Marine Bearing Installation Manual PDF

SYMBOLS & UNITS
THORDON MARINE BEARING INSTALLATION MANUAL

Version 2008.1
SYMBOLS AND UNITS APPROXIMATE COMPARISON OF
Units VARIOUS HARDNESS SCALES
Metric Imperial
Ct = Thermal Expansion
Allowance mm inches
Cs = Absorption Allowance mm inches
d = Shaft diameter mm inches
Eo = Modulus of elasticity MPa psi
I.D. = Inside diameter of bearing mm inches
O.D. = Outside diameter of bearing mm inches
L = Length of bearing mm inches
N = Shaft speed R.P.M. R.P.M.
P = Pressure MPa psi
Ta = Machine Shop Ambient
Temperature (Nominally
21°C (70°F)) °C °F
To = Operating temperature °C °F
W.T. = Wall thickness of bearing mm inches
α = Coefficient of
Thermal Expansion °C °F
µ = Coefficient of Friction - -
V = Velocity m/sec. ft./min.
γ = Poisson’s Ratio
FREEZE FIT COOLANT TEMPERATURES

Dry Ice: -78°C (-109°F)
Liquid Nitrogen: -196°C (-320°F)
NOTE: All clearances referred to in this manual are
diametrical clearances
METRIC CONVERSION TABLE

• Length
1 Metre (m) = 39.37 Inches (in.)
1 Millimetre (mm) = 0.03937 Inches (in.) OTHER THORDON
• Force TECHNICAL INFORMATION AVAILABLE
1 Newton (N) = 0.2248 lbs. a) Thordon Engineering Manual
1 Kilogram (kg) = 2.205 lbs. (for elastomeric bearings)
• Pressure
b) ThorPlas Bearings Engineering Manual
* 1 kg/cm2 = 14.223 psi (lbs./in.2)
** 1 Mega Pascal (MPa) = 145 psi (lbs./in.2) c) Thordon Bearing Sizing Calculation Program
1 N/mm2 = 145 psi (lbs./in.2) = 1 MPa
1 MPa = 10.195 kgf/cm2 Please contact your local Thordon Distributor or Thordon Bearings Inc.
1 Bar = .981 kg/cm2 if you require any of the above.
1 Mega Pascal (MPa) = 10 Bar
* Kilo = 1,000
** Mega = 1,000,000 ThorPlas® is a registered trademark owned by Thordon Bearings Inc.
INDEX
CHAPTER 1
PROPELLER SHAFT BEARINGS
1.1 GENERAL...........................................................................................................................................................5
1.1.1 Introduction............................................................................................................................................5
1.1.2 Bearing Length ........................................................................................................................................5
1.1.3 Hydrodynamic Operation............................................................................................................................5
1.2 CYLINDRICAL BEARINGS ......................................................................................................................................5
1.2.1 Fully Finished ..........................................................................................................................................5
1.2.2 Semi Finished ..........................................................................................................................................6
1.2.3 Machined from Stock Tube.........................................................................................................................6
1.3 STAVE CONSTRUCTION..........................................................................................................................................6
1.3.1 STAXL Semi Finished Staves .......................................................................................................................6
1.3.2 Custom Moulded Staves.............................................................................................................................8
1.3.3 Dovetail Staves........................................................................................................................................8
1.4 GRADE SELECTION ..............................................................................................................................................9
1.4.1 COMPAC ..................................................................................................................................................9
1.4.2 XL..........................................................................................................................................................9
1.4.3 SXL ........................................................................................................................................................9
1.4.4 Composite...............................................................................................................................................9
1.5 LUBRICATION ...................................................................................................................................................10
1.5.1 Seawater ...............................................................................................................................................10
1.5.2 Oil .......................................................................................................................................................10
1.5.3 Grease ..................................................................................................................................................10
1.5.4 Thor-Lube Lubricant................................................................................................................................11
1.6 FITTING OPTIONS..............................................................................................................................................11
1.6.1 Tubular Bearings ....................................................................................................................................11
1.6.2 Stave type Bearings ................................................................................................................................11
CHAPTER 2
RUDDER BEARINGS AND OTHER MARINE BEARINGS
2.1 GENERAL .........................................................................................................................................................12
2.2 CYLINDRICAL BEARINGS.....................................................................................................................................12
2.2.1 Complete tube .......................................................................................................................................12
2.2.2 Split bearings ........................................................................................................................................12
2.3 STAVE CONSTRUCTION........................................................................................................................................12
2.3.1 Semi Finished Staves ..............................................................................................................................12
2.4 GRADE SELECTION.............................................................................................................................................13
2.4.1 XL ........................................................................................................................................................13
2.4.2 SXL.......................................................................................................................................................13
2.4.3 Thorplas (For Highly Loaded, Non-standard Applications) .............................................................................13
2.5 LUBRICATION ...................................................................................................................................................13
2.5.1 Seawater ...............................................................................................................................................13
2.5.2 Grease ..................................................................................................................................................13
2.5.3 Dry Running ..........................................................................................................................................13
2.6 OTHER MARINE APPLICATIONS ............................................................................................................................13
CHAPTER 3
OPERATIONAL REQUIREMENTS
3.1 ALIGNMENT .....................................................................................................................................................14
3.2 HOUSING BORE ................................................................................................................................................14
3.3 PRESSURES ......................................................................................................................................................14
3.3.1 Propeller Shaft Bearings ..........................................................................................................................14
3.3.2 Rudder Bearings .....................................................................................................................................14
3.4 MONITORING....................................................................................................................................................15
3.4.1 Temperature...........................................................................................................................................15
3.4.2 Water Flow ............................................................................................................................................15
1
INDEX
3.5 MATING SURFACES ............................................................................................................................................15
3.5.1 Bronze ..................................................................................................................................................15
3.5.2 Carbon Steel ..........................................................................................................................................15
3.5.3 Hard Metal Sleeves .................................................................................................................................15
3.5.4 Inconel 625...........................................................................................................................................16
3.5.5 Stainless Steel .......................................................................................................................................16
3.5.6 Unacceptable Mating Materials .................................................................................................................16
3.6 MATING SURFACES - FINISH ...............................................................................................................................16
3.7 CORROSION PROTECTION ....................................................................................................................................16
3.7.1 Thor-Coat ..............................................................................................................................................16
3.8 MARINE GROWTH..............................................................................................................................................17
3.9 CATHODIC PROTECTION - CATHODIC CHALK............................................................................................................17
3.10 ANTI ROTATION DEVICES...................................................................................................................................17
3.11 MAXIMUM CLEARANCES ....................................................................................................................................18
3.11.1 Rudder Bearings ...................................................................................................................................18
3.11.2 Propeller Shaft Bearings ........................................................................................................................19
CHAPTER 4
DIMENSIONING
4.1 GENERAL........................................................................................................................................................20
4.2 INFORMATION REQUIRED ..................................................................................................................................20
4.3 DIMENSIONING USING THORDON BEARING SIZING CALCULATION PROGRAM ...............................................................20
4.3.1 Sample Calculations using Thordon Bearing Sizing Program...........................................................................20
4.3.2 Temperature chart ..................................................................................................................................23
4.4 CALCULATION DETAILS......................................................................................................................................25
4.4.1. Bearing Outside Diameter (O.D.) ..............................................................................................................25
4.4.1.1 Interference .................................................................................................................................25
4.4.1.2 Machining Tolerance ......................................................................................................................25
4.4.1.3 Bonding.......................................................................................................................................25
4.4.2 Bearing Inside Diameter (I.D.) .................................................................................................................26
4.4.2.1 Bore closure .................................................................................................................................26
4.4.2.2 Running clearance .........................................................................................................................26
4.4.2.3 Dimensional changes due to absorption ............................................................................................26
4.4.2.4 Thermal Expansion.........................................................................................................................26
4.4.2.5 Minimum Installed Diametrical Clearance ..........................................................................................26
4.5 WATER GROOVES ..............................................................................................................................................27
4.5.1 Propeller Shaft Bearings ..........................................................................................................................27
4.5.2 Rudder Bearings .....................................................................................................................................27
4.6 STAXL STAVES..................................................................................................................................................27
4.6.1 Introduction ..........................................................................................................................................27
4.6.2 Pre Assembly .........................................................................................................................................27
4.6.3 Interference Calculation ..........................................................................................................................27
4.6.4 Final Stave Width ...................................................................................................................................27
4.6.5 Stave Assembly I.D. ................................................................................................................................27
4.6.6 Longitudinal Expansion Allowances ...........................................................................................................28
4.6.7 Encapsulated Keeper Strips ......................................................................................................................28
4.7 DOVETAIL STAVE ASSEMBLIES ............................................................................................................................28
4.8 KEYED TUBULAR BEARINGS ...............................................................................................................................28
4.9 SPLIT BEARINGS WITH NO KEEPERS ....................................................................................................................29
4.10 WORKING WITH THE THORDON BEARING SIZING CALCULATION PROGRAM .................................................................29
4.10.1 Metric Sizing Calculation Example - Bearing Machined After Fitting Into Housing...........................................29
4.10.2 Imperial Sizing Calculation Example - Bearing Machined After Fitting Into Housing........................................31
CHAPTER 5
MACHINING AND MEASURING THORDON BEARINGS
5.1 GENERAL MACHINING ........................................................................................................................................33
5.2 MACHINING XL, SXL AND COMPAC........................................................................................................................33
5.2.1 Cutting Tool...........................................................................................................................................33
5.2.2 Machining Speeds and Feeds ....................................................................................................................34
2
INDEX
5.2.3 Bearing Set Up.......................................................................................................................................35
5.2.4 Parting to Length ...................................................................................................................................37
5.2.5 Machining Lubrication Grooves .................................................................................................................37
5.2.6 General Machining Tips ...........................................................................................................................37
5.2.7 Machining Large Bearings - 1000mm (40”) or larger ....................................................................................37
5.2.7.1 First Stage Machining ....................................................................................................................38
5.2.7.2 Final Machining ............................................................................................................................38
5.3 MACHINING COMPOSITE.....................................................................................................................................38
5.3.1 Cutting Tool...........................................................................................................................................38
5.3.2 Machining Speeds and Feeds ....................................................................................................................39
5.3.3 Machining Procedure (O.D. up to 250mm (10.0")) .......................................................................................39
5.3.4 Machining Procedure (O.D. larger than 250mm (10.0")) ...............................................................................39
5.4 MACHINING THORPLAS ......................................................................................................................................39
5.4.1 General Machining ..................................................................................................................................39
5.4.2 Groove Cutting.......................................................................................................................................40
5.4.3 Chamfers...............................................................................................................................................41
5.4.4 Step-By-Step Machining Process ...............................................................................................................41
5.5 SPLITTING THORDON BEARINGS ..........................................................................................................................43
5.5.1 Splitting a Thordon Bearing Using a Saw Blade...........................................................................................43
5.5.2 Splitting a Thordon Bearing Using a Knife..................................................................................................45
5.6 DIMENSIONAL AND SURFACE FINISH MEASUREMENTS..............................................................................................45
5.6.1 Dimensional Measurements.......................................................................................................................45
5.6.2 Surface Finish and Tolerances...................................................................................................................46
5.6.3 Machining Tolerances ..............................................................................................................................46
CHAPTER 6
INSTALLATION METHODS
6.1 GENERAL .........................................................................................................................................................47
6.2 FREEZE FITTING................................................................................................................................................47
6.2.1 General .................................................................................................................................................47
6.2.1.1 Dry Ice ........................................................................................................................................47
6.2.1.2 Liquid Nitrogen.............................................................................................................................47
6.2.2 Tubular Bearings ....................................................................................................................................48
6.2.2.1 Recommended Procedure ................................................................................................................48
6.2.2.2 Recommended Procedure for Rudder Bearings ....................................................................................49
6.2.3 Stave Bearing Installation .......................................................................................................................49
6.2.4 Split Bearings (single key, double key) ......................................................................................................49
6.2.4.1 Single Tapered Keyset Design ..........................................................................................................49
6.2.4.2 Double Key Design.........................................................................................................................50
6.3 PRESS OR DRIVE FITTING ...................................................................................................................................50
6.3.1 Cylindrical Bearings ................................................................................................................................50
6.3.2 Single Tapered Keyset Design ...................................................................................................................50
6.4 ALTERNATIVE METHODS - BONDING......................................................................................................................51
6.4.1 Dimensioning for Bonding........................................................................................................................51
6.4.2 TG-75 ...................................................................................................................................................51
6.4.3 Filling Recesses......................................................................................................................................51
6.4.4 Chocking Compounds ..............................................................................................................................51
6.4.4.1 Bonding Directly into the Housing using Chock..................................................................................51
6.4.4.2 Making a Housing from Chock .........................................................................................................51
6.4.4.3 Chocking Stern Tubes or Bearing Carriers ..........................................................................................52
6.5 INSTALLING CARRIERS FOR SINGLE TAPERED KEYSET DESIGN....................................................................................52
6.6 REMOVAL OF THORDON BEARINGS........................................................................................................................52
6.6.1 General .................................................................................................................................................52
6.6.2 Removal of Single Tapered Keyset Bearings ................................................................................................52
APPENDIX 1. Thordon COMPAC Bearing with Single Tapered Keyset Installation Manual ..........................................................53
APPENDIX 2. Bonding with TG-75 ...................................................................................................................................57
WARRANTY .............................................................................................................................................................61
3
INTRODUCTION
Thordon Bearings Inc. develops and manufactures Thordon Bearings has recently introduced a new bearing
synthetic polymer bearings for use as a high performance grade: ThorPlas, a proprietary engineered thermoplastic.
bearing material, particularly in marine applications. ThorPlas is a homogeneous, self-lubricating polymer
Thordon bearings provide long life and offer a unique material capable of working at dynamic pressures up to 31
combination of low friction, high elasticity and good MPa (4500 psi). It is not as abrasion resistant as the
mechanical properties (abrasion and shock resistance). other Thordon elastomeric materials. The primary marine
Thordon bearings are homogeneous. They have a relatively applications for ThorPlas are in highly loaded bearings
high coefficient of thermal expansion that facilitates where lubrication is difficult, such as fairleads, tiller arm
freeze fitting. They are also resilient and shock resistant. bushings, ride control mechanisms, sheaves and davits. It
Thordon marine bearings are much easier to handle and is approved by most Classification Societies for use in ride
install than other traditional marine bearings. control mechanisms at pressures up to 31 MPa (4500 psi).
The important thing to remember is that Thordon This manual is designed to provide the necessary
elastomeric bearings are different from other bearing information to install Thordon marine bearings of any size.
materials and therefore require slightly different handling. For detailed technical information about Thordon Bearings
Anyone accustomed to working with bronze or other refer to the Thordon Engineering Manual, or the ThorPlas
metallic bearing materials will find that the recommended Bearings Engineering Manual. If you have any questions or
amounts of interference and running clearance for Thordon concerns please contact your local Thordon Distributor, or
elastomeric bearings are greater than for metals. The Thordon Bearings Inc., for further information or design
securing methods common for bronze or bronze-shelled assistance. For easy reference we have divided the manual
bearings must also be re-considered when fitting Thordon into chapters as follows:
elastomeric bearings. For example, flanged fitting, set
screwing along the outside diameter (O.D.) and welding
1) Propeller Shaft Bearings
near the bearing are not acceptable with Thordon
elastomeric bearings. Alternate methods of axially 2) Rudder Bearings and Other Marine Bearings
securing the bearing such as bolted retaining rings must 3) Operational Requirements
be used. Thordon is a very easy material to machine. It is
4) Dimensioning
non-toxic and machines dust free. Therefore there are no
health hazards involved. 5) Machining and Measuring Thordon Bearings
6) Installation Methods
Thordon elastomeric bearings are available in four grades

for marine bearing system installations: XL, SXL, COMPAC
and Composite. XL is the standard grade used in general
marine applications. SXL is accepted as the preferred
rudder bearing material, especially for highly loaded
rudder applications, because of its lower coefficient of
friction and ability to run dry. SXL is also used in
propeller shaft bearings. COMPAC is a uniquely designed
grade specified for propeller shaft applications to promote
early formation of a hydrodynamic film between the shaft
and the bearing. Composite is specially designed to
provide long life in extremely abrasive conditions such as
river boats, or suction cutter head dredges. These four
Thordon grades are similar in their basic chemical
composition, and the same approach can be taken to
installing any of them. Where differences do exist, they
will be pointed out in this manual.
4
PROPELLER SHAFT BEARINGS Ch. 1
1.1. GENERAL bearing segment. The annular groove, as shown in Figure 1,
allows water to flow from one segment to the next even if
1.1.1 INTRODUCTION
the grooves are not perfectly aligned. The annular groove
Thordon propeller shaft bearings are available to fit any size can be added easily when machining the I.D. of the bearing.
of shaft from 20mm (3/4") to 2000mm (80"), and larger if The machining sizes for Thordon bearings can be determined
required. A standard range of bearings is available for shafts by using the Thordon Bearing Sizing Calculation Program.
up to 305mm (12”). Custom made bearings can be supplied
to suit any size of shaft and housing. Thordon bearings are
available in a variety of forms that are described in the Figure 1: Drawing Showing Annular Groove in COMPAC Bearing
following sections of this chapter. Thordon propeller shaft
bearings are normally fitted using an interference fit to hold
them in place, however, where the orientation of the
bearing is critical, anti rotation devices should be used.
Thordon bearings may also be bonded in place in certain
circumstances. Axial retention is recommended for all
Thordon bearing installations. Water lubrication is most
commonly used with Thordon propeller shaft bearings but
comments on oil lubrication are provided in section 1.4.2.
1.1.2 BEARING LENGTH

