this guide specification may be used without further approval. Furnish the manufacturer's warranty. The warranty shall be issued directly to the Government and shall not be limited in dollar value. The warranty period shall be not less than 1 year from the date of Government acceptance of the work. PART 2 PRODUCTS 2.1 EXTRUDED AND MOLDED FENDERS 2.1.1 Configuration 2.1.1.1 _{Extruded Fender} Fenders shall be extruded and continuous in the length indicated. The fenders shall be black in color. The fenders shall have a truncated "A" cross section shape and be attached to the structure at the base, the widest dimension, of the arch. The connecting hardware shall be fully exposed. No encased hardware or molded fenders shall be allowed. The fender and hardware shall be designed and factory tested to the loads per linear meter foot of fender specified in paragraph entitled "Performance," for angles of approach of 0 and 0.26 rad 0 and 15 degrees. Fender anchor bolts and method of anchorage shall be of the size and spacing required by the manufacturer's design and testing; however, the size and spacing of anchor bolts indicated on the drawings shall be construed to be the minimum required, unless exceeded by the requirements of the fender manufacturer's design. 2.1.1.2 _{Molded Fender} Fenders shall be molded and continuous in the length indicated. The fenders shall be black in color. Each fender shall be molded of rubber, homogeneous and free from any defects, impurities, pores or cracks, and bonded to integral, steel mounting plates. The mounting plates shall be fully encased in rubber with a minimum thickness of 1/16 inch1.6 mm. The fender and hardware shall designed for and be factory tested to the loads specified. Fender anchor bolts and method of anchorage shall be of the size and spacing dimensions required by the manufacturer's design and testing; however, the size and spacing of anchor bolts indicated on the drawings shall be construed to be the minimum required, unless exceeded by the requirements of the fender manufacturer's design. 2.1.2 Elastomer The elastomer shall be the ethylene propylene dimonomer (EPDM), as specified in ASTM D 2000, with the following line callout: NOTE: Coordinate values with calculated design requirements. The 3BA 720 compound is the typical compound. The 3BA 620 compound has approximately 70% of the energy capacity and a reduced reaction. Other compounds may be available. a. 3BA 720 A14 B13 C12 EA14 F17 [b. 3BA 620 A14 B13 C12 EA14 F17] Tests shall include _{Ozone Resistance}, _{Low Temperature Impact Resistance}, _{Water Absorption}, _{Heat Resistance}. 2.1.3 Performance Requirements NOTE: This performance criteria should be tailored for extruded and molded shapes. Coordinate values with calculated design requirements. Each of the _{rubber fenders} shall have the following performance characteristics: SIZE ENERGY ABSORPTION REACTION FORCE at 48% compression at predicted energy attainment [___' x ___'] [_____ ft-kips] [_____ kips][___m x ___m] [_____ kN-m] [_____ kN] When vertically compressed by a plate extending the full length and width of a 300 mm one foot section of the fender, the fender shall absorb [_____] [_____] newton-meters [_____] foot-pounds of energy +10 percent when [48] [_____] percent compressed (i.e., to a dimension of [52] [_____] percent of its original height) with a corresponding load of not more than [_____] [_____] N [_____] [_____] pounds +10 percent. 2.1.4 Break-In Deflection Break-in deflection is required for buckling type fenders with reaction ratings of 100 tonnes or more, or if the energy-absorbing material has a reaction decrease of more than 10 percent between its original deflection and and its fifth deflection. Break-in deflection shall be to at least the manufacturer's rated deflection. The number of break-in cycles shall be sufficient to assure each elements first on-dock reaction will not exceed it fully broken-in reaction by more than 5 percent. 2.1.5 _{Stainless Steel Hardware} NOTE: It is recommended that all concrete inserts be of stainless steel materials. 2.1.5.1 Plates and Angles ASTM A 479/A 479M, Type 316L stainless steel for plates, angles, and miscellaneous hardware required to attach the fenders to the structure. 2.1.5.2 Bolts, Nuts, and Washers ASTM F 593 or ASTM F 594, Group 2 (316 alloy) stainless steel for nuts and bolts. ASTM F 844 for washers, except fabricate washers of 316 alloy stainless steel. 