New service combines 3D scanning, tailored solutions, and recycling – and eliminated downtime for 3 ASD tugs

Boluda Towage Rotterdam has successfully upgraded the fender systems of three of their ASD tugboats through a new rapid, on-site fender service by Bencros. The new method eliminates the risk of costly installation errors and operational delays, and can be provided worldwide.

The project originated from a practical challenge: missing and outdated vessel drawings. This is a common issue in operational fleets where vessel drawings go missing or vessel modifications over time make standard fender specifications unreliable. In such cases, ordering replacement fenders without verification can result in misfits, requiring structural rework such as re-welding of mounting systems, leading to significant downtime and cost.

To address this need, Bencros developed an on-site service model, measuring fender mounting systems directly on board during drydock. For all three vessels, time was of the essence, so Bencros executed its Rapid Service Model.

Three workboats, three solutions

For one vessel, measurements had to be taken manually, for which Bencros sent off one of its specialist fender engineers, Jakub Bartoň. The second workboat was originally not designed to be outfitted with proper marine fenders. Hence, Bencros used its advanced 3D scanning technology to generate an accurate digital model for a fitting fender configuration. From this, a drawing for the company’s CAD system was created – and within one week the replacement fender was produced and later successfully installed.

Ronald Tomassen, General Manager at Bencros, says: “I am very happy to see that our new on-site measuring service, including recycling the old fenders, works so well. It clearly fills the void the market was asking us about, and I’m thankful to Boluda for giving us the opportunity to prove this service in practice.”

The third tug needed a very long replacement fender; one that couldn’t be transported in a normal truck. Here, Bencros proposed a solution based on three separate fender parts that could be connected seamlessly. This was easier to produce, more economic to transport, and kept full functionality.

Seven days

Based on these measurements, Bencros produced the fenders in only 3 days, and delivered custom-fit fenders within another 4 days directly from its own factory in Bošany, Slovakia. The solution guaranteed a precise fit without the need for modifications to the vessel fender mounting structure.

In addition to speed and accuracy, the project incorporated a circular approach. Existing fenders were removed, taken back and recycled, with recovered materials reused in the production of new fender systems.

Operational impact

Ronald: “Boluda Towage Rotterdam required solutions that fit their vessels instead of having to adapt their tugboats to standard fender solutions. Our approach delivered clear operational benefits.” In practice, the vessels’ downtime was reduced, no structural adjustments were needed, the new replacement method lowered overall cost and guaranteed fit, and the old fenders were taken by Bencros for recycling and reuse of rubber in Bencros’ own production facilities.

Joren van Delft, Fleet Manager at Boluda, says: “This was an interesting project. At the time, we did not have access to the drawings. That brought the very real risk of ordering a replacement fender system and then having to weld a new mounting system, which costs a lot of time and money. Hence, we needed a specialist on site. As it turned out, no-one was willing to do that, except Bencros. We had an immediate click, in part due to their willingness to think in solutions, not products. Another positive point was that they proposed to take back our old fenders and recycle them, which neatly fits Boluda’s Net Zero Target.”

A shift towards service-driven fender solutions

With this project, Bencros introduces a service model that goes beyond traditional supply. Unlike standard procurement processes that rely on existing drawings, the on-site approach ensures that each fender system is tailored to the actual vessel condition — even when drawings are missing or outdated. By combining 3D on-site measurement, rapid production and circular material handling, the company aims to support vessel operators in reducing risk, time and lifecycle costs.