Bearing length is dictated by Classification Societies based 1.1.3 HYDRODYNAMIC OPERATION
on load, operating speeds, and bearing design. Conventional Thordon propeller shaft bearings are designed to operate
water lubricated propeller shaft bearings are normally under hydrodynamic principles, where the shaft has to
supplied with an L/D ratio (ratio of bearing length to shaft rotate faster than a threshold value to develop a
diameter) of 4:1 for the bearing next to the propeller hydrodynamic water-film between the shaft and bearing.
(shorter lengths are used for FWD bearings). Fully grooved The threshold speed is predominantly influenced by the
XL, SXL and Composite grades are normally designed to the bearing load and bearing configuration. Different
4:1 L/D standard. Composite at 3:1 L/D ratio has been used configurations (length/diameter ratios, grooved or smooth,
and approved for use on pushboats. Thordon COMPAC is etc.) have different threshold speeds.
approved by all major marine Classification Societies for use
with an L/D ratio of 2:1 next to the propeller. This means
that Thordon COMPAC bearings can be half the length of Through testing, Thordon has developed constants for
conventional water lubricated marine bearings. Comments various styles and configurations of Thordon bearings.
that relate specifically to the shorter length option will be These values are used to estimate the hydrodynamic
provided where appropriate in this manual. thresholds for the bearings. When designing a vessel, the
appropriate thresholds can be considered to ensure that the
vessel’s minimum continuous shaft speed is high enough to
Since Thordon bearings can be supplied in standard lengths, generate the hydrodynamic film. This should avoid
it will often be necessary to use a number of segments to prolonged operation at speeds where hydrodynamic film is
make one marine bearing. The multiple segment concept is not properly formed and where the sliding contact between
common with Thordon bearings. During installation, please shaft and bearing can accelerate wear.
ensure that:
1) the lubrication grooves are aligned 1.2 CYLINDRICAL BEARINGS
2) part of the axial expansion allowances are allocated to gaps 1.2.1 FULLY FINISHED
between segments rather than leaving it all on the ends.
Any Thordon bearing can be provided in fully finished
form, ready to install. Such bearings may be machined by
In view of the risk of misalignment on installation, Thordon Thordon Bearings Inc., by the shipyard, or by your local
Bearings recommends an annular groove (approximately the distributor. Fully finished bearings can be supplied to
width and depth of the longitudinal grooves) be machined meet any inch or metric housing and shaft combination.
on one end of each segment where it will meet another
5
Ch. 1 PROPELLER SHAFT BEARINGS
Fits and Clearances Figure 2: Semi Finished COMPAC Bearing with Overbuild
Thordon bearings are normally designed for a press or
shrink (interference) fit into the strut or stern tube.
Sufficient oversize is allowed on the outside diameter (O.D.)
of the bearing to prevent bearing movement, provided that
the housing has not been pitted, corroded or rebored
beyond its nominal diameter. Fully finished bearings are
designed for an interference fit to suit specific shaft and
housing dimensions. If actual shaft and housing dimensions
vary from the original dimensions used to calculate the
fully finished sizes, the bearing size may need to be
recalculated using the Thordon Bearing Sizing Calculation
Program. Fully finished bearings suitable for bonding into
place can also be provided on request. Final dimensions for
machining Thordon bearings can be easily determined by
using the Thordon Bearing Sizing Calculation Program.
Setscrews, which press against the bearing O.D., are not The use of semi finished bearings is an excellent way to
recommended for securing the bearing in place. make provision for “surprises” that may arise when the shaft
and housing measurements are verified. With a semi finished
1.2.2 SEMI FINISHED bearing, sizes can be adapted on site to actual measured
shaft or housing dimensions that may vary from those
Semi finished bearings have similar dimensions to the fully
shown on drawings available before the vessel is docked.
finished bearings mentioned in section 1.2.1, but they have
an oversize allowance on the outside, and undersize
allowance on the inside as shown in Figure 2. This extra 1.2.3 MACHINED FROM STOCK TUBE
material is added to give flexibility to allow onsite machining Thordon bearing material is available from stocking
should there be alterations in the shaft or housing distributors in standard tube form. These tubes are 1 metre
dimensions. All semi finished propeller shaft bearings have (39.4”) long and come in a variety of inside and outside
moulded or machined lubrication grooves. Semi finished diameters to suit any application. However, using stock
bearings are also supplied with some extra length to be used tubes for propeller shaft bearing installations requires
as a chucking allowance. It should be noted that the water machining lubrication grooves in the tube. These grooves
grooves may not extend the full length of this chucking must be machined prior to installation.
allowance. For propeller shaft bearing applications, it is
essential that the lubrication grooves extend along the full
length of the final bearing. Custom made semi finished Line boring of the grooves in interference fitted bearings after
bearings can be supplied to suit any combination of shaft fitting must be avoided because it has a negative impact on
and housing. The O.D., I.D. and length of Thordon semi the interference pressure. The Thordon Bearing Sizing
finished bearings must be machined before installation. Refer Calculation Program will provide groove dimension details.
to chapter 4, or the Thordon Bearing Sizing Calculation Groove machining is normally done by using the boring bar
Program. Refer to Chapter 5 for machining instructions. on the lathe as a "shaper". Custom moulded large bearings
are often supplied without water grooves because they can be
produced and delivered more quickly than grooved bearings.
The “oversize” dimensions of semi finished bearings are
based upon the calculated dimensions from the Thordon
Bearing Sizing Calculation Program, not on nominal shaft 1.3 STAVE CONSTRUCTION
and housing sizes. For example, the I.D. of a small semi 1.3.1 STAXL SEMI FINISHED STAVES
finished bearing will be approximately 1.5mm (0.06") smaller
Thordon STAXL staves are preformed profile sections, each
than the calculated I.D., not the nominal I.D. (shaft size).
designed to cover a range of housing and shaft diameters
with a minimum of machining. All STAXL sections are supplied
1000mm (39.4") long. The profile of STAXL staves shown in
Figure 3 is designed so that, in most cases, the only
6
machining required is the boring of the I.D. after the staves staves are designed for tangential contact between
have been installed in the housing, carrier or machine shop stave and liner. This does not apply to Thordon staves).
rig. Alternatively, the I.D. of each stave can be fly cut to the
appropriate radius before fitting. In the fitting process, it is
If a standard STAXL segment is not suitable for a given
often necessary to adjust the width of one or two staves to
installation "as supplied", it is normally possible to adapt
achieve the required circumference and interference.
one by machining the side angles and exterior/back radius.
If a very thin stave is required, it may be necessary to
Figure 3: Thordon STAXL Stave Profile
machine the back of the stave, or deepen the lubrication
grooves as machining of the I.D. only may eliminate the
lubrication grooves. If staves are being fitted with
interference, but without keeper strips, the minimum wall
thickness required for an interference fit must be retained,
similar to interference used for tubular bearings. Refer to
section 4.6 or the Thordon Bearing Sizing Calculation
Program for minimum wall thickness requirements.
The number of staves required for an installation will vary with

STAXL staves are available in eleven different standard the actual size of the housing and the L/D ratio of the
sizes as shown in Figure 4 below. For each cross section, bearing. It also will vary with the number and size of keepers
the suitable range of shaft and housing sizes is shown. used (if any). The number and type of staves to make a
This information should be used as a guide to the complete circle can be determined using the Thordon Bearing
suitability of a specific STAXL stave segment for a Sizing Calculation Program. When the Input Screen is open,
particular combination of shaft and housing. In select “STAXL Stave” as the type of installation. Enter the
addition, the thickness of the stave should be checked shaft and housing details and confirm the temperature
to ensure that there is sufficient material to machine to parameters. The Thordon Bearing Sizing Calculation Program
the required bore size without eliminating the will determine if the dimensions are suitable for a STAXL stave
preformed lubrication grooves. It should be noted that, installation, make recommendations for changes, and then
in all cases, the I.D. of the STAXL staves must be provide the reference to the appropriate stave cross section
machined to the appropriate radius (some rubber and the number of staves required to make a complete
Figure 4: Thordon STAXL Stave Dimensions
STAXL Staves (1000mm, 39 inches length)

Housing Shaft Chordal Housing Shaft Chordal
Segment Diameter Diameter Width Thickness Diameter Diameter Width Thickness
(mm) (mm) (mm) (mm) (inches) (inches) (inches) (inches)
G22 275 - 320 232 - 288 50 22 10.8 - 12.5 9.17 - 11.3 1.968 0.866
F27 320 - 365 270 - 325 58 27 12.5 - 14.3 10.6 - 12.7 2.283 1.063
E32 365 - 420 304 - 380 66 32 14.3 - 16.5 11.9 - 14.9 2.598 1.260
D42 420 - 480 340 - 430 75 42 16.5 - 18.8 13.3 - 16.9 2.953 1.653
D35 420 - 480 355 - 430 75 35 16.5 - 18.8 13.9 - 16.9 2.953 1.378
C42 480 - 555 400 - 505 78 42 18.8 - 21.8 15.7 - 19.8 3.071 1.653
C35 480 - 555 415 - 505 78 35 18.8 - 21.8 16.3 - 19.8 3.071 1.378
B42 555 - 660 475 - 610 78 42 21.8 - 25.9 18.7 - 24.0 3.071 1.653
B35 555 - 660 490 - 610 78 35 21.8 - 25.9 19.2 - 24.0 3.071 1.378
A42 660 - 790 580 - 740 84 42 25.9 - 31.1 22.8 - 29.1 3.307 1.653
A35 660 - 790 595 - 740 84 35 25.9 - 31.1 23.4 - 29.1 3.307 1.378
7
bearing. The number of staves must be increased appropriately time for fully moulded staves may be 6-8 weeks, this type of
for bearing lengths greater than one meter (39”). stave is more suited to a planned docking.
Fully moulded staves are available in XL, SXL
The number of staves required to make a complete circle or Composite grades.
for a specific installation can also be estimated manually
by using the following formula: 1.3.3 DOVETAIL STAVES
Thordon staves are also available in dovetail form, as
C-K = number of staves
shown in Figure 5, for installation in slotted housings.
W
where C = Calculated bearing O.D. with interference, Figure 5: Thordon Dovetail Stave Profile
converted to circumference
K = Total width of all keepers
W = Chordal width of stave to be used
NOTE 1: The number of staves is rounded up to the next whole

number when one keeper strip is used, or to the next even
number when two keeper strips are used.
NOTE 2: To make a complete circle, the above number must be
increased appropriately for bearing lengths greater than one
meter (39"). Avoid using multiple small pieces to make up the
stave lengths.
NOTE 3: Figure 4 gives the chordal width of each STAXL stave
cross section.
Ten sizes are available for standard dovetail groove and
housing dimensions. All staves are supplied with a flat top
1.3.2 CUSTOM MOULDED STAVES
to be machined or bored after assembly and a standard 10
Thordon staves are also available in a fully moulded form. degree side angle. (15 degree side angle staves are
In this case full details of the housing and shaft, including available on special order). Thordon dovetail stave
drawings where possible, must be provided to Thordon dimensions are shown in Figure 6.
Bearings in advance. Fully moulded staves are designed to
be fitted directly into the housing. Machining of the O.D or Figure 6: Thordon Dovetail Stave Dimensions
I.D. is not required. It may, however, be necessary to - Supplied in 1 metre (39”) Lengths
machine the width of the last stave during fitting. The
staves would normally be fitted using the freezing method US NAVY Width Width
(see Section 1.6). When installing fully moulded staves Standard of Slot Tickness of Slot Tickness
Thordon recommends that the I.D. of the bearing be No. (mm) (mm) (inches) (inches)
checked after assembly of the staves to ensure that it is
001 43 22.2 1.687 7/8
consistent with the calculated I.D. from the Thordon
Bearing Sizing Calculation Program results. When fitting 002 46 22.2 1.812 7/8
staves, either by freezing or with a press fit, the staves 003 49 23.8 1.937 15/16
should be tapped frequently with a rubber mallet to ensure 004 52 23.8 2.062 15/16
that they are well seated against the housing. 005 56 23.8 2.187 15/16
006 59 23.8 2.312 15/16
The "housing" referred to in this section can be either the 007 70 26.9 2.750 1 1/16
stern tube or strut itself, or a metallic carrier. In either case, 008 75 26.9 2.937 1 1/16
the housing must be in good condition, and the dimensions 009 78 30.1 3.062 1 3/16
must be as indicated in the drawings provided to Thordon
010 81 30.1 3.187 1 3/16
Bearings, or the fully moulded staves will not fit correctly.
In view of this requirement, and the fact that production
8
Thordon dovetail staves are designed to be freeze fitted into Figure 8: XL and SXL Fully Grooved Bearing Profile
the dovetail slots in the housing or carrier. After installing
all the staves, they must be line bored to the correct I.D.
Many rubber type staves are designed with flat interior
surfaces to facilitate hydrodynamic development. This
concept works with soft rubber, but will not work with
harder Thordon grades. A contoured inside surface is
essential in all cases where Thordon dovetail staves are
used. One acceptable alternative to line boring is fly cutting
of each stave to the correct radius prior to installation.
1.4 GRADE SELECTION

1.4.1 COMPAC
This orange coloured bearing is specifically designed to 1.4.3 SXL
provide the lowest friction in operation. This is achieved by This off-white Thordon grade has a low coefficient of
using the Thordon elastomeric bearing that has the lowest friction. Being slightly softer, it is also slightly more tolerant
friction, by not having grooves in the bottom half of the of abrasion than XL. SXL can be used in vessels operating up
bearing (see Figure 7), and by reducing the bearing length to 20% of their time in abrasive waters. SXL is normally
relative to fully grooved bearings. The L/D ratio of the designed with a L/D ratio of 4:1 for the bearing closest to
COMPAC bearing adjacent to the propeller can be as short as the propeller, and is fully grooved as shown in Figure 8.
2:1 versus the conventional water lubricated bearing ratio of
4:1 L/D. The length may be increased to accommodate low
speed operation, but COMPAC is not normally used with an 1.4.4 COMPOSITE
L/D ratio greater than 3:1. COMPAC is designed mainly for Composite (see Figure 9) is a two-component bearing (yellow
blue water operation. It is not recommended when the outside and black inside). The black inside material (known
vessel will operate more than 10% of the time in abrasive as GM2401) is softer and tougher than the other Thordon
water unless the water entering the bearing is cleaned. grades. As a result, Composite is the most abrasion resistant
material of all Thordon grades and is designed for vessels
Figure 7: Thordon COMPAC Bearing Profile operating over 20% of their time in abrasive operating
environments. To ensure the optimum performance of
Composite bearings, they should be used in conjunction with
a very hard shaft or shaft liner. See section 3.5 for additional
comments on mating materials. Composite is typically
designed with an L/D ratio of 4:1 for the bearing closest to
the propeller, however, Composite bearings at a 3:1 L/D ratio
have been used and approved for use on riverboats.
Figure 9: Thordon Composite Bearing Profile
1.4.2 XL
The black XL grade provides good abrasion resistance,
relatively low friction and good shock resistance (see Figure
8). Fully grooved XL propeller shaft bearings are normally
designed with an L/D ratio of 4:1 for the bearing closest to
the propeller. XL is not recommended if the vessel will
operate more than 15% if its time in abrasive waters.
9
1.5 LUBRICATION source of clean water for bearing lubrication. A strainer or
cyclone separator system can be used. Thordon Bearings
1.5.1 SEAWATER
manufactures a self contained Water Quality Package to
Water is the most common lubricant used with Thordon ensure an adequate supply of clean water is consistently
propeller shaft bearings. Water serves three purposes in being delivered to both the forward seal and the bearings
the operation of the bearing. First, it forms a thin layer of – see Figure 10. The life of the bearings will be extended
hydrodynamic film between the shaft and bearing which if clean lubricating water is supplied to the bearings.
reduces wear. Second, a flow of water removes heat
generated during rotation of the shaft. Third, the water Figure 10: Thordon Water Quality Package
flow facilitates the removal of abrasive particles which can
accelerate bearing wear. In order to accomplish this, a
positive flow of cooling water from a pump source is
recommended. The minimum flow rate required is 0.15
litres per minute per mm (1 U.S. gallon per minute per
inch) of shaft diameter. The water pressure should be
sufficient to overcome hydrostatic pressure from the
draught of the vessel and flow losses, and to ensure
positive flow at the aft end of the stern tube when the
vessel is fully loaded. If vessel has two stern tubes, two
water supply pipes are preferable to one large supply pipe
that is split. The cooling water should be as close as
possible to the temperature of the water in which the
vessel is operating. Water which has already been used to
cool the main engine, gear box or other machinery before
it reaches the bearings may not be suitable. Water over
40°C (104°F) should not be used as it may have a
detrimental effect on the Thordon bearing.
A pumped flow of water to a Thordon strut bearing is not

normally required. Movement of the ship provides sufficient
flow. Fairwaters and rope guards must be arranged so as
1.5.2 OIL
not to impede water flow to the bearings. However, if the
vessel spends a significant amount of time with the shaft Although Thordon can operate in oil lubrication, it is not
turning and little or no forward or aft movement of the the preferred lubricant for propeller shaft bearings
vessel (as in dynamic positioning or station keeping), a because it does not have the heat dissipation capacity of
pumped flow of water to the strut bearings is water. Although all Thordon grades are chemically
recommended. Such a flow will also impede ingress of compatible with petroleum lubricants, please consult with
abrasive water when the vessel operates in shallow water. Thordon Bearings before installing Thordon in an oil filled
stern tube.
Water should be injected ahead of the inboard bearing in
a stern tube. Thordon bearings can run without water flow
for a limited time, but any sign of heating should be 1.5.3 GREASE
investigated immediately and corrected. For larger Grease lubrication of Thordon propeller shaft bearings is
installations, water flow monitoring (see section 3.4 of not recommended because grease cannot facilitate heat
this manual) is recommended to ensure that an adequate dissipation readily. Although all Thordon grades are
flow of cool water is being maintained. If a vessel chemically compatible with petroleum lubricants, please
equipped with Thordon elastomeric bearings spends a consult with Thordon Bearings before installing Thordon
significant amount of time manoeuvring in very shallow or where grease is used.
dirty water, consideration should be given to providing a
10
1.5.4 THOR-LUBE LUBRICANT half into the carrier. Detailed instructions are provided in
In the mid 1980's, Thordon Bearings developed a unique Section 6.2.4 of this manual. There is also usually a
environmentally friendly sealed stern tube system as an second carrier permanently fixed in the strut or stern
alternative to the conventional sealed oil/white metal tube, into which the split carrier is fitted.
system. The system consists of a biodegradable water-based
lubricant, a system circulating and monitoring package and Thordon has developed a simpler approach that allows
Thordon XL bearings. The combination of Thor-Lube bearing removal with the shaft still in place. This involves
lubricant and Thordon XL bearings provides lower start-up using split Thordon bearings (typically COMPAC), a set of
friction than a conventional oil/white metal system. Thor- tapered keys, and a single non-split tubular metallic
Lube systems are available for new construction projects as carrier which is permanently bolted or chocked into the
well as for conversion of existing ships from oil lubricated strut or stern tube. One half of the tapered key set is
stern tube systems. Care should be taken to use compatible fixed to the I.D. of the carrier, usually at the 3 or 9
shaft seals in a Thor-Lube system. Typical seals used with o’clock position. The other half of the tapered key set is
mineral oils may not be compatible. a sliding fit. First, the split Thordon bearings are installed
in the housing. They are dimensioned using a normal
interference fit. Second, the sliding half of the tapered
Installation of both the XL bearings and Thor-Lube system
key set is installed. As the key is inserted, it generates
are explained in the Thor-Lube Installation and Operation
the interference. To remove the bearings, the sliding key
Manual available from Thordon Bearings. The steps for
is ‘pulled’ to remove the interference. Then the split
installing a Thor-Lube XL bearing are the same as for our
bearing halves can be easily removed for inspection or
other marine bearings.
replacement. This approach has also been used with stave
type bearings. A more detailed overview is presented in
1.6 FITTING OPTIONS Appendix 1 – Thordon COMPAC with Single Tapered Keyset
Installation Manual.
1.6.1 TUBULAR BEARINGS
Tubular bearings are normally interference fit using a
Bonding of Thordon bearings is an alternative to press or
freeze or press fit into a “housing”. The “housing” can be
freeze fitting. Bonding is used when the wall thickness of
the stern tube or strut of the vessel. It can also be a
the bearing is not sufficient for an interference fit – for
bronze or metallic carrier which is in turn fitted into the
example when re-lining small bronze-backed rubber
strut or stern tube. Thordon bearings can even be fitted
bearings. Bonding may also be used when the housing is
into the bronze carriers of rubber-type bearings. In this
not suitable for an interference fit – if it is not round, or
case, the rubber is machined out to provide a smooth
not machined to provide full support along the full length
round bronze housing so the Thordon bearing can be
of the bearing. Detailed instructions for bonding are in
fitted. Care should be taken to ensure there is enough
Chapter 6 - Installation Instructions and in Appendix 2:
bearing wall thickness to accommodate the stresses of an
Bonding with TG-75.
interference fit. If not, the Thordon bearing may have to
be bonded into place.
1.6.2 STAVE TYPE BEARINGS
Thordon STAXL stave bearings can be fitted into tubular
With some water lubricated propeller shaft bearing
housings with or without the use of keepers. For repair or
installations such as naval or cruise ships, there is a
conversions, Thordon staves typically replace existing
requirement for being able to remove the bearings without
phenolic laminate or lignum vitae staves. These are usually
removing the shaft. Shaft withdrawal of long shafts can
fitted with keepers, so Thordon staves are usually fitted
be expensive and time consuming. The traditional
into the same configuration.
configuration to facilitate removal of bearings with the
shaft in place is by using split bronze carriers. The carriers In the case of an installation where there are no keepers,
are split on a taper to facilitate installation. Thordon consideration should be given to using Thordon tubular
bearings can be fitted into split carriers using split bearings rather than staves. Thordon tubes are easier and
Thordon tubes either by using an interference fit and quicker to fit.
keepers along the edges of each half, or by bonding each
11
Ch. 2 RUDDER BEARINGS AND OTHER MARINE BEARINGS
2.1 GENERAL Thordon rudder bearings are normally supplied in rough