2.1.5.3 Antiseize Compound MIL-PRF-907. 2.1.6 _{Galvanized Steel Hardware} NOTE: Galvanized steel hardware may be used at locations where the hardware can be easily replaced. All hardware shall be hot-dip galvanized in accordance with ASTM A 123/A 123M, ASTM A 153/A 153M or ASTM B 695 , as applicable. 2.1.6.1 Plates ASTM A 36/A 36M. 2.1.6.2 Bolts, Nuts and Washers Bolts shall be ASTM A 307. Nuts shall be ASTM A 563, grade A heavy hex. Washers shall be ASTM F 844 of carbon steel. 2.1.7 _{Restraint Chains} and Shackles Chain and shackles shall meet the requirements of FS RR-C-271. The chain assembly shall have a design safety factor of 3:1 based on minimum breaking strength. 2.1.8 _Panels Panel design shall be of closed box construction for optimum strength and corrosion resistance. Material thickness shall be 3/8 inch9.5 mm minimum when one side is exposed and 1/2 inch12.7 mm minimum when both sides are exposed. 2.1.8.1 _Facing Facing on the panels shall be UHMWPE (ultra high molecular weight polyethylene), ultraviolet stabilized with 2.5 percent carbon black or equivalent, minimum 1/2 inch12.7 mm wear thickness, with a 0.20 maximum coefficient of friction per ASTM D 1894. The UHMWPE shall exhibit no failure when tested per ASTM D 256, Method B. The facing connections shall be configured to account for the thermal properties of the polyethylene. 2.2 FOAM-FILLED FENDERS 2.2.1 Configuration Fenders shall have cylindrical mid-bodies with conical or hemispherical shaped ends terminating in an end fitting on the cylinder's centerline at each end. If conical ends are provided, they shall have an angle of 60 to 75 degrees, when measured from the central axis of the fender. The fittings at either end shall be connected through the center of the fender by a chain, shall terminate in a clevis fitting sized for the indicated shackle and shall swivel to allow the end fitting to rotate freely on the axis of the fender. Design end fitting as small as possible to transmit the ultimate load of the shackle to the fender. End fitting shall be sized so as not to contact loading surfaces when the fender is compressed to 30 percent of its original diameter (70 percent compression). Fill interior of the fender with energy absorbing closed-cell foam as specified. The use of chipped or particulate foam is not acceptable. 2.2.2 Foam Core The energy absorbing foam core shall be a closed-cell cross-linked polyethylene foam with the following properties: a. Density, ASTM D 1667, [52 to 104] [_____] to [_____] kg/m3 [3.3 to 6.5] [_____] to [_____] lbs/ft3 b. Tensile strength, ASTM D 3575 or ASTM D 412, [550] [_____] kPa [80] [_____] psi minimum c. Elongation (ultimate), ASTM D 3575 or ASTM D 412, [40 percent] [_____] to [_____] minimum d. Water absorption percent volume after 24 hour exposure, ASTM D 1667, [5.0 percent] [_____] maximum e. Continuous service temperature, [-54 to 49 degrees C] [-65 to +120 degrees F] [_____] to [_____] f. 25 percent compressive set, ASTM D 1667, [8 percent] [_____] maximum * g. 50 percent compressive set, ASTM D 3575, [12 percent] [_____] maximum * * Contractor option: Compressive Set of foam core material shall be based on either the 25 percent or the 50 percent requirement listed. 2.2.3 Fender Skin The outer fender skin shall be minimum [32] [_____] mm [1.25] [_____] inches thick and constructed of elastomer as specified. Filament reinforcing is required. [Twelve] [_____] separate filament reinforcing wraps shall be applied as specified under Filament Wrap. The filament wraps shall be evenly distributed in the inner 80 percent to 90 percent of the coating thickness. The outer 10 percent to 20 percent of elastomer shall have no filament reinforcing. The elastomer and filaments shall be applied in a continuous manner to assure adhesion between the various layers. The connection of the skin to the end fittings shall be designed and sized to transmit twice the safe tensile capacity of the chain into the fender skin. 2.2.3.1 Elastomer The elastomer used in the fender skin shall be 100 percent PTMEG (polytetramethyleneether glycol) polyether urethane elastomer, ultraviolet stabilized with 2.5 percent carbon black or equivalent, with the following unreinforced properties: a. Shore A. hardness, ASTM D 2240, [80 to 95] [_____] to [_____]. b. Tensile strength, ASTM D 412, [19.3] [_____] MPa [2800] [_____] psi minimum. c. Elongation (ultimate), ASTM D 412, [300 percent] [_____] minimum. d. Tear strength, ASTM D 470, [1.25] [_____] kg per mm [70] [_____] lbs/inch minimum. e. Flex life (Ross), ASTM D 1052, [200,000] [_____] cycles minimum. f. Abrasion resistance (NBS), ASTM D 1630, [100] [_____] minimum. 