When Old Fenders Started Causing Problems

A privately operated bulk cargo terminal in Southeast Asia had been using conventional rubber fenders for more than 15 years. The berth handled a mix of bulk carriers ranging from 10,000 DWT to 60,000 DWT.

As vessel traffic increased, the maintenance team began noticing several issues:

• Rubber surfaces had developed deep cracks.
• Some fenders showed permanent deformation.
• Steel frontal panels had become misaligned.
• Reaction force was inconsistent during berthing.
• Maintenance shutdowns became more frequent.

Although the berth remained operational, the terminal management wanted a longer-term solution before serious structural damage occurred.

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Looking for a Better Berthing Solution

The engineering team compared several marine fender systems, including:

• Arch fenders
• Cone fenders
• Cell fenders

Because the berth received vessels of different sizes while requiring high energy absorption with moderate reaction force, the engineers selected cell fenders.

The reasons included:

• High energy absorption efficiency
• Stable performance under repeated compression
• Long service life
• Compatibility with UHMW-PE frontal panels
• Lower maintenance requirements

The objective was not simply replacing old equipment, but improving long-term berth reliability.

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Installation Process

The project was completed during a scheduled maintenance shutdown.

The work included:

• Removing existing damaged fenders
• Inspecting embedded anchor systems
• Replacing anchor bolts where necessary
• Installing new cell fenders
• Mounting steel frontal panels
• Installing UHMW-PE facing pads
• Performing alignment and load inspection

Because the existing concrete structure remained in good condition, installation progressed smoothly without major modifications.

Within several days, the berth returned to service.

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Performance After Several Months

After months of operation, the maintenance department reported several noticeable improvements.

More Stable Vessel Berthing

Pilots reported that vessel contact felt smoother during final approach.

Instead of experiencing sudden impact loads, ships contacted the berth more progressively, making berthing easier under varying tidal conditions.

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Lower Maintenance Requirements

Unlike the previous system, the new cell fenders required only routine visual inspections.

No abnormal deformation or bolt loosening was observed during scheduled maintenance.

This significantly reduced maintenance workload.

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Better Protection for Both Ships and Berth

The combination of cell fenders and UHMW-PE frontal panels distributed impact loads more evenly.

Minor paint damage that had occasionally appeared on vessel hulls became much less common.

The berth structure also experienced less concentrated loading.

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Reliable Performance Under Daily Operations

The terminal handled multiple vessel calls every week.

Despite continuous operation, the cell fenders maintained consistent performance without noticeable loss of elasticity.

The maintenance manager commented:

“Our previous fenders required frequent repairs. Since installing the new cell fender system, maintenance has become much more predictable. We spend less time fixing equipment and more time focusing on normal terminal operations.”

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Lessons Learned

The project highlighted several important points for port operators.

Choosing the correct fender system is more important than selecting the largest one.

Proper selection should consider:

• Vessel size range
• Berthing velocity
• Berth structure
• Environmental conditions
• Maintenance strategy

In this case, the cell fender system provided the balance of energy absorption, durability, and lifecycle cost that the terminal required.

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Final Results

Although the terminal did not expect dramatic operational changes, the upgrade delivered steady long-term benefits:

• More reliable berthing performance
• Reduced maintenance interruptions
• Improved protection for ships and quay structures
• Consistent energy absorption
• Lower long-term operating costs

For ports handling medium to large commercial vessels, upgrading aging rubber fender systems to modern cell fenders can improve both operational reliability and maintenance efficiency over the long service life of the berth.

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Frequently Asked Questions

How long do cell fenders typically last?

With proper installation and routine inspection, quality cell fenders commonly remain in service for many years, depending on vessel traffic, environmental conditions, and maintenance practices.

Are cell fenders suitable for large commercial ports?

Yes. Cell fenders are widely used at container terminals, bulk cargo berths, oil terminals, LNG facilities, and general cargo ports because they offer high energy absorption with relatively low reaction force.

Do cell fenders require frequent maintenance?

Routine inspections are generally sufficient. Maintenance usually focuses on checking anchor bolts, steel frontal panels, and UHMW-PE facing pads rather than the rubber body itself.

Why are UHMW-PE panels used with cell fenders?

UHMW-PE panels reduce friction between the vessel hull and the fender system, helping minimize hull damage while allowing ships to move slightly with tides and loading conditions.