moulded form for local machining to the final dimensions
Thordon has over 4000 rudder bearings installed on all
required. Use the Thordon Bearing Sizing Calculation
sizes and types of vessels. The bearings can be supplied in
Program for calculating dimensions, or refer to Chapter 4
either tube or stave form, and designed to operate with
for further dimensioning information. Chapter 5 contains
any type of lubrication - water, grease, oil, or, in the case
machining instructions. Bearings can be machined by
of SXL, dry. This allows Thordon bearings to be installed
Thordon Bearings, by the local distributor, or most
without the need for lubrication lines and eliminates the
commonly by the shipyard where the bearings will be
pollution associated with grease. Where Thordon rudder
installed. It is preferable to machine the bearings on site
bearings are expected to run dry, Thordon SXL grade
so the dimensions can be adapted to suit actual measured
should be used rather than XL because SXL has a lower dry
shaft and housing dimensions which may vary from those
coefficient of friction. SXL is also recommended for highly
on the vessel drawings.
loaded submerged rudder bearings because its lower
coefficient of friction provides better performance when
high pressure reduces or eliminates the lubricating 2.2.2 SPLIT BEARINGS
properties of water.
It is sometimes preferable to use split tubular bearings rather
than complete tubes. Split bearings facilitate installation
Thordon elastomeric bearings can be specified in all without removing the complete rudder, or completely
rudder bearing locations including stock, pintle and carrier dismantling the steering gear. Any Thordon tubular bearing
bearings, while ThorPlas bearings can be used for tiller can be split to facilitate installation. A standard milling
arm and steering gear linkage bushings. ThorPlas marine machine is normally used for this purpose, although Thordon
bearings are designed to withstand radial loads as high as Bearings has developed technology for splitting rudder
bronze in relatively non-abrasive dry or wet applications. bearings without a saw cut, thus leaving no gap. If the split
On some spade rudder designs for military vessels, is made by milling or cutting a tube, the bearing can still be
ThorPlas bearings are also recommended due to the high fully machined before splitting. See Chapter 5 for detailed
pressures generated by extreme maneuvers at high speeds. instructions. Split bearings can be fitted into split carriers, or
can be held in place by an interference fit developed when
the housing is bolted back together.
Thordon SXL rudder bearings are approved by all major
Classification Societies for pressures of 10 to 12 MPa
(1450 to 1740 psi). This high pressure approval allows the 2.3 STAVE CONSTRUCTION
designer to match bearing pressure limits more closely to Stave type bearings are sometimes used in large rudders,
the bending and torsion requirements for the rudder stock. particularly for retrofit when it is desirable to avoid
Significant weight and cost savings can often be achieved unshipping the rudder assembly or steering gear. Thordon
as well as a more slender rudder profile. XL or SXL can be supplied in stave form. Working with
staves usually requires more time and labour than working
with tubes, so the use of tubes is recommended when
2.2 CYLINDRICAL BEARINGS
feasible. If Thordon is replacing laminated phenolic staves
2.2.1 COMPLETE TUBE for example, just because the phenolic bearing was made in
Thordon SXL and XL tubular bearings are recommended for stave form is no reason to make the replacement Thordon
the pintle, stock and neck bearings, while SXL can be also bearing from staves. Thordon cylindrical tubes would be
be used as a carrier disc bearing. Because rudders move recommended, as they are much easier to work with.
very slowly over a limited range, there is no need for a
forced cooling water system, and therefore no need for the
2.3.1 SEMI FINISHED STAVES
water grooves normally found in propeller shaft bearings. A
full range of Thordon SXL rudder bearings in nominal A standard range of semi finished Thordon rudder bearing
diameters from 300mm (12") to 950mm (37") and an L/D staves has not been produced because of the general
ratio of 1.5:1 are available. Larger custom sizes can be preference for tube type bearings. Some sizes are available,
supplied to suit many combinations of shaft and housing however, for particularly large diameters. Details are
dimensions. Thordon rudder bearings can also be made available from Thordon Bearings. Other sizes can be
from Thordon standard stock 1 metre (39.4”) long tubes. produced on request. Semi finished rudder staves are
12
RUDDER BEARINGS AND OTHER MARINE BEARINGS Ch. 2
moulded to suit the required O.D., but must be machined 2.5.2 GREASE
on the I.D. to suit the specific stock dimensions and Grease lubrication can be used with any type of Thordon
clearance requirements. The difference between rudder rudder bearing if the assembly is designed for grease
bearing staves and STAXL propeller shaft bearing staves is lubrication. However, since one of the advantages of Thordon
that the rudder bearing does not have lubrication grooves. SXL is its ability to run dry, removal of an existing greasing
system tends to make the Thordon installation more cost
2.4 GRADE SLECTION effective. It eliminates a potential source of pollution and
the associated cost of grease and labour. Using grease will
2.4.1 SXL
also leech out the bearings internal lubricant, so if grease is
Thordon SXL (off-white) has a low coefficient of friction used, it must always be used.
with high resistance to shock loading and vibration in
rudder and other marine bearing applications. SXL can
operate dry or with water lubrication, thus eliminating the 2.5.3 DRY RUNNING
need for greasing systems. Thordon SXL is approved by most If a rudder bearing is expected to run dry, Thordon SXL
Classification Societies for bearing pressures between 10 should be used. Liquid soap can be used to facilitate
and 12 MPa (1450 to 1740 psi). Thordon Bearings Inc. assembly and initial bedding in of the bearing.
offers a 15-year wear life guarantee for SXL rudder bearings
in newbuild Classed vessels. In conversions, Thordon offers
a wear life of twice the life of the non-Thordon bearing
2.6 OTHER MARINE APPLICATIONS
replaced, up to a maximum of 10 years. There are numerous applications other than propeller shaft
and rudders for Thordon bearings on ships. The dry
running capabilities of SXL, and the load carrying capacity
2.4.2 XL of ThorPlas offer unique advantages. The following is a
Thordon XL (black) has a low coefficient of friction with partial list of applications:
high resistance to abrasion but is not suitable for dry - Stern Roller Bearings - either SXL or ThorPlas with
running in rudders. Thordon XL is approved by most greasing for extreme loading
Classification Societies for maximum bearing pressures
- Fairlead and Davit Bearings - dry running with
between 5.5 to 7.5 MPa (800 to 1090 psi).
either SXL or ThorPlas depending on the bearing pressure
- Ride Control Mechanisms on Fast Ferries - ThorPlas
2.4.3 THORPLAS (FOR HIGHLY LOADED, not greased at pressures up to 31 MPa (4500 psi)
NON-STANDARD APPLICATIONS)
- Stabilizer Bearings - either SXL or ThorPlas not
ThorPlas is a proprietary engineered thermoplastic capable of greased depending on pressures
withstanding operating pressures up to 31 MPa (4500psi)
- Diving Plane Bearings on Submarines - SXL not greased
installed in a full form, interference-fit bearing configuration.
It has a very low coefficient of friction similar to SXL and - Suction Cutter Head Dredge Bearings and
can operate dry without grease. Its properties make it an Intermediate Lineshaft Bearings - Composite with
ideal bearing for highly loaded marine applications such as flushing water flow
tiller arms, jockey bars and ride control mechanisms, where - Dredge Ladder Pivot Bearings - SXL
grease lubrication is difficult and sporadic causing failure of - Pumps - SXL, XL, Composite or ThorPlas
bronze and other metallic bearings. A separate ThorPlas
Engineering Manual is available from Thordon Bearings or
your authorized Thordon Distributor. The dimensioning, machining and fitting instructions provided
in chapters 4, 5 and 6 are applicable to these applications
except for ThorPlas, which is covered in a separate manual.
2.5 LUBRICATION The Thordon Bearing Sizing Calculation Program can be used
2.5.1 SEAWATER for dimensioning of any of these bearings.
Rudder pintle bearings are immersed in the water under
most loading conditions. Rudder stock bearings may
operate wet or dry. SXL is also recommended for highly
loaded rudder bearings.
13
Ch. 3 OPERATIONAL REQUIREMENTS
3.1 ALIGNMENT It is recommended that the housing be machined to
within an ISO H7 tolerance and have a surface finish of
Good alignment between the shaft and the bearing assists
3.2 micro-metres (126 micro-inches) Ra.
in ensuring satisfactory wear life. As the angle between
shaft and bearing increases from misalignment, the load
will be distributed over a smaller bearing area. This leads Offset line boring of interference fit Thordon bearings to
to localized high pressure on the bearing, increased speed correct misalignment is not recommended because of the
necessary to develop hydrodynamic lift and a possible negative impact such boring can have on the actual
increase in adhesive wear. interference. Offset boring of Thordon bearings before
fitting is feasible, but great care must be taken to index
the bearing correctly so that final fitting achieves correct
It is recommended for design that the maximum
alignment. In any offset boring operation, care must be
misalignment between the shaft and bearing be limited to
taken to ensure that the minimum required wall thickness
3 x 10-4 radians. Due to the visco-elastic properties of
(wall behind grooves) for the interference fit is maintained
Thordon elastomers, the actual misalignment that can be
at the thinnest point in the bearing. The use of
tolerated and still provide satisfactory service can be
mechanical anti rotation devices (keys or pins) is required
greater than this and is dependent upon the magnitude of
for offset bored bearings to ensure that rotation does not
the misalignment, direction and loading. For consideration
change the orientation of the bearing (see Section 3.10).
of misalignment greater than 3 x 10-4 radians, Thordon
Bearings should be consulted.
3.3 PRESSURES
3.2 HOUSING BORE Nominal bearing pressures are calculated using
the following:
All Thordon bearings require radial support around the
circumference and along the full length. It is important
that the housing be circular, consistent along its length Pressure = Bearing Load / (Bearing Length x Shaft Diameter)
and properly aligned. The bearing material will conform to
the shape of the housing and transmit any irregularities in
circularity or shape to the bearing surface. 3.3.1 PROPELLER SHAFT BEARINGS
The maximum allowable pressure is limited by the
Classification Societies. Information on particular
For out-of-round or misaligned housings, there are three
Classification Society requirements may be obtained
alternatives:
directly from Thordon Bearings or your authorized Thordon
1. The preferred option is to repair the housing either Distributor. Most Classification Societies have approved all
by boring it, or for small local areas, by using epoxy Thordon elastomeric grades for propeller shaft applications
and grinding at pressures up to 0.6 MPa (87 psi).
2. The bearing can be bonded into place using TG-75
adhesive available from Thordon Bearings, or an
3.3.2 RUDDER BEARINGS
epoxy resin
Because rudder bearings are not exposed to continuous
3. The last, and least preferable option is that the
high shaft rotation speeds, they can accept much higher
bearing can be pressed into the housing and then
loads. Thordon SXL is approved by most Classification
bored to ensure it is round and aligned. Boring after
Societies for bearing pressures between 10 and 12 MPa
fitting of an ungrooved rudder bearing should be
(1450 to 1740 psi). Part of the reason for this high
limited to 5% of the wall thickness. Boring of a
pressure approval of SXL is its low coefficient of friction.
grooved propeller shaft bearing should be limited to
Thordon XL is approved for maximum pressures from 5.5 to
no more than 10% of the wall thickness, or 25% of
7.5 MPa (800 to 1090psi).
the groove depth, whichever is less. Removal of more
wall than indicated above will have an adverse effect
on the interference fit as stresses are concentrated on
the I.D. of the bearing. Machining of lubrication
grooves for propeller shaft bearings must always be
done before the bearing is fitted into the housing.
14
OPERATIONAL REQUIREMENTS Ch. 3
3.4 MONITORING are acceptable for propeller shaft service as long as the
vessel is not operating continually in abrasive conditions.
3.4.1 TEMPERATURE
In abrasive water environments, a harder liner material
Temperature probes are usually not installed in water should be used.
lubricated bearing systems. However, for large Thordon
propeller shaft bearing installations, temperature
monitoring near the aft end of the aft bearing can be When operating in significant abrasive environments, the
installed. Due to the thermal insulating qualities of theoretical optimum mating surfaces are the hardest
Thordon, temperature sensors installed within the bearing practical surface on the shaft combined with the softest
wall will have a significant time lag in identifying bearing material that will support the load and resist the
problems. A probe can be inserted in the bottom of the abrasion. For severe, abrasive environments, a Thordon
bearing. The probe should be as close as possible to the Composite bearing and a mating surface with a hardness
I.D. of the bearing after allowing for maximum bearing of at least 40 Rockwell C are recommended. Nickel chrome
wear. Typically the probe would be 8 to 10mm (0.315” to boron coated liners can achieve 60+HRC.
0.394”) below the bearing I.D.
For rudder bearing applications, bronze or stainless steel
Because of the low probability of heat generation, are acceptable liner materials. Lower pintle bearing
temperature monitoring for rudder bearings is unusual. positions for vessels operating in dirty environments
should be equipped with a harder liner if wear has been
experienced in this position.
3.4.2 WATER FLOW
To achieve optimum life with Thordon propeller shaft
3.5.2 CARBON STEEL
bearings it is essential that an adequate flow of cooling
water be supplied to stern tube bearings under all Carbon steel shafts are relatively inexpensive in smaller
operating conditions. Monitoring of the flow of water is sizes. As long as there is not a corrosion problem, (i.e.
recommended, especially for larger vessels. Simple flow fresh water service) these shafts can be fitted without
alarms are acceptable. The alarm should be set at 90% or liners. If, however, the vessel experiences a layover during
more of the recommended minimum flow required for the which corrosion occurs on the shaft in way of the bearing,
bearings. Any reduction or stoppage of flow should be a high bearing wear rate may occur upon start-up. This
immediately investigated. Thordon’s Water Quality Package high wear is a result of the rough, corroded shaft surface
incorporates a flow alarm to alert the operator to any low effectively "machining away" the Thordon bearing. Carbon
water flow condition to the bearings. steel shafts should not be used in salt water unless fitted
with appropriate liners in way of the bearings and
appropriate corrosion protection between the liners.
3.5 MATING SURFACES
3.5.1 BRONZE
3.5.3 HARD METAL SLEEVES
Bronze is the most commonly used shaft liner material in
Sleeves manufactured from hard, corrosion and abrasion
marine service. It resists seawater corrosion, is easily
resistant steels are particularly common on tug or push
machined, commonly available, and can be shrunk onto
boats operating in dirty river environments. These
shafts. Nickel aluminum bronze is not recommended
operating conditions are usually very abrasive and a hard
because experience has shown that it can lead to high
liner material is necessary for long life operation. There
bearing wear rates. Static cast bronze should be avoided
are many alloys available. Cost and availability play a role
for similar reasons.
in selection. Some hard sleeves use a carbide coating such
as boron carbide or tungsten carbide. The typical hardness
There is a vast range of materials commonly called bronze. would be in the range of 50-60 Rockwell C. A flame
Two specific types which have given good service with sprayed coating of a nickel chrome boron alloy over a
Thordon bearings, and that are fully approved by stainless steel substrate and Thordon Composite bearings
Classification Societies, are Gunmetal (88% Cu, 10% Sn, provide consistently good wear performance in abrasive
2% Zn) and "70-30 Copper Nickel". Both are relatively water conditions in propeller shaft applications.
hard. In conjunction with Thordon bearings, bronze liners
15
3.5.4 INCONEL 625 painting the interior of the housing with a corrosion
The U.S. Navy, and several other navies have experienced resistant epoxy paint prior to installation of the Thordon
excellent results with submerged arc welded Inconel 625 bearing. Freeze fitting of the bearing will minimize
alloy coatings. This alloy is a high nickel content (60%), damage to the paint during bearing installation. The stern
corrosion resistant alloy that can be applied by cladding tube I.D. between housings should also be painted with
or in the form of a tubular liner or sleeve. corrosion resistant epoxy paint
NOTE: Some Classification Societies will not permit welded liners,
but many Naval authorities do. Propeller shafts, which are subject to corrosion in
seawater, must be protected between the liners by a
3.5.5 STAINLESS STEEL corrosion resistant coating. The most common coatings
used are vulcanized rubber and epoxy fiberglass. Both
Most stainless steel alloys are not particularly good wear
have disadvantages, and consequently the shaft survey
resistant materials; this is especially true of its easily
interval for open systems is a maximum of only 5 years.
machinable alloys. A liner should offer both good
corrosion and abrasion resistance. This combination is
often difficult to achieve; the most corrosion resistant 3.7.1 THOR-COAT
alloys often offer poor abrasion resistance. Thordon has Thor-Coat is an epoxy modified to enhance dynamic
observed stainless steel shafts exhibiting substantial performance. Thor-Coat is designed primarily for the
wear when running against a Thordon bearing. It is protection of propeller shafts exposed to seawater from
probable that the vessels were operating in abrasive corrosion. Easily applied on a rotating lathe to a thickness
water conditions. Some types of stainless steel shafting of 2mm (0.08”), application is straightforward, as
are good under abrasive conditions. Alloys with hardness Thor-Coat is a one-coat product (Figure 11). Thor-Coat is
higher than 30 Rockwell C would be the most flexible, shock resistant, and in the event of coating
appropriate. In very abrasive conditions, however, a damage where corrosion can then occur, the corrosion is
separate hard liner should be fitted, (see 3.5.3 above). limited to the damaged area only and will not migrate
along the shaft under the coating to unexposed areas.
3.5.6 UNACCEPTABLE MATING MATERIALS Localized damage can be easily repaired if necessary.
Other uses such as coating stern tubes, rudder stocks and
Neither Aluminum nor Titanium should be used with
trunk surfaces are also possible. Detailed information on
Thordon bearings. Soft stainless steels should be avoided
Thor-Coat can be obtained from Thordon Bearings or your
if there are any abrasives present in the water. As
local authorized Thordon distributor.
mentioned above, Thordon does not recommend the use of
nickel aluminum bronze. Non-metallic shaft liners should
Figure 11: Easy Application of Thor-Coat
also be avoided.
3.6 MATING SURFACES - FINISH