2.2.3.2 Filament Wrap Construct each filament reinforcing wrap of continuous filaments applied in a helical pattern, at a helix angle of 0.79 to 1.05 rad 45 to 60 degrees to the longitudinal axis of the buoy. A wrap shall consist of two such filament helixes of equal but opposing helix angles. The spacing between the filaments in the same helix shall be no more than 3 mm 1/8 inch, measured in a direction parallel to the longitudinal axis of the fender. Each wrap shall extend along the entire longitudinal axis of the fender and shall also encase the fender end fittings and secure them to the fender body. The reinforcing filaments shall be nylon tire cord of 0.00028 kg per m 2540 denier weight with the following properties: a. Breaking strength, [235] [_____] N [53] [_____] pounds b. Elongation (ultimate), [18] [_____] percent 2.2.3.3 Color Fender skin color shall be black throughout the entire thickness. Galvanized hardware shall be unpainted. 2.2.3.4 Repairability The fender casing shall be repairable in the event of tears or punctures in the elastomer skin. The repaired area shall have not less than 90 percent of the properties as specified in paragraph entitled "Elastomer." Required repair materials shall be readily available from the fender manufacturer. 2.2.4 Internal Hardware The internal chain connecting the two end fittings and the two end fittings shall be galvanized in accordance with ASTM A 123/A 123M or ASTM A 153/A 153M as appropriate. The chain and end clevis fitting shall have a minimum ultimate tensile capacity of [640,000] [_____] N [144,000] [_____] pounds. The internal chain and end clevis fitting shall have a minimum ultimate tensile capacity of [578,000] [_____] N [130,000] [_____] pounds. Shackles shall be [45] [_____] mm [1 3/4] [_____] inches and shall have a minimum ultimate tensile capacity of [289,000] [_____] N [65,000][_____] pounds. 2.2.5 Performance Requirements Each foam-filled fender shall have the following performance characteristics: SIZE ENERGY ABSORPTION REACTION FORCE at 60% compression at predicted energy attainment [___' x ___'] [_____ ft-kips] [_____ kips][___m x ___m] [_____ kN-m] [_____ kN] The resilient, _{foam filled marine fenders} shall be designed so that when compressed across its diameter by two parallel flat plates extending the full length and width of the fender, the fender shall absorb [300,265] [_____] newton-meters [221,500] [_____] foot-pounds of energy +15 percent when [60] [_____] percent compressed (i.e. to a dimension of [40] [_____] percent of its original diameter) with a corresponding load of not more than [712,000] [_____] N [160,000] [_____] pounds +15 percent. The fender shall also be designed to withstand a sustained reaction force of 667,200 [_____] N [150,000] [_____] pounds for a duration of not less than 24 hours each occurrence for at least 200 occurrences during its 10-year predicted life. 2.2.6 Source Quality Control 2.2.6.1 _{Fender Cyclic-Compression Test} Compress the fender along its diameter between two parallel flat plate surfaces to a compressed dimension of 40 percent of its original diameter. Repeat the compression and release cyclic loadings for a minimum of 10 full cycles of compression. Permanent deformation, cracking, or tearing of the fender skin, fender core, or end fittings shall constitute failure of this test. 2.2.6.2 _{Fender Sustained-Load Test} Apply a [667,000] [_____] N [150,000] [_____] pound compressive load and hold this load for 24 hours. Record load and deflection each hour. Immediately after release of the load, measure rebound of the fender. Continue to record fender rebound for 24 hours. Failure of the fender or foam core to rebound to 90 percent of its original diameter after 24 hours shall constitute failure of this test. If the foam core is not bonded to the skin of the fender, devise and execute a means for measuring rebound of the foam core and for measuring the void between the foam core and the skin. The maximum rate of compression per minute shall be 20 percent of the total reaction force at 60 percent compression. The full compression cycle, not including rebound, shall take a minimum of 5 minutes. 