Thordon bearings operate better with a highly polished
mating surface. Badly corroded or scored shafts or liners
should be avoided. The optimum surface finish is 0.4 to
0.8 micro-metres (16 to 32 micro-inches) Ra.
3.7 CORROSION PROTECTION

Thordon bearings are non metallic and avoid the type of
electrolytic corrosion normally found between a metallic
bearing and the housing. Thordon bearings, installed with
an interference fit, normally press against a housing
tightly enough to avoid penetration of corrosive water
between the bearing O.D. and the housing. Additional
protection of carbon steel housings can be achieved by
16
3.8 MARINE GROWTH Figure 13: Dovetail Key (partial length)
Cannot be used for multi piece bearings.
Marine growth is a problem typically associated with, but
not limited to, propeller shafts in warm water. If marine
growth occurs on the shaft or bearing surface, it can easily
cut the bearing when the shaft is turned. Any shaft
immersed in water should be rotated a few revolutions
every second day. Flushing with fresh water will also help
to reduce the amount of marine growth.
3.9 CATHODIC PROTECTION – CATHODIC CHALK

Cathodic protection is a normal part of any ship. Thordon
Bearings has observed some examples of high levels of
impressed cathodic protection causing the buildup of
cathodic chalk on the shaft liners. This white chalk has
been the cause of accelerated wearing of bearings. If Figure 14: Flat Bar Key (partial length)
white chalk appears on the shaft liner, the level of Cannot be used for multi piece bearings.
cathodic protection should be reviewed.
3.10 ANTI ROTATION DEVICES

Interference is normally sufficient to prevent rotation of a
bearing in a housing, however, where the orientation of
the bearing is critical (COMPAC bearings, for example) an
anti rotation device should be fitted.
Some options for providing positive anti rotation are
listed below:
Figure 12: Radial Pin or Screw

Figure 15: Bolted Key (full length)
Grub screws are not accepted as anti rotation devices.

Shear pins or screws will work if fitted properly. Any
radial pin must be fitted into a hole drilled completely
through the full wall thickness of the bearing as shown in
Figure 12. If fitted into blind holes, there is a significant
risk that they will deform the wall of the bearing. The
length of the actual pin in the bearing should typically
be half of the wall thickness.
17
Figure 16: Traditional Double Key Figure 18: Maximum Wear is Wall Thickness of Bearing
Figure 17: Tapered Keyset

As most freeze fit bearings are fit with axial retaining rings
the first metallic contact would be between the shaft and
the retaining rings as the bearing wears. The maximum
wear would then be the wall thickness of the bearing
proud of the retaining ring I.D. as shown in Figure 19.
Figure 19: Maximum Wear is I.D. of Retaining Ring
3.11 MAXIMUM CLEARANCES

Bearings, when properly designed, installed and
maintained, will provide many years of satisfactory
service. However, in service, the bearings will wear either
as a result of abrasive or adhesive conditions. The
maximum wear can be a function of either a physical
limitation of the bearing or a limit of the application. In addition to physical constraints listed above, the
maximum wear in a bearing may be limited by regulatory
authorities or in the case of marine applications,
As wear normally increases the maximum clearances in Classification Societies. Each Classification Society will
the bearing and as clearance is normally easier to have guidelines on the maximum wear (or maximum
measure than wear, the maximum clearances for different clearances) that would be allowed in rudder or propeller
applications will be used. shaft bearings. The following guidelines are general in
nature and provide a basis for acceptable practice.
As Thordon materials are homogeneous, the bearing
material properties will not change as wear occurs in the 3.11.1 RUDDER BEARINGS
bearing wall. The first limitation is the wall thickness of the
The maximum clearances for rudder bearings will vary
polymer material to ensure that there is no metallic
slightly depending upon the Classification Society and the
material contact between the shaft and the housing parts.
rudder arrangement. As a general rule, the maximum
This applies equally whether the bearing is a freeze fit
clearances for a rudder bearing can be calculated from the
bearing or a thin walled bonded bearing. In any case,
following formula:
maximum possible wear would be the wall thickness of the
bearing as shown in Figure 18.
18
Metric: Maximum Clearance = arrangement dictates the positional relationship between
shaft diameter (over liner) x 0.002 + 5mm the bearing and the propulsion machinery.
Imperial: Maximum Clearance =
shaft diameter (over liner) x 0.002 + 0.20” The maximum allowed bearing clearance is normally
governed by the Classification Society involved. The
graphs below show the typical maximum recommended
3.11.2 PROPELLER SHAFT BEARINGS
clearance for propeller shafts. If no Classification Society
The maximum clearances recommended for water-lubricated is involved, then the groove depth can be used as an
propeller shaft bearings is dependent upon the bearing indication, i.e. replace bearings when groove depth has
design and the shafting arrangement. Bearing design reduced to 0.5 - 1mm or 0.02” - 0.04”. For COMPAC
includes bearing wall thickness, bearing configuration bearings with no grooves on the bottom wear area, the
(grooved or ungrooved), loading, and shaft size. Shafting maximum wear can be calculated using the upper grooves.
Figure 20: Typical Maximum Clearance (metric) for Stern Tube and Strut Bearings
Figure 21: Typical Maximum Clearance (imperial) for Stern Tube and Strut Bearings
19
Ch. 4 DIMENSIONING
4.1 GENERAL 4.3 DIMENSIONING USING THORDON BEARING
Dimensioning procedures for Thordon bearings are SIZING CALCULATION PROGRAM
different from traditional bearing materials. Thordon The recommended way to calculate the dimensions of a
bearings cannot be made to the same dimensions as the Thordon bearing is to use the Thordon Bearing Sizing
bronze, rubber, wood or other bearing materials they may Calculation Program. The program is available from
be replacing. This chapter will provide the information Thordon Bearings or your local Thordon distributor. Once
necessary to dimension Thordon bearings. The process the application parameters indicated in section 4.2 above
should be followed in the sequence indicated. are entered, the Program will provide the dimensions for
machining. Manual calculations are also feasible; refer to
the Thordon Bearings Engineering Manual or the ThorPlas
4.2 INFORMATION REQUIRED Engineering Manual for detailed instructions.
The following information is required for dimensioning a
The current version of the Thordon Bearing Sizing Program
Thordon bearing:
calculates all dimensions using an ambient temperature of
21°C (70°F). The program then provides adjusted values
Housing: Maximum diameter for different ambient temperatures. It also provides a
Minimum diameter reference chart that provides machining dimensions for a
Length range of ambient temperatures allowing easy adjustment
Shaft: Maximum diameter for changes in ambient temperature – from day to night
for example. When machining Thordon bearings, use the
Temperature: Minimum expected operating temperature
bearing O.D. and wall thickness dimensions instead of the
Maximum expected operating temperature
O.D. and I.D.
Ambient temperature in the machine shop
Lubrication: Water, Thor-Lube lubricant, oil,
grease, or dry 4.3.1 SAMPLE CALCULATIONS USING THORDON BEARING
Application: Propeller shaft, rudder, or other SIZING PROGRAM
Type of The following are examples of the Thordon Bearing Sizing
Installation: Interference or bonded Program used to calculate typical bearing dimensions:
It is important to check that the housing is round and has

not been worn or pounded into an oval shape. Thordon
elastomeric bearings will adapt to the shape of the
housing. The preferred solution is to machine or repair the
housing, but if this is not possible, Chapter 6 provides
installation instructions for an out-of-round housing.
Prior to calculating bearing dimensions, the housing

should also be checked for alignment. Correction of
misalignment by reboring of the housing is preferable to
line boring of the bearing after installation. Once the
housing is rebored, the bearing O.D. can be sized to the
new housing dimensions. If reboring is not appropriate,
Chapter 6 provides alternative installation procedures.
20
DIMENSIONING Ch. 4
SAMPLE CALCULATION - METRIC
Given Data Once the information above is entered, the Bearing Sizing
1. Type of Service . . . . . . . . . Marine Propeller Shaft Program gives the following results:
2. Grade of Thordon . . . . . . . . XL
3. Lubrication . . . . . . . . . . . . Water
4. Type of Installation . . . . . . Interference Fit
5. Grooved Bearing Style . . . . Grooved
6. Shaft Diameter . . . . . . . . . 100mm +0.00/-0.13mm
7. Housing Diameter . . . . . . . 150mm+ 0.08mm/-0.00,
8. Housing Length . . . . . . . . . 400mm
9. Operating Temp. . . . . . . . . Min. -2°C Max. 45°C Figure 22: Output Sheet From Metric Example
10. Ambient Temp. . . . . . . . . . 21°C - Thordon Bearing Sizing Calculation Program
21
Ch. 4 DIMENSIONING
SAMPLE CALCULATION - IMPERIAL
Given Data Once the information above is entered, the Bearing Sizing
1. Type of Service . . . . . . . . . Marine Propeller Shaft Program gives the following results:
2. Grade of Thordon . . . . . . . XL
3. Lubrication . . . . . . . . . . . Water
4. Type of Installation . . . . . . Interference Fit
6. Shaft Diameter . . . . . . . . . 4” +0.000”/-0.005”
7. Housing Diameter . . . . . . . 6” +0.003”/-0.000
8. Housing Length . . . . . . . . 16”
9. Operating Temp. . . . . . . . . Min. 28°F Max. 113°F Figure 23: Output Sheet From Imperial Example -
10. Ambient Temp. . . . . . . . . . 70°F Thordon Bearing Sizing Calculation Program
22
DIMENSIONING Ch. 4
4.3.2 TEMPERATURE CHART The machinist should then select the appropriate
As part of the Thordon Bearing Sizing Calculation Program, dimensions from the temperature chart based on the
a Temperature Chart (see Figure 24) is available to recorded bearing temperature. The Temperature Chart
facilitate adjustment of machining dimensions when the should always be consulted if the bearing temperature is
machine shop temperature varies from that used for the different than the ambient temperature used for the
original calculation. The chart can be found by clicking original calculation. The Temperature Chart is particularly
the [T] on the top of the RESULTS page of the program. important in situations where machine shops are not
climate controlled and where there are significant changes
in temperature during the day, or from day to night.
The default chart covers a 5 to 35°C (41 to 95°F) range of
machine shop ambient temperatures. For temperatures
NOTE: Should the machine shop temperature change significantly
outside this range, the chart temperatures can be adjusted
between when the bearing O.D. is machined and when the I.D. is
by clicking the “Options” button at the top of the screen to be machined, the wall thickness line in the Temperature Chart
and selecting "Customize Temperature Chart". By shifting used for the O.D. dimension must be used to control the I.D.
the “Start Temperatures on Chart” up to 21°C (70°F) the dimension. Do not attempt to machine the I.D. using a different
Temperature Chart is able to show a range up to 51°C temperature from the chart than that used for the O.D.
(123.8°F). This option also provides a box to print a
longer chart (select Print Long Temperature Chart) which EXAMPLE: If machining the bearing O.D. at 12°C (54°F) in morning
prints the entire chart shown on the screen while the and the machine shop temperature rises to 24°C (75°F), the
short chart provides a “window” to print only the bearing wall thickness should be machined to the 12°C (54°F)
dimensions (from the Temperature Chart) used for machining the
interested temperature range near 21°C (70°F).
O.D. and not the 24°C (75°F) dimensions.
The recommended procedure is to calculate the machined

bearing dimensions either using Thordon Bearing’s default
temperature of 21°C (70°F) or using the expected actual
ambient temperature in the machine shop at time of
machining. A Temperature Chart should be printed along
with the dimension calculation results sheet. Both should
be provided to the machine shop. Prior to final machining,
the machinist should first check the temperature of the
bearing by using a calibrated temperature gun or confirm
that the bearing temperature is the same as that of the
machine shop.
23
Ch. 4 DIMENSIONING
Figure 24: Temperature Chart
24
DIMENSIONING Ch. 4
4.4 CALCULATION DETAILS temperature used by Thordon bearings for propeller shaft
applications is –2°C (30°F). For rudder stock bearings that
4.4.1 BEARING OUTSIDE DIAMETER (O.D.)
operate out of the water, a minimum temperature of
TUBE TYPE BEARINGS –25°C (-38°F) is often used to allow for possible
operation in cold environments.
Figure 25: Interference Fit Parameters
INTERFERENCE FIT PARAMETERS Thordon bearings can be installed with an interference fit
PRESS
PressIN
In FORCE
Force by either press or freeze fit. An entry chamfer on the
bearing and/or a rounded corner on the housing will
facilitate press fitting. Remember however, that the
bearing will not be able to support load in way of the
chamfer. If the “Interference Press Fit” type of installation
1.
option is selected in the Thordon Bearing Sizing
Calculation Program, the press in force required for a
2. Where: bearing is provided in the results output.
Housing Shaft 1. is Interference
3.
2. is Bore Closure
3. is Installed Running When freeze fitting a Thordon bearing, the selection of a
Clearance
suitable cooling agent depends on the temperature
differential for which the bearing’s interference fit is
Where: 1. Is Interference.
NOTE: Minimum Installed Clearance = Running Clearance designed. [Temperature differential is the difference
2. Is Bore Closure.
+ Clearance.
3. Is Installed Running Thermal Expansion Allowance (if applicable) between ambient machine shop temperature and the
Note: + Water=Absorption Allowance
Minimum Installed Clearance (if applicable) coldest temperature to which the installed bearing will be
Running Clearance
+ Thermal Expansion Allowance (if applicable) exposed during operation.] If the differential is 40°C
+ Water Absorption Allowance (if applicable) (100°F) or less, then dry ice can normally be used. If the
Figure 26: Bond Fit Parameters differential is greater than 40°C (100°F), the use of liquid
BOND FIT PARAMETERS nitrogen is recommended. The Thordon Bearing Sizing
Press In Force Program provides O.D. dimensions for freezing in dry ice or
liquid nitrogen. This can be compared with the housing
1.
diameter to see which freezing option is appropriate.
2. Where:
Shaft
The theoretical amount of liquid nitrogen required to cool a
Housing 1. is Bond Thickness
2. is Installed Running Thordon bearing for installation can be calculated as follows:
Clearance Metric: Litres of liquid nitrogen required =
1.78 x Weight of bearing (kg.)
Imperial: US Gallons of liquid nitrogen required =
0.21 x Weight of bearing (lbs.)
NOTE: Minimum Installed Clearance = Running Clearance
Where: 1. Is Bond Thickness.
+ Thermal
2. Is Installed Running Expansion Allowance (if applicable)
Clearance.
Note: + Water Absorption
Minimum Installed Clearance = Allowance (if applicable)
The actual amount of liquid nitrogen required may be
Running Clearance
+ Thermal Expansion Allowance (if applicable) greater than this amount depending on the sizing of the
+ Water 4.4.1.1
Absorption Allowance (if applicable)
INTERFERENCE container used, how well insulated it is, etc.
Thordon bearings are normally installed with an
interference fit (Figure 25). The amount of interference
4.4.1.2 MACHINING TOLERANCE
will vary with the size of the bearing and with the
minimum temperature at which it will operate. Additional The Thordon Bearing Sizing Calculation Program provides
interference is required for cold operation. Additional the appropriate machining tolerance.
interference causes no harm, but insufficient interference
for cold operations could cause the bearing to come loose 4.4.1.3 BONDING
in the housing. The amount of interference required is
An alternative to an interference fit bearing is bonding a
added to the maximum housing diameter to give the
bearing into the housing. If bonding is used, interference
minimum bearing outside diameter. The normal minimum
25
Ch. 4 DIMENSIONING
is not used (Figure 26). The bearing O.D. will be the housing For rudder stock bearings that are usually above the water
I.D. less an allowance for the thickness of the bonding line, the absorption allowance should still be used
agent. The Thordon Bearing Sizing Program provides because the bearings will be exposed to water.
dimension calculations for bonded bearings including a If a Thordon XL bearing is being installed with oil
reference to the thickness of the bonding agent. lubrication, the same absorption allowance will be used.
4.4.2 BEARING INSIDE DIAMETER (I.D.) 4.4.2.4 THERMAL EXPANSION

4.4.2.1 BORE CLOSURE In cases where the maximum operating temperature of a
Bore closure is the diametric reduction of the bearing I.D. bearing exceeds the ambient temperature in the machine shop
that occurs when it is installed in a housing using an where it is machined, an allowance for Thermal Expansion is
interference fit to hold it in place. (Bore closure does not included in the bearing I.D. and length calculations.
occur with bonded bearings, and is therefore not a factor in NOTE: Thordon Bearings uses a standard maximum operating
calculating bearing I.D. for bonded bearings.) The temperature of 45°C (113°F) for the design of propeller shaft
interference oversize is transferred to the bearing I.D. A bearings. This temperature provides for the removal of heat
bore closure factor is applied to the interference amount to generation with standard water flow and seawater temperature of
32°C (90°F). This temperature can be increased if the bearings
calculate the effect on bearing I.D. Actual bore closure may are exposed to warmer waters.
vary +/-15% from the calculated amount. Since the volume
of a Thordon bearing at any given temperature remains
constant, constraining the O.D. results in a reduced I.D. 4.4.2.5 MINIMUM INSTALLED DIAMETRICAL CLEARANCE
and may result in an increase in bearing length. After installation, a Thordon bearing has a “Minimum
Installed Diametrical Clearance” which is the difference
4.4.2.2 RUNNING CLEARANCE between diameters of shaft and the bearing bore. This is
composed of three factors: 1) The design running
The recommended running clearance for Thordon bearings
clearance 2) an allowance for thermal expansion of the
is calculated based on the type of application. Different
material and 3) an allowance for water (or other
running clearances are used for propeller shaft and rudder
lubricant) absorption by the material.
bearings. Rudder bearing clearance can be less because the
movement is oscillating rather than full rotation. Low
frequency, oscillating motion generates less frictional heat. As the operating temperature of the bearing increases, the
material expands and the bearing bore reduces - this is
4.4.2.3 DIMENSIONAL CHANGES DUE TO ABSORPTION accommodated by the thermal expansion allowance. The
material also expands due to water (or other lubricant
When immersed in water or other lubricants, Thordon only
absorption) causing a reduction in the bearing bore - this
increases in volume 1.3% under normal conditions. Some
is accommodated by the lubricant absorption allowance.
of this expansion simply increases the amount of
For example, after all water or lubricant absorption has
interference, but there is also an effect on the I.D. and
occurred (may take several months), and the bearing is
length of the bearing. The Thordon Bearing Sizing
operating at the maximum design temperature, the
Calculation Program calculates the effect of absorption on
bearing clearance is equal to the design running clearance
the bearing I.D. and length.
value. The design running clearance is calculated as a
function of shaft diameter and type of service.
Axial absorption is important when calculating the gap to
leave between the last bearing segment and the ring
Minimum Installed Diametrical Clearance is used as an
keeper, and between segments of multi piece bearings.
important final check before putting the Thordon bearing
Refer to section 6.2.2.1.
into service. Early examination of clearances may show
negative wear - this is due to the growth in water or
lubricant absorption exceeding bearing wear.
26
DIMENSIONING Ch. 4
4.5 WATER GROOVES extensive field experience in recent years, a more precise
dimensioning method has evolved that is recommended
4.5.1 PROPELLER SHAFT BEARINGS
for all installations.
Thordon propeller shaft bearings must always have
lubrication grooves to facilitate an adequate flow of cooling
water or lubricant. Most small propeller shaft bearings are 4.6.2 PRE ASSEMBLY
supplied with lubrication grooves already moulded or We believe that pre assembly is the most accurate method
machined in place (Figure 27). When lubrication grooves of dimensioning Thordon STAXL staves. In this method the
must be machined into an ungrooved tube, the Thordon staves, at room temperature, are placed in the housing
Bearing Sizing Calculation Program provides the necessary until a gap of less than one stave width is left. For most
lubrication groove design information. installations with two keeper strips, each half of the
bearing would be dimensioned separately. Once the staves
have been placed in the housing, use threaded jacking
Figure 27: Thordon Propeller Shaft Bearings with Water Grooves
bars, a small Enerpac© jack, or other similar means to press
them together to eliminate any gaps. With the staves
pressed together, measure the gap between the last stave
and the keeper. Note this measurement.
4.6.3 INTERFERENCE CALCULATION

Use the Thordon Bearing Sizing Calculation Program to
determine the amount of circumferential interference. For
Type of Installation, select “STAXL Staves”, and the
program will provide the circumferential interference. In
the typical case of two axial keeper strips, where each
half of the bearing is dimensioned separately, divide the
circumferential interference by two.
For Thordon SXL, XL and Composite propeller shaft

4.6.4 FINAL STAVE WIDTH
bearings, grooves are evenly spaced around the whole
circumference of the bearing. COMPAC 2:1 L/D ratio Add the calculated circumferential interference in
bearings have lubrication grooves in the upper half only. Section 4.6.3 for the full or half bearing as appropriate
This design improves hydrodynamic performance. If a to the measured gap noted in section 4.6.2 to determine
propeller shaft bearing is made up of more than one the required width of the final stave. Mill the last stave
segment, an annular groove should be machined in one to this width.
end of each segment where it meets the next segment.
The groove should be the same width and depth as the 4.6.5 STAVE ASSEMBLY (I.D.)
axial grooves. This annular groove facilitates passage of
IN ALL CASES THE I.D. OF THORDON STAXL STAVES MUST
cooling water from one segment to the next if there is
BE MACHINED TO THE APPROPRIATE DIAMETER. STAVES
any misalignment of the grooves.
ARE SUPPLIED FLAT ON THE I.D., BUT UNLIKE SOME
RUBBER STAVES, THEY CANNOT BE USED WITH THE FLAT
4.5.2 RUDDER BEARINGS I.D. IT MUST BE CONTOURED.
There is no need for lubrication grooves in Thordon
rudder bearings because there is no flow of lubricant Normally staves are line bored after installation in the
through the bearings. housing, carrier, or machine shop dummy housing. The
I.D. dimensions can be obtained from the Thordon Bearing
4.6 STAXL STAVES Sizing Calculation Program. It is also possible to mill the
I.D. of each stave to the appropriate radius and thickness.
4.6.1 INTRODUCTION
In the past Thordon has used several different methods
for dimensioning Thordon STAXL staves. As a result of
27
Ch. 4 DIMENSIONING
4.6.6 LONGITUDINAL EXPANSION ALLOWANCES Figure 28: Side View of Dovetail Stave Assembly
End keepers or stops are always recommended with
Thordon bearings as added security to prevent axial
movement in the event of unbalanced loads, excessive
vibration, or other unanticipated factors. A gap should be
left between the end keeper and the staves to allow for
axial water absorption and thermal expansion. The
Thordon Bearing Sizing Calculation Program will indicate
the required length of the staves.
4.6.7 ENCAPSULATED KEEPER STRIPS

Occasionally, stave installations are designed so that
keeper strips fit into machined grooves in the back of
staves rather than between staves. In this case
dimensioning should be the same as for an installation 4.8 KEYED TUBULAR BEARINGS
using no keeper strips. Grooves should be machined in the Thordon bearings are often installed with both an
backs of the appropriate staves. These grooves should interference fit and a set of locking keys.
provide ample clearance over the keepers so that a proper
To size the Thordon bearings and split gap widths to
fit can be achieved even when the staves are frozen.
obtain the correct interference for a keyed bearing
application, the following procedure should be used.
4.7 DOVETAIL ASSEMBLIES 1. Calculate the bearing dimensions based on a normal
Thordon staves are also available in dovetail form for tube, and an interference fit using the Thordon
dovetail (slotted) housings. Bearing Sizing Calculation Program.
2. Machine the bearing according to the calculated
Thordon dovetail staves are designed for interference fitting dimensions.
into slotted carriers as shown in Figure 28. This ensures a 3. Measure the circumferential width of the key(s) and
snug fit throughout the length of the stave. To dimension measure or approximate the width of the cut on the
dovetail staves, select “Type of Installation” as “Dovetail side opposite the key in the case of a single key as
Staves-Standard or Custom” in the Thordon Bearing Sizing illustrated in Figure 29.
Calculation Program. For standard staves, the Thordon
Bearing Sizing Calculation Program will select the appropriate
Figure 29: Measuring Key Widths
stave, and give the required width of the slot. This width
must be verified. The standard side angle of Thordon dovetail
staves is 10 degrees. If a standard stave is not suitable, then
select “custom” and the Thordon Bearing Sizing Calculation
Program will indicate the options available. If the carrier has
a 15-degree side angle, then the staves should be milled to
suit. Thordon staves must fit well into the grooves. If the
grooves have been damaged or widths are uneven, the staves
may vibrate in service and suffer hysteresis.
The I.D. of the Thordon dovetail stave assembly must

be machined. Although a flat interior surface is
acceptable for some rubber staves, it is not acceptable for 4. Cut the slot(s) in the bearing so the total width of
Thordon staves. The Thordon Bearing Sizing Calculation material removed equals the width of the keys/keyset
Program will calculate the I.D. of the Thordon dovetail plus the width of the cut if any. Ensure that the
stave assembly at the same time as it calculates the stave combined circumferential interference of bearing and
details above. key(s) is the same as for a non-split bearing.
28
DIMENSIONING Ch. 4
For an installation with two keys or key sets, the same Next steps, assuming machine shop temperature
basic approach should be used. The bearing should be is 21°C (70°F).
dimensioned as if it were not split. Then each cut in the Step 1: Bearing O.D. is machined to 150.81mm as per
bearing should be machined to the exact width of one of Thordon Bearing Sizing Calculation Program
the keys. Again, this is done to ensure that the correct
Step 2: Machine bearing length to 395.97mm
circumferential interference is maintained.
Step 3: Fit bearing into housing
Step 4: Machine bearing I.D. to maximum shaft diameter
4.9 SPLIT BEARINGS WITH NO KEEPERS
plus Minimum Installed Diametrical Clearance –
In some applications such as rudder bearings, it may be 100 + 0.91 = 100.91mm
necessary to split a Thordon bearing to facilitate fitting
(Thordon Bearing Sizing Calculation Program gives bearing
without removing the complete rudder assembly. In this
I.D. including bore closure, which has already happened,
case bearing dimensions should first be calculated as if
when the bearing is fitted into the housing).
the bearing were a normal non split tubular bearing. Then
an allowance should be added to the calculated machined
bearing I.D. and O.D. to allow for material lost in the NOTE 1: If this procedure is used with interference fit ungrooved
cutting process. This allowance should be the total bearings, the machining of the I.D. after fitting in the housing
should not be more than 5% of the wall thickness. Machining
thickness of the splitting cuts divided by π (3.1416). The
more than this amount may have an adverse effect on the
resulting bearing will be slightly oval, but will become interface pressure of an interference fit. If the procedure is used
round when interference is applied from the housing. with grooved bearings, the amount of machining after fitting
must be limited to 10% of the wall thickness or 25% of the
groove depth, whichever is less. It may be necessary to pre-
4.10 WORKING WITH THE THORDON BEARING machine the bearing I.D. to remove enough material to allow for
SIZING CALCULATION PROGRAM final machining of the I.D. after fitting within the above limits.
4.10.1 METRIC SIZING CALCULATION EXAMPLE
– BEARING MACHINED AFTER FITTING INTO HOUSING NOTE 2: Grooves must always be machined before fitting the
bearing into the housing.
Given Data
1. Type of Service . . . . . . . . . Marine Propeller Shaft
2. Grade of Thordon . . . . . . . SXL
3. Lubrication . . . . . . . . . . . Water
4. Type of Installation . . . . . . Interference Fit, machined
. . . . . . . . . . . . . . . . . . . . after fitting in housing
6. Shaft Diameter . . . . . . . . . 100mm +0.00/-0.13mm
7. Housing Diameter . . . . . . . 150mm + 0.08mm
8. Housing Length . . . . . . . . 400mm
9. Operating Temp . . . . . . . . Min. 10°C Max. 45°C
10. Ambient Temp . . . . . . . . . 21°C
Use the Thordon Bearing Sizing Calculation Program to

calculate the finished dimensions of the bearing. In this
case the program gives the following results:
NOTE: See figure 30 on the next page
29
Ch. 4 DIMENSIONING
Figure 30: Metric Sizing Calculation Example – Bearing Machined After Fitting Into Housing
30
DIMENSIONING Ch. 4
4.10.2 IMPERIAL SIZING CALCULATION EXAMPLE Next steps.
– BEARING MACHINED AFTER FITTING INTO HOUSING Step 1: Bearing O.D. is machined to 4.077” as per
Thordon Bearing Sizing Calculation Program
Given Data Step 2: Machine bearing length to 15.845”
1. Type of Service . . . . . . . . . Marine Propeller Shaft
Step 3: Fit bearing into housing
2. Grade of Thordon . . . . . . . SXL
3. Lubrication . . . . . . . . . . . Water Step 4: Machine bearing I.D. to maximum shaft diameter
4. Type of Installation . . . . . . Interference Fit, machined plus minimum installed clearance – 4” + .0035”
. . . . . . . . . . . . . . . . . . . . after fitting in housing = 4.035” (Thordon Bearing Sizing Calculation
5. Grooved Bearing Style . . . . Grooved Program calculation gives bearing I.D. including
6. Shaft Diameter . . . . . . . . . 4” +0.000/-0.005” bore closure which has already happened when
7. Housing Diameter . . . . . . . 6” +.003”/-0.000” the bearing is fitted into the housing).
8. Housing length . . . . . . . . . 16”
9. Operating Temp. . . . . . . . . Min. 50°F Max. 110°F NOTE 1: If this procedure is used with interference fit ungrooved
10. Ambient Temp. . . . . . . . . . 70°F bearings, the machining of the ID after fitting in the housing
should not be more than 5% of the wall thickness. Machining
more than this amount may have an adverse effect on the
Use the Thordon Bearing Sizing Calculation Program to interface pressure of an interference fit. If the procedure is used
calculate the finished dimensions of the bearing. In this with grooved bearings, the amount of machining after fitting
must be limited to 10% of the wall thickness or 25% of the
case the program gives the following results: groove depth, whichever is less. It may be necessary to pre
machine the bearing I.D. to remove enough material to allow for
NOTE: See figure 31 on the next page final machining of the I.D. after fitting within the above limits.
NOTE 2: Grooves must always be machined before fitting the

bearing into the housing.
31
Ch. 4 DIMENSIONING
Figure 31: Imperial Sizing Calculation Example – Bearing Machined After Fitting Into Housing
32
MACHINING & MEASURING THORDON BEARINGS Ch. 5
5.1 GENERAL MACHINING NOTE: If adequate running clearance is not provided, bearing
failure is almost certain.
Thordon XL, SXL, COMPAC and Composite are hard, tough
elastomeric polymer products that can be easily machined. Virtually all operations that can be performed on metal,
ThorPlas is a thermoplastic and requires slightly different including machining, drilling, tapping, shaping, routing,
machining than the elastomeric grades and is covered in sawing, milling and bonding, can be performed on Thordon.
Section 5.5. It is necessary, however, to remember that Thordon can also be worked or shaped with conventional
Thordon elastomers and ThorPlas are non-metallic hand tools, keeping in mind that carbide tipped cutting
materials, and must be machined differently than metal. blades should be used to prevent heat build up when sawing.
Due to the elastomeric nature of Thordon it has a
tendency to “move away” from anything that exerts
5.2 MACHINING XL, SXL AND COMPAC
pressure on it, including machine tools of all types.
Thordon cannot be burnished or chipped; it must be cut 5.2.1 CUTTING TOOL
with a sharp tool. The importance of sharp cutting tools To machine Thordon elastomers, it is critical that the correct
cannot be over emphasized if Thordon is to be cutting tool be used. The tool must be designed to slice the
successfully machined. material and project it away from the machined surface.
NOTE: Machining videos are available from Thordon Bearings Inc. When machining Thordon properly, a continuous streamer
or from your local distributor. This is an excellent tool for is projected from the cutting tool. The cutting tool must
understanding the requirements for machining Thordon bearings. be sharp. After grinding, the cutting tool should be honed
with an oilstone to ensure a sharp cutting edge. Some of
the new carbide cutting tools currently available provide
When thin wall bearings are being machined it is
excellent results machining Thordon. They are extremely
important to recognize that the exertion of excess
sharp initially and hold their edge very well.
pressure may actually deform the bearing. In some
situations it may be necessary to use modified chuck jaws,
to support the tube using a spider, plug or a mandrel or Thordon Bearings recommends a tool bit manufactured by
to mount the tube using screws to fix it to a faceplate. Kennametal that is available worldwide. The tool bit is
For large, thin-walled tubular bearings, it is recommended Titanium Nitride PVD coated carbide and is Kennametal part
to machine them on a vertical boring mill. number: CPGT3251HP-KC730 as shown in Figure 32. The tool
holder is part number: SCMPN-083V. There are a number of
tool bits and holders offered in the Kennametal KC730 series.
Cutting speeds are also important. Low feed rates
The applicable ISO standards are M05 - M20, S15 - S25. If
combined with too low a turning speed tend to produce a
you have trouble locating this, or a similar product, please
rough cut due to the toughness and elastomeric nature of
contact Thordon Bearings or your local Thordon Distributor.
Thordon. High speeds combined with a low feed rate may
produce excessive frictional heat, resulting in a gummy-
Figure 32: Kennametal Tool Bit
galled finish. The most suitable speed/feed combinations
are similar to those used when machining aluminum.
Clearances, as specified using the design information in

this manual, may seem excessive in comparison to metals.
Thordon, however, expands from temperature change and
submersion in liquids. Thordon also exhibits bore closure
shrinkage at a rate greater than 100% of interference.
This is due to the incompressible nature of Thordon. The
minimum installed clearance takes all of these factors into
account. As well, clearance for a liquid lubrication film if
the bearing is water or oil lubricated and safety clearance
for frictional heat build up are also accounted for. The
recommended running clearance should not be decreased
without first consulting your Thordon distributor or
Thordon Bearings Inc.
33
Ch. 5 MACHINING & MEASURING THORDON BEARINGS
It is important when machining Thordon and particularly 5.2.2 MACHINING SPEEDS AND FEEDS
when boring, to ensure that the machining streamer is Suggested turning speeds for bearings of various
removed from the work. If this is not done, it will interfere diameters are provided in the chart below.
with the cutting tool and a rough finish will result.
NOTE: Due to the very elastic nature of the material, caution
should be taken when removing cuttings from the work area. Figure 35: Typical Speeds and Feeds
Bearing Bearing
The drawings on this page illustrate the proper cutting Diameter Diameter Coarse Fine
(mm) (inches) RPM Feed Feed
tool configuration when using conventional tool bits.
High speed steel can be used for SXL and COMPAC; 75mm 3” 600 0.6mm/rev. 0.4mm/rev.
tungsten carbide tool bits are used with XL. 150mm 6” 450 (0.025”/rev.) (0.015”/rev.)
300mm 12” 300 for HSS tool for HSS tool
Figure 33: General Machining Tool Bit 450mm 18” 150
General Machining Tool Bit 600mm 24” 120 0.3mm/rev. 0.2mm/rev.
10 500" SQ. HIGH SPEED STEEL 750mm 30” 95 (0.012”/rev.) (0.007”/rev.)
12.7 mm.
900mm 36” 80 for tipped tool for HSS tool
1/16" R
1.5 mm.
NOTE 1: The turning and feed speeds are provided as a guide
3/16" R
only. The optimum speed may vary higher or lower depending on
5 mm. such variables as the length of tube, the wall thickness, and how
60˚ 30˚
the bearing is being supported, i.e. simply chucked, spider at
60˚
chuck or on a full length mandrel. As is common with all
machining operations, some experimentation is required to
obtain optimum results.
NOTE 2: Cutting lubricants are not required and are not

recommended.
Figure 34: Step Machining Tool Bit
Step Machining Tool Bit
SQUARE 3/16" R.
5 mm.
10˚
30˚ 30˚
1/16" R.
1.5 mm.
34
5.2.3 BEARING SET UP MACHINING (I.D.) - THIN WALL TUBE WITH EXTERNAL SLEEVE
MACHINING - PARTIAL LENGTH FROM A TUBE
A thin wall tube I.D. can also be machined by first