2.2.6.3 _{Fender Pull-Through Test} Devise and perform a test which will measure the resistance of the end fittings and internal chain to pull through the longitudinal axis of the fender. Failure of the chain, end fittings, or skin to resist at least [178,000] [_____] N [40,000] [_____] pounds of pull-through tension shall constitute failure of this test. After loading, evidence of permanent deformation, cracking, or tearing of the fender or end fittings shall also constitute failure of this test. 2.2.6.4 _{Skin Thickness Core Test} NOTE: The suggested number of fenders that should be tested is as follows: Fenders Number Procured to test 1 - 3 1 4 - 8 2 9 - 20 3 21 and above 4 [After delivery of all of the fenders to the construction site and before fender installation, perform a minimum of [3] [_____] skin thickness tests per fender for each of [1][2][3][4] fenders to be selected at random by the Contracting Officer.] [After fabrication of all of the fenders and prior to fender shipment to the construction site, perform a minimum of [3] [_____] skin thickness tests per fender for each of [1] [2] [3] [4] fenders to be selected at random by the Contracting Officer.] Test locations on the fenders will be selected by the Contracting Officer. Each test shall consist of taking a 6 mm 1/4 inch diameter (minimum) to 13 mm 1/2 inch diameter (maximum) core from the fender skin which can be removed from the skin and examined for thickness of elastomer and placement of reinforcing (when reinforcing is required). Take skin thickness measurements from the core sample and record measurements noting placement of reinforcing. Where the skin thickness measurement is less than the specified minimum, or the minimum required by the Contractor's design (whichever is greater) by more than 10 percent, reject the fender. In addition, if the average of skin thickness tests for one fender is not equal to or greater than the specified minimum, or the minimum required by the Contractor's design (whichever is greater), reject the fender. If tested fender is rejected, at the option of the Contracting Officer, the Contractor shall then conduct thickness tests for additional fenders. Replace rejected fenders with fenders meeting the provisions of this specification. Test replacement fenders for skin thickness as specified herein. Skin thickness tests will be witnessed by the Contracting Officer. The Contractor shall notify the Contracting Officer 10 working days prior to conducting skin thickness tests. After skin thickness testing, patch core holes with elastomer of the same composition and thickness as the specified elastomer skin. Nylon reinforcing is not required in core hole patches. 2.2.7 Connecting Hardware The connecting chain, swivel and shackles shall be galvanized in accordance with ASTM A 123/A 123M or ASTM A 153/A 153M , as appropriate. The hardware shall be as follows: Item Type _________ _________________________________________ Chain ABS 2, Grade 2, Stud Link or Open Link Shackle FS RR-C-271, Type IVA, Class 3, Grade A Swivel FS RR-C-271, Type VII, Class 2 All connecting bolts and pins shall be of mild steel, matching the properties of the shackle bow. For Class 3 shackles, the bolt or pins shall be secured in place with stainless steel (Type 316) cotter pins or locking pins. 2.3 PNEUMATIC AND HYDRO-PNEUMATIC FENDERS 2.3.1 Configuration Fenders shall be manufactured in accordance with ISO 17357. Fenders shall have cylindrical mid-bodies with hemispherical shaped ends terminating in an end fitting on the cylinder's centerline at each end. The end fittings shall be shall be sized (not to exceed 12 percent of fender diameter) so as not to contact loading surfaces when the fender is compressed to 20 percent of its original diameter (80 percent compression). Pneumatic and hydro-pneumatic fenders shall incorporate for fenders 2500 mm8 feet in diameter and larger, a safety valve and a pressure monitoring system in their manufacture. 2.3.2 Dimensions Diameter and length as indicated. 2.3.3 Fender Skin The fender skin shall have a minimum strength in accordance with ISO 17357. When designing the skin thickness, the Manufacturer shall consider skin strength and the stress induced by the internal operating and berthing pressure, and the abrasion and impact loads caused by handling and berthing operations. The Manufacturer shall ensure an adequate margin of safety is incorporated for the fender's intended use. The connection of the skin to the end fittings shall be designed to resist the internal pressure of the fender at 60 percent compression per ISO 17357 . 