A bearing that is being made from the partial length of a machining the O.D. to size, lightly pressing the tube into
tube can be chucked at one end in a normal 3 jaw chuck, a machined metal housing, chucking the housing and then
the O.D. rough machined, the I.D. finish machined, the machining the I.D. of the tube. It is possible to obtain
O.D. finish machined and then parted to length. Care tighter tolerances than those obtained with external soft
must be taken not to over tighten the chuck and distort jaws with this method but it is more complicated and
the tube. typically not necessary.
MACHINING (I.D.) - THIN WALL TUBE WITH SOFT JAW CHUCK MACHINING (O.D.) - FULL LENGTH OF A LUBRICATION
GROOVED BEARING - SUPPORTED ON CENTRES
To machine the I.D. of a thin wall tube, the O.D. should

be rough machined, the tube gripped in an extended soft After the I.D. of a bearing with lubrication grooves has
jaw chuck and the I.D. finish machined. The extended been finish machined, the bearing can be chucked on
chuck will grip and support the tube without deforming. centres, driven by a key in one of the grooves and the
O.D. finish machined. This method is acceptable for
propeller shaft bearings, but will not yield the tight
tolerances required for pump bearings.
35
MACHINING (O.D.) - MACHINED STEEL PLUG OR MACHINING (O.D.)
ADJUSTABLE SPIDER PREFERRED MACHINING METHOD - O.D. AND I.D.
After the I.D. of a tube has been finish machined, a Bearings larger than 380mm (15”) O.D. are most easily
machined steel plug can be slip fit into the I.D. of the mounted for machining by lag screwing them to a faceplate.
bearing. On larger tubes, a 3 or 4 arm spider can be set to The faceplate can then be set up on a vertical mill, or
the inside diameter of the tube and located opposite the chucked in the lathe. An additional 50mm (2”) must be
chuck jaws. Both of these devices eliminate distortion added to the required length of the bearing as a chucking
from chuck jaw pressure. A simply constructed 4-arm allowance. The faceplate is centered as accurately as possible
spider is illustrated below. With either of these methods it and then screwed to the tube using lag screws into pre-
is necessary to add a 50mm (2”) chucking allowance to drilled holes. After mounting, the tube can be trued for
the required length of the bearing. machining, if required, by loosening the screws and adjusting
the position of the tube using the slots in the faceplate.
Adjustable Spider The O.D. of the tube is rough machined first, then the I.D.
finish machined, the O.D. finish machined and then the
SPIDER bearing is parted to length from the tube. If the bearing is
too large to safely catch as it is parted off from the tube, the
Bar or Tube
following procedure should be used. Part the tube approximately
80-90% of the way through, remove faceplate and tube from
the lathe and knife cut the bearing from the tube.
ADJUSTABLE 16 mm (5/8")
SCREW & LOCKNUT
If the bearing is mounted in a lathe, it should be
completely machined without stopping for extended
periods of time. This prevents the bearing drooping or
going out of round under its own weight.
NOTE: Ensure that the tube is securely mounted to the faceplate
before turning. Failure to mount the tube securely could result
in the tube coming loose and causing personal injury.
36
5.2.4 PARTING TO LENGTH The outside diameter of the chuck can be divided and marked
Thordon can be parted to length with a standard parting to act as a guide for locating the grooves in the bearing.
tool, however, additional rake and side clearance are
helpful to prevent heat generation resulting from the
Thordon contacting the side of the parting tool. Cuttings
from Thordon should be constantly removed during parting
off, in order to achieve a uniform cut face.
NOTE: Due to the very elastic nature of the material, caution
should be taken when removing cuttings from the work area.
5.2.5 MACHINING LUBRICATION GROOVES
NOTE: Lubrication grooves must always be machined before the

bearing is fitted into the housing. Bearing I.D. can sometimes
be machined after fitting into the housing, but grooves cannot.
Lubrication grooves can be machined by hand or with 5.2.6 GENERAL MACHINING TIPS
a router. 1. To obtain optimum dimensional and surface finish
results, the final machining cut should be 1.5mm
To machine lubrication grooves by hand, a formed tool bit (0.060”) to 2.5mm (0.100”) and the cutting tool
is mounted to the lathe boring bar and manually pushed razor sharp.
through the bearing (broached). Several passes may be 2. If machining is not done in a temperature controlled
required to achieve the final groove depth. environment, the Thordon Temperature Chart must be
used to adjust the machining dimensions to suit the
actual temperature at the time of machining. Changes
in temperature can result in significant bearing
dimensional changes.
3. Due to the elastomeric nature of Thordon bearings, if
a machining error is made on the I.D. and if the wall
thickness is still adequate, it may be possible to
recalculate the O.D. of the bearing and still use it.
Contact Thordon Bearings for corrected O.D. value.
4. Before making a final machining cut, the bearing should
The grooves can be machined much more easily by mounting
be checked to ensure that it has not retained any heat
a 90 degree router to the boring bar and then machining to
from previous cuts. If the temperature of the bearing is
the correct depth in one pass through the bearing.
higher than the machine shop ambient temperature, the
resulting final cut dimensions will not be correct.
5.2.7 MACHINING LARGE BEARINGS

- 1000MM (40”) OR LARGER
The easiest way to machine large Thordon elastomeric
bearings is on a vertical boring mill. When machining
on a vertical boring mill, the following basic steps
should be followed:
37
- Use a two stage machining procedure (see below) 5.3.1 CUTTING TOOL
to avoid significant dimensional issues after part off, The new Kennametal or equivalent Titanium Nitride PVD
- Machine on a vertical boring mill, carbide coated tool bits described earlier in the section on
- Use a PI tape for checking O.D. dimensions, machining XL, SXL or COMPAC are highly recommended for
- Use a ball micrometer to check wall thickness. machining Thordon Composite bearings. With these tool
bits, the black GM2401 I.D. of the bearing material can be
A large Thordon bearing will change dimensions finish machined to an acceptable surface finish without
significantly with changes in temperature, so it is using a grinding hog as was recommended in the past.
essential to monitor the temperature of the bearing
during inspection. Use an accurate temperature gun to If a conventional high speed cutting tool is used for
verify temperature of the bearing for all inspections. Take machining the inner Composite bearing material it should
care when measuring temperature. Thordon streamers and be made to the configuration illustrated in Figure 36. As
the heat generated from the chuck can be misleading. with other types of Thordon bearings, it is essential that
the cutting tool is kept sharp.
5.2.7.1 FIRST STAGE MACHINING
Rough machine O.D. and I.D. and leave overbuild on all Figure 36: High Speed Cutting Tool
High Speed Steel Cutting Tool
diameters including stepping the length (flange) with a
groove for final machining/clamping.
10
500" SQ. HIGH SPEED STEEL
12.7 mm.
5.2.7.2 FINAL MACHINING
Clamp on grooved flange step as described above. Thordon
1/16" R
recommends machining from chuck/flange up as Thordon 1.5 mm.
streamers will generate heat and will cause difficulties 3/16" R
5 mm.
determining actual bearing temperatures for getting finish
cuts. Also, material streamers around the cutting tool will 60˚ 32˚
60˚
tend to push the tool and may cause a very rough finish or
issues holding tolerances.
- Skim O.D. and I.D.
- Finish O.D. - use temperature charts. Check O.D. at a When using a conventional high speed tool bit to machine
minimum of three positions (top, middle and bottom) the I.D. of a Thordon Composite bearing some extra steps
must be taken. Due to the nature of the GM2401 (black)
- Finish I.D. by measuring the wall thickness - use wear surface material, conventional tool bits wear very
temperature charts. Check wall thickness. Machine a partial quickly. In the course of one machining pass through the
part-off, and knife cut. I.D., the tool bit will wear enough to produce a taper
Recommend flipping and facing to length. Holding method along the bearing I.D. This taper must be corrected for on
needs to be determined by the machine shop (best method a second pass, so the first step is to ensure that two final
available) as part off will result in the end collapsing and passes in a range of 2.0 to 3.0mm (0.080” to 0.120”)
clamping stress which may lead to gouging. deep are required to finish machine the I.D. of the
Re-check O.D. at 3 positions and wall thickness at bearing. The first pass is used to measure the amount of
both ends. taper that is occurring (a taper of 0.15mm (0.006”) over
the length of a standard Thordon tube is common) and
then this taper must be corrected for on the second pass.
5.3 MACHINING COMPOSITE NOTE: It is very important to note that the final pass must be made
Machining Thordon Composite is different from machining at the same depth, speeds and feed rate as the preceding one.
Thordon XL, SXL or COMPAC because of the softer (black) Otherwise the wear on the tool bit producing the taper will change
bearing wear surface material, GM2401. The O.D. or yellow and the correction that is being made by hand will not be correct.
shell, can be machined using the same techniques as
outlined in section 5.2. The I.D. (black), however,
machines differently and is covered in this section.
38
Machining the I.D. results in a burr at the lubrication 5.3.4 MACHINING PROCEDURE (O.D. LARGER THAN 250MM (10”))
grooves that can be removed using emery cloth or a Composite bearings larger than 250mm (10”) are best
deburring tool. The surface finish of the bearing will be machined by mounting them to a faceplate and then
somewhat rough but the bearing will bed in quickly and machining the I.D., machining the O.D., parting oversize
perform well. and facing to length.
NOTE: Ensure that the bearing is securely mounted to the
faceplate before turning. Failure to mount the bearing securely
could result in it coming loose and causing personal injury.
5.4 Machining ThorPlas

5.4.1 GENERAL MACHINING
ThorPlas is easily machined to fine tolerances. ThorPlas
can be milled, sawed, planed, drilled, tapped and
threaded. Depending on bearing sizes, allow for 25 to
Deburring tool 40 mm (0.984” to 1.575”) of material length for chucking
and holding the part to any standard lathe.
5.3.2 MACHINING SPEEDS AND FEEDS

GUIDELINES FOR SAFE MACHINING:
Suggested turning speeds for Composite bearings of
- Use sharp tools (carbide grade) with fast speed rates
various diameters are given in the chart below.
- Provide good support to the part without over-clamping
(to avoid cracking)
Figure 37: Typical Speeds and Feeds for Machining Composite - Avoid sharp corners/edges
- Adequate material cuttings removal during machining
Bearing Bearing
Diameter Diameter Feed Feed - Coolants may be considered for drilling holes
(mm) (inches) RPM HSS Tipped Tool
150mm 6” 250 0.5mm/rev. 0.25mm/rev. Typical cutting speeds for ThorPlas are between 150 to
300m/min (492 to 985 fpm) as shown in Figure 38.
300mm 12” 100 (0.020”/rev.) (0.010”/rev.)
450mm 18” 75
600mm 24” 60 Figure 38: Typical Cutting Speeds for Machining ThorPlas
750mm 30” 50
Diameter RPM
900mm 36” 40
200 mm (7.874”) 350
300 mm (11.811”) 300
5.3.3 MACHINING PROCEDURE (O.D. UP TO 250MM (10”))
400 mm (15.750”) 200
The procedure for machining Thordon Composite bearings
500 mm (19.685”) 150
up to 250mm (10”) O.D. can be summarized in the
following steps. 600 mm (23.622”) 100
a) Part the bearing oversize and face to the required
finished length.
Cutting Feeds used for rough turning are 0.38 mm to 0.5
b) Mount the bearing on centres and rough machine mm (0.015” to 0.020”) per revolution. For finish turning,
the O.D. 0.12 mm to 0.25 mm (0.005” to 0.010”) per revolution
c) Press the bearing (light press fit) into a housing to are recommended.
support it and finish machine the I.D.
d) Lightly press the bearing onto a mandrel and finish As mentioned, fine tolerances can be achieved for
machine the O.D. ThorPlas, as shown in Figure 39.
39
Figure 39: ThorPlas Machining Tolerances
A - Bearing OD Machining Tolerances C - Bearing LENGTH Machining Tolerances

METRIC: METRIC:
Tolerance
Bearing OD Bearing Length on OD(mm) Bearing Length Tolerance on LENGTH (mm)
Up to 150mm up to 100mm +/-0.03 Up to 150mm +0.00
above 100mm +/-0.05 -0.25
150 to 250mm up to 150mm +/-0.05 150 to 250mm +0.00
150 to 250mm +/-0.07 -0.50
250mm and up maximum L/D of 1:1 +/-0.07 250mm and up +0.00
IMPERIAL: -1.00
Tolerance
Bearing OD Bearing Length on OD(in.) IMPERIAL:
Up to 6.00” up to 4.00” +/-0.001 Bearing Length Tolerance on LENGTH (in.)
above 4.00” +/-0.002 Up to 6.00” +0.000
6.00” to 10.00” up to 6.00” +/-0.002 -0.010
6.00” to 10.00” +/-0.003 6.00” to 10.00” +0.000
10.00” and up maximum L/D of 1:1 +/-0.003 -0.020
10.00” and up +0.000
B - Bearing WALL THICKNESS Machining Tolerances
-0.040
METRIC:
Tolerance
Bearing OD Bearing Length on Wall (mm) D - ThorPlas Washer Tolerances
Up to 150mm up to 100mm +0.00 METRIC:
-0.03 Bearing Dimension Tolerance (mm)
above 100mm +0.00 OD +0.00
-0.05 -1.00
150 to 250mm up to 150mm +0.00 ID +1.00
-0.05 -0.00
150 to 250mm +0.00 Thickness +/-0.50
-0.07 IMPERIAL:
250mm and up maximum L/D +0.00 Bearing Dimension Tolerance (in.)
of 1:1 -0.07 OD +0.000
IMPERIAL: -0.040
Tolerance
Bearing OD Bearing Length on Wall (in.) ID +0.040
Up to 6.00” up to 4.00” +0.000 -0.000
-0.001 Thickness +/-0.020
above 4.00” +0.000
-0.002 5.4.2 GROOVE CUTTING
6.00” to 10.00” up to 6.00” +0.000 Water grooves, when required, are normally broached using
-0.002 a custom-made boring bar on the lathe. The boring bar
6.00” to 10.00” +0.000 and tools should be designed to produce the dimensions
-0.003 given in Figure 40 and 41. The following custom made tool
10.00” and up maximum L/D +0.000 bits can be ordered from Thordon Bearings or your Thordon
of 1:1 -0.003 distributor using the appropriate Part Numbers:
F99TB003: Toolbit with profile to machine 3mm (0.118”)
radius groove with 7 mm (0.276”) radius edge
F99TB004: Toolbit with profile to machine 4mm (0.157”)
radius groove with 7 mm (0.276”) radius edge
40
Figure 40: Typical Groove Configuration for ThorPlas Bearings Figure 43: Chamfer on ThorPlas bearings
5.4.4 STEP-BY-STEP MACHINING PROCESS

Figure 41: ThorPlas Water Groove Dimensions Steps 1 through 7 illustrate the machining process for
ThorPlas in a standard lathe.
A A B C C
Shaft Shaft Number Groove Groove
Diameter Diameter of Radius Radius Step 1 - Cut part allowing extra length for chucking,
(mm) (in.) Grooves (mm) (in.) parting off and facing. Typically chucking lengths of 25mm
up to 30 up to 1.20 3 3 0.120 (1”) are sufficient for bearings up to 152mm (6”) O.D.
31 to 50 1.21 to 2.00 4 3 0.120 For large parts - O.D. in excess of 152mm (6”), thin wall
51 to 80 2.01 to 3.15 6 3 0.120 bearings and/or for parts with tighter than standard
81 to 120 3.16 to 4.70 6 4 0.160 tolerances, an internal plug or “chucking ring” is
121 to 160 4.71 to 6.30 8 4 0.160 recommended to support the bearing in the chuck jaws.
161 to 200+ 6.31 to 7.90+ 10 4 0.160
A, B and C re f e r t o d i m e n s i o n s i n F i g u re 4 0 . Step 2a - Set the part in the chuck jaws as shown below. These
figures show a piece with sizes of 76.2mm O.D. x 25mm I.D.
NOTE: Water grooves are only used when there is a flow of water (3” x 1”) squared in the chuck using a three-jaw configuration.
through the bearing such as a vertical pump. Grooves are not Use light to moderate clamping forces. Do not over clamp as
required when a bearing is immersed in water with no significant
this can cause stresses in the material resulting in cracking.
flow, as in a wicket gate bearing application.
5.4.3 CHAMFERS
Chamfers should be machined on the O.D. of each end of
the bearing to facilitate installation following guidelines
in Figure 38 and the dimensions in Figure 42.
Figure 42: Dimensions for Machining Chamfers
METRIC
Bearing Length Chamfer Detail
Below 25mm 1.5mm x 25O
25mm to 100mm 3.0mm x 25O
Over 100mm 5.0mm x 25O
IMPERIAL
Bearing Length Chamfer Detail
Below 1 inch 1/16” x 25O
1 inch to 4 inches 1/8” x 25O
Over 4 inches 1/4” x 25O
41
Step 2b - For parts needing a metal chucking ring,
machine slightly the O.D. to clean uneven surfaces and
machine the I.D. so that the chucking ring has a slight
interference with the ThorPlas - interference of 0.03mm
(0.001”). Typical thickness of chucking rings vary from
12mm (0.5”) for small parts to as high as 25mm (1.0”) for
parts with O.D. values in excess of 250mm (10”). Figures
below show a ThorPlas bearing, size of 152mm (6.0”)
O.D., where a chucking ring is used for extra support.
Step 4 - Proceed to machine bearing I.D. using the tool

bit and the boring bar. Clearing of chips or shavings from
bearing I.D. is important to reduce heat build up and
to obtain desired tolerances. Finish the bearing O.D.
prior to routing the grooves using the round edge tool
shown below.
Step 5 - Machine the bearing O.D. using the

Step 3 - Sharp and smooth tool bits will ensure the appropriate tool.
best finish when machining ThorPlas. The photo below
illustrates the tools used to machine ThorPlas – the
bit on the left is used for machining the I.D. while
the bit on the right is used for the O.D.
NOTE: Cutting feeds for rough turning are 0.38 to 0.50mm

(0.015” to 0.020”) per revolution. For finish turning, 0.12 to
0.25mm (0.005” to 0.010”) feeds are recommended.
42
Step 6 - Part bearing to length using the parting tool. Depending on the length of the bearing, create two or
Support the bearing as the cut is made so that it does three support disks that are the same diameter as the
not fall. As shown below, fine streamers are collected fully machined bearing I.D. The wooden inserts should be
after machining ThorPlas. approximately 19.05mm or 0.75” thick. Two holes should
be cut in each insert, 180 degrees apart, to allow for two
threaded rods to be placed through for securing purposes.
Locate the support discs at the top and bottom (and mid
section if required) of the bearing ID. These will keep the
bearing “roundness” during the splitting process.
Step 7 - Include chamfers on the end of the bearings to

ease installation. Use Figure 42 to for proper dimension of
chamfers based on bearing size.
Centre the mill table and use four blocks to raise the
bearing up from the surface of the mill table. Use the
indicator so that the blocks are set to the centre of the
table and the bearing is centered on the mill. The blocks
should be positioned at approximately 90 degrees apart
from each other to support the bearing. The bearing is to
be set on the blocks and oriented to place the cut on the
split line shown on the Bearing Details Drawing.
NOTE: Measure the ID of the bearings at the temperature at

which they are being machined and use these numbers to create
the wooden inserts. Maintain the machine shop temperature
constant as the splits are being machined. If the temperature
5.5 SPLITTING THORDON BEARINGS changes drastically, the bearings may shrink or expand and the
There are two methods to split a Thordon elastomeric woooden inserts will not fit properly.
bearing, either using a saw blade or with a knife. These
methods are explained further below.
5.5.1 SPLITTING A THORDON BEARING USING A SAW BLADE

The O.D., I.D., bearing length, lubrication grooves, and all
chamfers must be fully machined prior to initiating the
procedures to split the bearing segments.
A horizontal boring mill with an indexed rotating table is

the best type of equipment to use to ensure proper
location and accurate measurement of the splits. The
pictures below illustrate the recommended process and
equipment.
43
The bearing is clamped onto the table with 2 threaded
rods secured with “T” nuts located in a groove on the
table. Two metal bars are placed on the top of the bearing
located directly over the metal support blocks on the mill
table and clamped into position using a nut threaded
onto the rod. Care is to be taken to ensure the clamps are
not secured too tight.
Begin cutting the split line. Position the spindle to make

the incision from the bottom up, cutting from the O.D.
towards the I.D. of the bearing. The depth of the cut
should leave a 0.794 mm (1/32”) section of material at
the bottom of the cut for further cutting after opposite
side is cut. See figure below. If the bearing is cut all the
way through, the material will have a tendency to spring
back losing its roundness and making it very difficult to
continue with the split on the opposite side (180 degrees).
Line the spindle of the machine to the split line indicated on

Rotate the table 180 degrees and proceed with the second
the drawing and square to the bearing surface. A high-speed
cut, again leaving approximately 0.794 mm (1/32”) of
steel metal slitting saw 203.2 mm x 3 mm x 31.75mm (8” x
bearing material behind. Ensure that both halves have the
1/8” x 1 1/4”) cutter is typically used by the Thordon
same arc length. Air should be used constantly during
Machine Shop (saws with side chip clearance) to do the splits.
slitting to remove shavings. If shavings are not removed,
The cutting speed should be approximately 0.25 m/min (10
the saw blade could get stuck and break. Take the bearing
inches/min) at 140 RPM. The blade should be positioned with
off the boring mill table. Using a sharp knife cut through
its saw teeth on the opposite direction of the bearing so that
the 0.794mm (1/32”) gap of material that was left behind
the saw is cutting away from the bearing.
until the two segments are separated. Clean off the edges.
44
NOTE: Use compressed air to remove the material as it is being
split away from the bearing. If the material is not removed it
will tend to melt on the blade as the splitting process continues.
5.5.2 SPLITTING A THORDON BEARING USING A KNIFE

The O.D., I.D., bearing length and grooves of the bearing
must be fully finished before proceeding with this technique.
Mark the split before splitting.
Rotate bearing180 degrees, and support the bearing so that

there is no movement while the second cut is being made
5.6 DIMENSIONAL AND SURFACE FINISH

MEASUREMENTS
5.6.1 DIMENSIONAL MEASUREMENTS
A Hydraulic Press is used to “knife” cut bearings without a

gap. The knife or blade holder has been made in house to
fit our press. The two holders at the bottom support the
shaft used to position the bearing.
Outside micrometer
In most cases Thordon bearings can be measured using the

same instruments and methods as any other material. It must
The shaft is placed inside of the bearing to be split and be remembered that Thordon elastomeric bearings require a
the assembly is located over the two stand supports. light touch when measuring because it is possible to deform
the bearing out of round. In addition, Thordon elsatomeric
bearings have a high coefficient of expansion compared to
metals, so measurements must be taken at machine shop
temperature. If this is not possible then the dimensions must
be corrected for the thermal expansion and contraction that
has occurred because of the difference between the machine
shop and ambient measuring temperatures.
In the case of larger diameter, relatively thin wall bearings

that have been machined and removed from the lathe, it is
typical to find that they show ovality. This deformation can
The first cut is made. Hold the bearing so that there is no be the result of the bearing sagging under its own weight or
movement while the blade is being lowered. from being secured to a pallet for shipping. The bearing may
appear to be out of tolerance due to the fact that it has
45
become out of round. This is not a problem because when NOTE: Due to the unique characteristics of Thordon bearings,
the bearing is pressed into a housing, it will conform to the compared to metals, optimal performance can still be obtained
at relatively high (compared to metal) surface finishes.
shape of the housing and will be round. To accurately
measure the bearing outside the housing, use a pi tape to
measure the O.D. and then measure the wall thickness using 5.6.3 MACHINING TOLERANCES
a ball micrometer to obtain the correct I.D. dimension.
Thordon bearings are non-metallic and consequently
cannot be machined to the same tight tolerances as
bronze or other rigid materials. Conversely tight metallic
tolerances are not necessary to obtain optimum
performance. The standard machining tolerances for
Thordon elastomers is shown in Figure 44.
Figure 44: Machining Tolerances- XL, SXL, COMPAC

and Composite
Bearings up to 330mm (13.00”)
O.D. +0.13mm, -0.00mm (+0.005”, -0.000”)
A pi tape is a precision steel tape calibrated to measure I.D. +0.13mm, -0.00mm (+0.005”, -0.000”)
diameters by measuring circumference. Bearings between 330 and 530mm (13.00” and 21.00”)
O.D. +0.18mm, -0.00mm (+0.007”, -0.000”)
5.6.2 SURFACE FINISH AND TOLERANCES Wall thickness
(W.T.) +0.00mm, -0.13mm (+0.000”, -0.005”)
Thordon, due to its non-metallic elastomeric nature,
I.D.
cannot be machined to as smooth a surface finish as (Composite only) +0.18mm, -0.00mm (+0.007”, -0.000”)
metals. This is not a problem because the bearing goes Bearings over 530mm (21.00”)
through a normal break in period during which the initial
O.D. +0.25mm, -0.00mm (+0.010”, -0.000”)
surface roughness is worn smooth. It is important,
W.T. +0.00mm, -0.13mm (+0.000”, -0.005”)
however, to strive for as good a surface finish as possible
to reduce friction and initial break in wear. The mechanics I.D.
(Composite only) +0.25mm, -0.00mm (+0.010”, -0.000”)
of obtaining a good surface finish have been covered in
Bearing Length Tolerance:
the machining section but it is important to know how to
measure the surface finish of a Thordon bearing. For bearings
shorter than
500mm (20”)
long +0.00mm, -0.50mm (+0.000”, -0.020”)
Due to the non-metallic nature of Thordon bearings, they
For bearings
will tend to feel smoother to the touch in comparison to longer than
metal than they really are. To measure accurately the 500mm (20”)
long +0.00mm, -1.00mm (+0.000”, -0.040”)
Thordon bearing surface finish, a stylus type of surface
finish gauge should be used. Practical experience has NOTE 1: For Thordon XL, SXL and COMPAC bearings over 330mm
shown that the use of a comparator will usually result in a (13"), machined I.D. tolerance should be controlled by
value that is less than the actual value. This is because controlling the wall thickness of the bearing. For Composite
Thordon bearings are softer than metal and feel smoother bearings over 330mm (13") only, the actual I.D. of the bearing
than they actually are when measured with a stylus. should be controlled.
NOTE 2: If the wall thickness is less than 25mm (1”) then there
The tolerances on surface finish are as follows: may be restrictions as to the length of bearing that can be
properly machined. Consult Thordon Bearings for details.
XL, SXL, COMPAC, ThorPlas:
3.2 micro-metres (125 micro-inches) Ra
NOTE 3: If an application requires tolerances that are tighter
Composite: than those outlined in this manual please contact your Thordon
4.2 micro-metres (175 micro-inches) Ra distributor or Thordon Bearings for guidance.
46
INSTALLATION METHODS Ch. 6
6.1 GENERAL - Each 10°C decrease in temperature will result in an
Thordon bearings are generally fitted with an interference approximate decrease in diameter of 0.0014mm/mm of
fit. Actual installation is very quick and easy, especially diameter.
when freeze fitting is used. The housing should always be - Each 10°F decrease in temperature will result in an
clean and dry. No grease or oil should be used to help press approximate decrease in diameter of 0.0008 inches/inch
or drive fitting, as this will have a negative effect on the of diameter.
interference. The housing should be round and not tapered Thordon elastomeric bearings do not become brittle at low
or bell mouthed. It should provide support to the Thordon temperatures. If a Thordon elastomeric bearing is dropped
bearing along its full length. Thordon bearings will not while frozen it will usually not shatter or crack. Simply
function properly when not fully supported. Gaps in the clean and degrease any surfaces which came into contact
housing must be filled, or a sleeve fitted before installing with the ground, re-freeze the bearing and install it into
the Thordon bearing. the appropriate housing.
The relatively light weight of Thordon bearings is a

6.2.1.1 DRY ICE
significant advantage in the installation of large bearings.
Large tubular bearings can be handled and freeze fitted When using dry ice, it should be in pelleted form or, if
manually or with light lifting equipment. The interference fit supplied in block form, the block must be broken into
is normally sufficient to prevent bearing rotation under smaller pieces. The dry ice must make good contact with
normal conditions, but anti rotation devices should be fitted both the inside and outside surfaces of the bearing. The
when the orientation of the bearing is critical (such as bearing should remain in the dry ice for a minimum of
COMPAC bearings). A forward stop and an end keeper ring are three hours and can then be checked to see if it has
recommended to avoid any possibility of axial movement. shrunk sufficiently for installation. If not, the bearing
These keeper rings must be of adequate proportion and have should be re-packed and checked in another hour.
an inside diameter equal to the maximum acceptable
bearing/liner weardown plus 10%. The removable keeper SAFETY CAUTION: Use of dry ice in closed or poorly ventilated
ring should be retained with bolts rather than welded. areas should be avoided, as the gases tend to displace the
existing oxygen and can be fatal.
If the housing is cast or machined steel, it should be
suitably protected from corrosion. The housing I.D. input 6.2.1.2 LIQUID NITROGEN
used for bearing size calculations should take account of
Liquid nitrogen can be used for fitting SXL, XL, COMPAC
any coating thickness.
and Composite grades using a gas tight container where
the liquid cannot leak out and cause harm. The bearings
As an alternative to interference fitting, it is possible to should be completely immersed (or as close to completely
bond Thordon bearings into housings. Bonding is used when submerged as is practical) or evenly coated with liquid
the bearing wall is too thin for an interference fit and also nitrogen. When the liquid nitrogen stops boiling, the
when the housing does not provide a smooth round support bearing has reached -196ºC (-320ºF) and can be easily
for the bearing. Further information on preparation and installed (approximately 5 to 30 minutes depending on
bonding techniques is found in Section 6.4. the surface area of the bearing).
6.2 FREEZE FITTING NOTE 1: ThorPlas bearings should not be exposed to liquid
6.2.1 GENERAL nitrogen. Freeze fitting of ThorPlas bearings should be done
with dry ice only. See the ThorPlas Bearings Engineering Manual
Because Thordon elastomers have relatively high coefficients for more detailed installation instructions.
of thermal expansion, they contract significantly when
NOTE 2: Any Thordon bearing bonded in a metallic carrier must not
cooled. This makes freeze fitting the easiest way to install be exposed to temperatures below 0°C (32°F) as the bond can fail.
Thordon bearings. Dry ice is a common cooling agent, but
liquid nitrogen is the optimum for XL, SXL, COMPAC and
Composite. The amount of shrinkage during freeze fitting is Typically, freeze fitting tanks are designed to fit as large a
calculated by the Thordon Bearing Sizing Calculation variety of bearings as possible while using as little liquid
Program, or can be estimated as follows: nitrogen as possible as shown in Figure 45.
47
Ch. 6 INSTALLATION METHODS
Figure 45: Typical Freeze Fitting Tanks positioned axially – the cooled segment will have also
contracted in length and must be free to expand in the
axial direction at each end as it warms. There will therefore
be gaps between each end of the bearing and the keepers,
and also between any bearing segments. Gaps should also
be provided to allow for a portion of the axial absorption
and thermal expansion to occur between segments.
Grooves of propeller bearing segments should be aligned

to avoid restriction of the water flow. This can be done
visually, or a piece of flat bar stock can be fitted so that
it engages the grooves on adjoining segments. To avoid
possible constriction problems from minor misalignment of
water grooves, each section of a Thordon tubular bearing
should be machined with a circular recess at one end (the
SAFETY CAUTION: Use of liquid nitrogen in closed or poorly
same width and depth as the water grooves). This
ventilated areas should be avoided as the boiled off gasses tend
to displace the existing oxygen and can be fatal. Do not let facilitates flow of water from one set of grooves to
liquid nitrogen come into contact with exposed skin; the another even if there is groove misalignment. Care must
extreme cold will cause burns. be taken to ensure that these recessed ends are properly
installed - in the middle, not the outside.
6.2.2 TUBULAR BEARINGS

Thordon tubular bearings, when frozen, can normally be 6.2.2.1 RECOMMENDED PROCEDURE FOR PROPELLER
slid into the housing without difficulty. It is possible, SHAFT BEARINGS
however, that a bearing may become stuck when only 1. Freeze the Thordon tubular bearing as described in
partially inserted. It is recommended that a hydraulic jack section 6.2
or rubber mallet be readily available to complete the 2. Slide the bearing section(s) into the housing. If there
installation – speed becomes important in such cases are multiple sections:
because the bearing will continue to warm up and expand.
If any fitting force is applied, then the frozen bearing
must be protected against localized damage. a) Immediately before each section is pushed into the
housing, its length should be measured. The segment
is then pushed into the housing until the centre of
For all tubular bearings, Thordon Bearings recommends a the segment is positioned correctly.
machined stop or ring at an appropriate point in the
housing to prevent the bearing from moving too far when
being installed. Frozen bearings can easily slide too far into EXAMPLES: A bearing for a 600mm (23.6”) housing would
be machined to approximately 596mm (23.5”) long (to
the stern tube or rudder housing if a stop is not provided. allow for axial water absorption and thermal expansion). It
Thordon also recommends a keeper ring at the other end to would shrink to 584mm (23.0”) after freezing in liquid
eliminate any possibility of axial movement. The designed nitrogen. The centre of the bearing should be 300mm
interference fit is usually sufficient, but a tapered housing, (11.8”) from the end of the housing, but the frozen bearing
or cyclical unbalanced loading may occasionally cause a is only 584mm (23.0”) long, so the gap to the internal
keeper is 300 - 584/2 = 8mm (11.8 – 23.0 / 2 = 0.315”).
large bearing to move axially if it is not secured.
For two segments in a 1200mm (47.2”) long housing,

To make handling and machining easier, Thordon bearings install the first segment as above. Install the second
are often supplied in multiple segments to make up one segment until it has passed the location of the external
length. Each segment can be installed and allowed to warm keeper by 8mm (0.31”). This will result in a gap between
segments which is normal. The size of this gap cannot be
up before the next is fitted, or the segments can be fitted
predicted as the first segment will have warmed some
immediately after each other, however, care must be taken amount and correspondingly expanded. Once the bearing is
not to disturb the position of the previous segment. Each operational and water absorption and thermal expansion
segment should be installed with its centre correctly have occurred, all gaps will disappear.
48
b) Place circumferential grooves (if any) towards the should be left in dry ice for approximately 2-3 hours.
inside of the bearing. A cylinder of liquid nitrogen large enough to immerse
c) Ensure all lubrication grooves (if any) are aligned the staves can also be used. The staves should be
either visually or with a piece of bar stock immersed until bubbling of the nitrogen stops.
d) Install the axial keeper ring at the open end. The 2. Frozen staves are placed side by side in the housing
keeper ring should not block the flow of water until all staves are assembled. When fitting staves on
through a propeller shaft bearing. the upper half of the assembly they may be kept in
place by using hoops, wooden discs or other devices.
e) Allow bearings to warm to ambient temperature. As
Once the staves begin to warm-up, no special support
Thordon bearings are an effective thermal insulator, it
will be required.
can take considerable time for the core material to
warm. It is recommended that at least 12 hours 3. Place machined staves next to the keeper strips. It is
elapse before measurements are taken. sometimes necessary to drive the last stave into the
housing if the assembly has begun to warm up during
f) Measure the bearing bore and record readings from
the installation. Once the staves are fully warmed-up,
throughout the bearing length and around its bore.
they will be held tightly in place by their interference
The difference between bearing I.D. and shaft
fit.
diameter should be checked against the calculated
Minimum Installed Diametrical Clearance. If the 4. While frozen, Thordon staves, especially Composite
measured clearance at any point in the bearing is less staves, may twist or warp a little, but this should not
than the Minimum Installed Diametrical Clearance, unduly affect the assembly.
this should be investigated and corrected. 5. Any staves that come loose should be hammered
back into place.
6.2.2.2 RECOMMENDED PROCEDURE FOR RUDDER BEARINGS 6. While it is warming up, the assembly should be
checked to ensure that all staves are tightly seated
The actual length of a Thordon rudder bearing will be less
against the housing.
than the housing length by the amount of the allowances
for thermal expansion and absorption. It is important that 7. A keeper ring should be used to prevent axial
this amount be evenly distributed. If the bearing is a movement of the staves under unusual conditions
single tube, then the total of the allowances should be
divided in two with half being allocated to the bottom of When staves of different lengths are used, an interlocking
the bearing and half to the top. If the bearing is made up pattern is recommended; long and short and then short
of two or more segments, then an appropriate portion of and long. Care should be taken to ensure the long and
the total allowances should be allocated to gaps between short machined staves are matched together against the
the segments. keeper strips.
With freeze fitted rudder bearings, positioning of the A forward stop and an end keeper ring should be used when
bearing(s) is more difficult than in horizontal bearings installing stave bearings to eliminate any possibility of axial
because the bearings want to slide down to the stop. To movement of the staves under unusual operating conditions.
avoid this, use shims made of wood or cardboard to hold
the bearing in the correct position until it starts to warm
up and establishes its “grip” on the housing. Then the 6.2.4 SPLIT BEARINGS (SINGLE KEY, DOUBLE KEY)
shims can easily be removed. Do not use metal shims 6.2.4.1 SINGLE TAPERED KEYSET DESIGN
because, once the bearing has warmed up, they will be The single tapered keyset design consists of a full form
very difficult to remove. Similar shims should also be housing, a single keyset split into two tapered components
used to create the appropriate space between bearing and split Thordon bearing segments, normally COMPAC. One
segments in the case of a multi segment bearing. key segment is fixed to the carrier while the other half is
loose as shown in Figure 46. One major advantage of this
6.2.3 STAVE BEARING INSTALLATION concept is that the bearings can be removed and replaced
without removing the shaft. Complete installation
1. Take care to ensure all staves are cooled by
instructions are found in Appendix 1: Thordon COMPAC
alternating layers of staves and dry ice. The staves
49
Bearing with Single Tapered Keyset Installation Manual. A Often, the spring force of the bearings against the keys
Bearing Technology Training CD containing videos on will cause the carrier to become slightly oval. The carrier
COMPAC bearing single tapered keyset design and can easily be forced round by inserting it into the housing.
installation is also available from Thordon Bearings.
6.3 PRESS OR DRIVE FITTING