2.3.3.1 Elastomer The elastomer shall meet the requirements of ISO 17357, _{material test of rubber}. Per ISO 17357, the elastomer used in the outer skin shall be rubber, with the following unreinforced properties: a. Durometer Hardness, Shore A [50 to 70] [_____] (ASTM D 2240 or ISO 37) b. Minimum Tensile strength [2600 psi] [18] MPa [_____] (ASTM D 412 or ISO 37) c. Minimum Elongation (ultimate) [400%] [_____] (ASTM D 412 or ISO 37) d. Minimum Tear strength [228 lbs/inch][400] [_____] N per cm [_____] (ASTM D 624 or ISO 34-1) The elastomer used in the inner skin shall be rubber, with the following unreinforced properties: a. Durometer Hardness, Shore A [40 to 60] [_____] (ASTM D 2240 or ISO 37) b. Minimum Tensile strength [1450 psi] [10] MPa [_____] (ASTM D 412 or ISO 37) c. Minimum Elongation (ultimate) [400%] [_____] (ASTM D 412 or ISO 37) 2.3.3.2 Color Fender skin color shall be black throughout the entire thickness. Galvanized hardware shall be unpainted. 2.3.3.3 Repairability The fender casing shall be repairable in the event of tears or punctures in the elastomer skin. The repaired area shall have not less than 90 percent of the properties as specified in paragraph entitled "Elastomer". Required repair materials shall be readily available from the fender manufacturer. 2.3.4 Performance Requirements The performance of each fender shall be meet the requirements of ISO 17357. The performance of the fender shall be confirmed with a _{prototype fender performance confirmation} per ISO 17357. The tests shall include a parallel performance, angular compression, durability, compression-recovery and puncture-resistance. 2.3.4.1 _{Design Proof} Design proof shall document minimum endurable pressure based on at least 30 test samples that cover entire range of compression from 0 percent to 60 percent deflection 2.3.4.2 Pneumatic Fenders Each pneumatic fender shall have the following performance characteristics: SIZE ENERGY ABSORPTION REACTION FORCE at 60% compression at predicted energy attainment [___' x ___'] [_____ ft-kips] [_____ kips][___m x ___m] [_____ kN-m] [_____ kN] The _{pneumatic fenders} shall be designed so that when compressed across its diameter by two parallel flat plates extending the full length and width of the fender, the fender shall absorb [943,000] [_____] N-m [695,500] [_____] ft-lbs of energy when [60] [_____] percent compressed +/-5 percent(i.e. to a dimension of [60] [_____] percent of its original diameter) with a corresponding load of not more than [2,019,000] [_____] N [453,900] [_____] lbs +/-10 percent. Performance test based on ISO 17357 procedure with fender full of air only. 2.3.4.3 Hydro-pneumatic Fender NOTE: The performance of the hydro-pneumatic fenders vary according to the size, water/air ratio and internel pressure. The Manufacturer should be consulted in the selection of the desired performance characteristics. Each hydro-pneumatic fender shall have the following performance characteristics: SIZE ENERGY ABSORPTION REACTION FORCE at 60% compression at predicted energy attainment [___' x ___'] [_____ ft-kips] [_____ kips][___m x ___m] [_____ kN-m] [_____ kN] The _{hydro-pneumatic fenders} shall be designed so that when compressed across its diameter by two parallel flat plates extending the full length and width of the fender, the fender shall absorb [4,281,000] [_____] newton-meters [3,157,504] [_____] foot-pounds of energy when [60] [_____] percent compressed +5 percent (i.e. to a dimension of [60] [_____] percent of its original diameter) with a corresponding load of not more than [6,907,000] [_____] N [1,552,755] [_____] pounds +10 percent. 2.3.5 Source Quality Control 2.3.5.1 _{Dimensional Inspection} The dimensions of all fenders shall be inspected. They shall meet the requirements of ISO 17357. NOTE: The dimensional tolerances per ISO 173578 are as follows: - length: + 10%, -5% - diameter: + 10%, -5% The diameter shall be obtained from the average of at least two different measurements taken at the middle of teh cylindrical section of the fender. 2.3.5.2 Air-leakage Test _{Air leakage test}s shall be performed per ISO 17357. The test shall confirm that there is no air leakage when the initial pressure is held for more than 30 minutes. 2.3.5.3 Hydrostatic-pressure Test Each pneumatic and hydro-pneumatic fender shall be _{hydrostatic-pressure test}ed for its rated operating pressure (internal pressure at 0 percent deflection). Testing shall be in accordance with ISO 17357. 2.3.5.4 _{Pressure Relief Valve Test} The pressure relief valve shall be mounted to a test chamber for a pressure relief test. After mounting, the chamber internal pressure shall be slowly increased until the specified relief pressure is attained. The pressure relief valve shall be set to relieve pressure according to the manufacturers recommendations. If the pressure relief valve opens at a higher or lower pressure than allowed, it shall be adjusted as required and tested again until within the specified limits. A written test procedure and records pertaining to this test shall be maintained. 2.3.6 Hardware, Chain, And Shackles The connecting chain, swivel and shackles shall be galvanized in accordance with ASTM A 123/A 123M or ASTM A 153/A 153M , as appropriate. The hardware shall be as follows: Item Type _________ _________________________________________ Chain ABS 2, Grade 2, Stud Link or Open Link Shackle FS RR-C-271, Type IVA, Class 3, Grade A Swivel FS RR-C-271, Type VII, Class 2 All connecting bolts and pins shall be of mild steel, matching the properties of the shackle bow. For Class 3 shackles, the bolt or pins shall be secured in place with stainless steel (Type 316) cotter pins or locking pins. 2.3.6.1 Hydro-pneumatic Guy Chain Guy chains shall be provided for attachment from the upper fender end fitting assembly to the pier. That portion of the chain extending from the fender itself shall be covered with protective rubber sleeves to a point beyond which the fender will be contacted for fender body protection. Size and lengths shall be as indicated on the Drawings. 2.3.6.2 Hydro-pneumatic Hanging Chain Hanging chains shall be provided for attachment from the counterweight to the pier. Size and lengths shall be as indicated on the Drawings. 2.3.6.3 Hydro-pneumatic Lower End Fitting Assembly The lower end fitting shall be fabricated of steel and shall provide connecting points for the connecting chain and the hanging chain. 2.3.6.4 Hydro-pneumatic Upper End Fitting Assembly The upper end fitting shall be fabricated of steel and shall be designed to house all necessary valves and fitting necessary to charge and discharge the fender body with air and water necessary for proper installation and operation of the deployed fender. This shall include the air charging assembly, the water charging assembly, the pressure safety relief valve assembly and lifting eyes adequately sized for guy chain attachment. All valves and related hardware shall be attached to the inner assembly plate. An outer assembly blind flange plate shall be included to provide protection during handling and operations. The pressure relief valve shall be stainless steel, shall be adjustable to ensure maintenance of the proper setting, and shall be capable of adequate flow (volume of air released per second) to maintain a safe internal pressure. 2.3.6.5 Hydro-pneumatic Counterweight A steel counterweight shall be provided for attachment to the fender's lower flange assembly by two shackles. It shall include an upper eye for shackle attachment of the hanging chain and shall be coated with a marine coating system. The counterweight shall be sized per the Manufacturer's recommendation. PART 3 EXECUTION 3.1 EXTRUDED FENDERS AND MOLDED FENDERS Install the fenders in the position and at the spacing indicated on the drawings. Tighten the bolts per the manufacturers requirements. 3.2 FOAM-FILLED FENDERS Install fenders as indicated on the drawings and in accordance with the manufacturer's specifications and shop drawings. Bolts shall be tightened an additional 1/3 turn of the nut, from the snug tight condition, and secured with cotter pins. 3.3 PNEUMATIC AND HYDRO-PNEUMATIC FENDERS The fendering system shall be installed in accordance with the Drawings, manufacturer's specifications and shop drawings. Bolts shall be tightened an additional 1/3 turn of the nut, from the snug tight condition, and secured with cotter pins. 3.4 WELDING Welding shall be performed in accordance with AWS D1.1/D1.1M. 3.5 CONNECTIONS 3.5.1 Antiseize Compound Coat threads of bolts prior to applying washers and nuts. Recoat bolt thread projection beyond nut after tightening.