Figure 46: COMPAC Single Tapered Keyset Design Installation 6.3.1 CYLINDRICAL BEARINGS
Although freeze fitting is the preferred way to install Thordon
bearings, it is also possible to use a drive or press fit when
freezing facilities are not available. Drive fitting is possible
for small bearings. Hammer impact will not harm the
bearings. Because of the significant amount of interference
on Thordon bearings, considerable pressing force is required
to install larger bearings. All press or drive fit bearings should
be machined with an entry chamfer to facilitate entry into
the housing. For multiple segment bearings, a piece of flat
steel bar should be fitted into adjoining grooves to ensure
proper groove alignment. To avoid possible constriction
problems from minor misalignments of lubrication grooves,
each segment of a Thordon tubular bearing should be
machined with a circular recess at one end (the same width
and depth as the lubrication grooves) This facilitates flow of
6.2.4.2 DOUBLE KEY DESIGN (FIGURE 47) water from one set of grooves to another, even if there is
1. Bearing segments can be installed individually. All minor misalignment of the grooves. Care must be taken to
the bearing halves do not have to be frozen at once. ensure that these recessed ends are properly installed - in the
middle, not on the outside. Pressing force required to fit a
2. Slide the bearing segments in place. Ensure each
Thordon bearing is provided by the Thordon Bearing Sizing
segment is in the correct spot (grooves on upper half
Calculation Program, or can be calculated as follows:
for COMPAC bearing).
3. Leave space between the bearing segments for axial
growth when the segments normalize to room Press force (kg) =
temperature. interference(mm) x wall thickness(mm) x length(mm) x 85
housing bore(mm)
4. Install keeper ring.
Press force (N) =
Figure 47: COMPAC Double Key Design Installation interference(mm) x wall thickness(mm) x length(mm) x 850
housing bore(mm)
Press force (lbs.) =

interference(inch) x wall thickness(inch) x length(inch) x 120000
housing bore(inch)
NOTE: These are estimations, using a 0.3 friction co-efficient and a

nominal Compression Modulus to suit all grades of Thordon elastomeric
polymer bearings.
6.3.2 SINGLE TAPERED KEYSET DESIGN

The single tapered keyset design consists of a full form
housing and a single keyset split into two tapered segments,
and split tubular Thordon bearings (normally COMPAC). One
half of the key is fixed to the carrier while the other half
50
slides along it. The single key design allows the bearings to Contact the chocking compound manufacturer or
be removed easily from the carrier without removing the distributor for details about their chocking compound.
shaft. Detailed instructions for press fitting are provided in
the Thordon COMPAC Bearing with Single Tapered Keyset
There are two installation methods using chocking
Installation Manual in Appendix 1.
compounds, one using the chock as an adhesive to bond the
bearings into place, and the other using chock to form a
6.4 ALTERNATIVE METHODS - BONDING housing into which a bearing can be interference fitted. The
6.4.1 DIMENSIONING FOR BONDING use of chocking compounds is popular in new construction
as an alternative to boring and aligning struts, and in repair
When bearings are bonded in place, there is no
when badly worn housings are encountered.
interference on the O.D. of the bearing, and no bore
closure allowance on the I.D. The allowances for running
clearance, absorption and thermal expansion must still be For any Thordon bearing installation involving chocking
considered. The Thordon Bearing Sizing Calculation compounds, anti rotation devices (as described in
Program will provide dimensions for a bonded fit. Consult Section 3.10) should be used to prevent relative
with Thordon Bearings if the bearing will be bonded at a movement between the chock and the housing and
temperature different from where it was machined. between the chock and the bearing. If using pins, then
two pins per bearing segment are recommended.
6.4.2 TG-75
TG-75 is a flexible, high strength, two-part epoxy based 6.4.4.1 BONDING DIRECTLY INTO THE HOUSING USING CHOCK
adhesive which has been specially selected by Thordon after The bearing O.D. must be clean before bonding. Use a rag or
extensive testing of a variety of adhesives. It cures with cloth wetted with a solvent to clean the bearing O.D. Ensure
enough flexibility to accommodate the stresses generated by the solvent is allowed to dry before chocking the bearing.
the thermal expansion and absorption of Thordon. It is used The bearing must be correctly aligned using jacking screws,
primarily to form strong bonds between cured elastomers etc. Follow the chock manufacturer’s instructions for venting
and metals. It can fill gaps up to 3mm (0.125”). Detailed and damming the assembly, and for mixing and pouring the
instructions for using TG-75 are found in Appendix 2. chock. Avoid abrupt drops in temperature during curing of
Alternative adhesives can be used in an emergency. the chock as these may cause the bearing to shrink. This in
turn can affect the integrity of the bond.
6.4.3 FILLING RECESSES

When gaps larger than 3mm (0.12”) are encountered it is Chocking bearings directly into the housing can make the
necessary to use a different type of adhesive. In such removal of worn bearings difficult. It is often necessary to
cases Thordon recommends the use of a chocking chisel out the chock. An alternative is to use the chocking
compound designed for marine applications. compound to make a housing into which a bearing can be
freeze or press fitted. See instructions below.
6.4.4 CHOCKING COMPOUNDS

6.4.4.2 MAKING A HOUSING FROM CHOCK
Chocking compounds can fill substantial gaps with
minimal shrinkage. Pot life and viscosity can be such that Making a housing from chock is an alternative to bonding.
they can be poured into the annular space between a It may be more expensive initially, but replacement of
bearing and its housing without difficulty as long as worn bearings is much easier. The process involves using a
proper venting provisions are allowed. “dummy bearing” which has the same O.D. as the nominal
O.D. of the final Thordon bearing. The dummy bearing is
coated with a mould release compound to prevent the
Most chocking compounds have a significant exothermic chock from sticking to it. The dummy bearing is then
curing process. When the wall of the chocking compound aligned and installed following the procedures outlined in
is thick, this heat may be sufficient to damage the 6.4.4.1 above. Once the chock has cured, the dummy
Thordon bearing. In this situation, Thordon Bearings bearing can be removed, leaving a round aligned chock
cautions that the temperature should be monitored when housing into which a Thordon bearing can be fitted using
chocking with a wall thickness greater than 12mm (0.5”). the normal interference fit methods described above.
51
6.4.4.3 CHOCKING STERN TUBES OR BEARING CARRIERS 2. It is also possible to pack a small bearing with dry
Some shipyards fit Thordon bearings into carriers or stern ice and freeze it enough to be able to pull it with
tubes, and then chock the carrier or stern tube into little force.
position. This procedure is acceptable as long as the 3. For larger bearings, the easiest way is to remove the
temperature on the inside of the carrier or stern tube does interference fit. This can be accomplished by cutting
not exceed 55°C (130°F). The exothermic reaction from a groove in the worn part of the bearing using a
some chocking compounds, especially if the wall is thick, router or similar tool such as a circular saw or a
can transfer sufficient heat through the carrier or stern chain saw. The groove should be 3-5mm (.01” - 0.2”)
tube wall to stress relieve the Thordon bearing, causing it wide. Recommended procedure is to cut the groove
to lose its interference fit. The preferred method is to almost through the wall of the bearing leaving 1-
chock the carrier or stern tube with the bearings removed. 2mm (0.04”-0.08”) of bearing wall that can then be
cut with a sharp knife. This procedure minimizes the
risk of damage to the bearing housing. Once the
6.5 INSTALLING CARRIERS FOR SINGLE bearing wall has been completely cut, one side can
TAPERED KEYSET DESIGN be pried up and doubled over the other to completely
The carriers are supplied in accordance with customer remove the interference pressure. Then the bearing
requirements and can either be chocked or fit directly into can be manually removed.
the bearing housing provided in the ship structure (stern
4. An alternative method is to heat the bearing to more
tube, strut, or other.)
than 70°C (158°F) for at least an hour, and then cool
it. This will effectively stress relieve the bearing and
All parts are finish machined, ready for installation, unless it should be easily removed.
otherwise directed.
6.6.2 REMOVAL OF SINGLE TAPERED KEYSET BEARINGS
NOTE: COMPAC bearings segments are to be removed from the – SEE APPENDIX 1
carrier prior to chocking and installed only after Chocking of the
carriers is complete
The tapered keyset concept allows removal of Thordon
COMPAC bearings for inspection with the shaft in place.
6.6 REMOVAL OF THORDON BEARINGS The removal of the tapered key and bearing is outlined in
6.6.1 GENERAL Appendix 1: Thordon COMPAC Bearing with Single Tapered
If Thordon bearings have to be removed, there are several Keyset Installation Manual. A Bearing Technology Training
acceptable procedures. CD containing videos on COMPAC bearing single tapered
keyset design and installation is also available from
Thordon Bearings.
1. For smaller bearings it is often feasible to use a
“come-along” to pull the bearings out. Fit a pulling
plate behind the bearing to be removed and pull with
a hydraulic jack. See Figure 48 below.
Figure 48: Technique For Removing Small Thordon Bearings
52
APPENDIX 1
Thordon COMPAC Bearing lower shaft speeds, the quick development of a fluid film
between the shaft and the bearing. Thus the bearings can
With Single Tapered Keyset operate more quietly and effectively at lower revolutions
per minute. The Thordon COMPAC bearings have inherent
Installation Manual self-lubricating properties facilitating lower startup torques.
The bearings are cooled by a flow of water over the

EQUIPMENT DESCRIPTION
bearing surface. Pumped lubrication flow is
The Thordon COMPAC bearing with Single Tapered Keyset recommended, the minimum recommended lubrication
system consists of the following items: flow rate is 0.15 litres per minute per millimetre (1 U.S.
a) A bronze or stainless steel bearing carrier. gal. per minute per inch) of shaft diameter. If pumped
b) A bronze tapered keyset. water lubrication is not provided in a strut bearing, the
c) Split COMPAC elastomeric bearing segment/segments forward motion of the vessel must provide sufficient
(orange colour). water flow to the bearings. Forced water flow to struts
d) Bronze or stainless steel axial retaining rings. can be provided in new vessel designs to assist in
preventing abrasive water ingress.
The bearing assembly for all sizes of single key COMPAC
bearings is similar in construction. A brief description The elastomeric nature of the bearing also allows for the
follows: passage of abrasive particles through the bearing without
Each bearing assembly comprises an outer metallic carrier causing excessive wear.
lined with Thordon COMPAC bearing segments, a single
axial key and axial retention at each end of the bearing.
The bearings are retained in the bearing carrier by an
interference force between the bearing and the carrier
NOTE: Shaft liners in way of bearings should be clean and developed by fitting of the key. Removing the key releases
smooth (0.8 µm surface finish) for optimum performance. The
the interference force allowing for easy removal of the
bearing carrier is supplied for permanent chocking or
interference fitting into the ship. One end of the carrier is bearing segments.
typically flanged to provide means for a positive location to the
mating face of the housing.
NOTE: Bearing Grooves are to be on top half only.
The COMPAC bearing is made up of segments; the top halves CARRIER INSTALLATION INSTRUCTIONS
have lubrication grooves while the bottom halves have a
smooth bore. The number of segments required per carrier is A Bearing Technology Training CD containing videos on
dependent upon the length and diameter of the bearing. COMPAC single tapered keyset design and installation is
available from Thordon Bearings.
A single axial key provides the interference to retain the

COMPAC bearing segments in the carrier. The key is split The carriers are supplied in accordance with customer
with a taper. The bottom half is bolted to the carrier and requirements and can either be chocked or press fit into
the top half is removable allowing easy extraction of the the bearing housing provided in the ship structure
bearing without removing the shaft. (sterntube, strut, or other.)
Retaining rings are bolted at the outer end of the carrier The carriers and bearings are shipped from the Thordon
to prevent any possible axial movement of the bearing factory on cradles in wooden crates. All parts are finish
segments. machined, ready for installation, unless otherwise directed.
NOTE: COMPAC bearings segments are to be removed from the

PRINCIPLE OF OPERATION carrier prior to chocking and installed only after Chocking of the
The bearings are designed using hydrodynamic theory. The carriers is complete
smooth bore in the bottom half of the bearing allows, at
53
APPENDIX 1
KEY AND BEARING INSTALLATION Figure 1: Dimensions are typical - vary to suit size of
(SHAFT REMOVED) actual bearing segments being cooled
The fixed key, lower half, is bolted into the required
position in the carrier. A coating of anti-seize compound
is recommended between the fixed and removable keys to
reduce galling on insertion.
Place the beginning end of the removable key (thinnest end

of the key) on the fixed key. Press the key into position using
hand pressure. A non-metallic 5 kg (10 lb.) mallet hammer
may be required to tap the key into the position. The COMPAC
bearing segments are delivered to the shipyard in a fully
machined state ready for installation in the metallic carriers.
The recommended method to cool the bearing segments is

using liquid nitrogen. To accomplish this, a holding tank KEY AND BEARING INSTALLATION
as illustrated in Figure 1 should be used. (SHAFT IN PLACE)
Place the beginning end of the removable key (thinnest
Place one segment at a time in the tank and leave the end of the key) on the fixed key. A coating of anti-seize
segment in the tank for approximately 20 minutes or until compound is recommended between the keys to reduce
the liquid nitrogen stops boiling. It is recommended that galling when removal is required. Press the key into
the bottom halves of the bearing are cooled first and fit position using hand pressure. A non-metallic 5 kg (10 lb.)
in the carrier followed by the top halves. In lieu of liquid mallet hammer may be required to tap the key into the
nitrogen, dry ice can be used as a cooling medium to cool position.
the bearing segments.
WARNING: Nitrogen, although not a poisonous gas, will displace

Leave approximately 150 to 160 mm (6") of the end of
air and if the work is being conducted in a depressed area, the the key withdrawn and proceed to install the COMPAC
localized atmosphere may become devoid of oxygen even though bearing segments as detailed below.
the area in general may be well ventilated - adequate precautions
must be observed to preserve personnel safety regarding oxygen
depletion and the low temperature of the coolant. The total length of the bearing segment lengths should be
measured. The length of the housing will be greater than
Slide the frozen bearing segments into the carrier starting this length. The difference in length should be divided
with the bottom segments, then slide the top halves in equally so that when the segments are installed there are
ensuring that the top and bottom segments are aligned. equal gaps between the segments and retaining rings and
between segments.
Care must be taken to ensure that the segments are

installed in the correct order making sure that: With the shaft centered in the carrier, install the bottom
segments one at a time and slide them into the bearing
- The lubrication grooves are on the top of the bearings
carrier measuring how far they are installed so that equal
- The circumferential grooves are positioned towards the gaps are maintained. The upper edge of the bearing on
centre of the bearing the key side should be in contact with the stationary
- Gaps are left between the bearing segments and the section of the key. When the bottom segments are fully
retaining rings and between adjacent bearing segments. in, the shaft should be lowered to allow insertion of the
These gaps allow for thermal growth of the bearing top segments. Each segment in turn is rested on the shaft
and slid into the housing measuring how far they are
Install the retaining ring and retaining ring screws onto installed to maintain gaps between segments and
the carrier. Tighten the screws to the torque recommended retaining rings and between segments.
on the arrangement drawing.
54
APPENDIX 1
When all segments are fully inserted, the Extractor Rod is Figure 3: Extractor tool set up to begin detachable single
removed from the extraction tool and the extraction tool key extraction
is threaded into the mounting holes in the housing. The
Extractor Bar is positioned to allow the fitting of a
hydraulic cylinder between the end of the key and the
Extractor Bar. The hydraulic cylinder is pressurized pushing
the key fully into the housing.
Install the retaining ring and screws and tighten in

accordance with torques specified on the drawing.
REMOVAL OF COMPAC BEARING SEGMENTS

(SHAFT IN PLACE)
KEY REMOVAL
Centre the shaft in the bearing by lifting with block and
tackle or other suitable securing method so that the shaft
is no longer contacting the bearing.
Remove the retaining ring bolts and retaining ring. Store

for re-installation later.
Remove the Wear Down Gauge, as it will impede the

removal of the bearing.
Attach the key extraction tool supplied by Thordon

Bearings shown in Figure 2. The tool must be firmly
attached to the key. Place the cross bar on the adjustable
rods so that it is extended from the key as far as possible,
while still allowing for a minimum 25 mm (1")
engagement of the Extractor Nut over the Extractor Rod
(puller) Figure 3. Using the hex wrench turn the nut onto the puller to
increase the nut engagement, which will extract the key.
Figure 2: Illustration of the extractor key tool

When the Extractor Nut has bottomed out on the puller, set
up the extraction tool as described in the previous section.
Move the nuts outward along the adjustable rods to extend
the distance between the crossbar and carrier. Turn the
Extractor Nut again until it bottoms out. Repeat the
procedure until the key can be removed by hand. Figure 4
illustrates what a typical key extraction procedure looks like.
Store the key for re-installation later. Store the extraction

tool for later use.
55
APPENDIX 1
Figure 4: Single Key removal using key extraction tool Insert the J-hook rod into the section between the
permanent key (attached to the carrier) and the top
section of the COMPAC bearing segment. The height of
the J-hook is such that there is sufficient clearance to
install the J-hook without becoming blocked. See
Figure 6 for a sketch.
Figure 6: Illustration showing how the J-hook is used to

remove COMPAC bearing segments.
BEARING REMOVAL
There are two methods of removing the COMPAC bearing
segments with the shaft in place.
a) Using Two Threaded Rods

The bearings segments, both upper and lower are
manufactured with two threaded holes approximately 50
mm (1") above and below the split line. To remove the
bearing segments, use two threaded rods, fastening the
two rods to each segment and use these to pull the
segment out. Repeat until all upper segments have Pull the J-hook rod and the COMPAC bearing segment will
been removed. Then raise the shaft to provide clearance come out of the carrier. Proceed to remove the bottom
and repeat until all bottom segments are removed. section using the same device.
b) Using a J-Hook
Use a J-hook shown in Figure 5 to remove the top half
of the bearing. Screw the J-hook to one of the ends of
the fully threaded steel rod. The rod should be
approximately 1 metre long with M6 thread (or similar).
Figure 5: J-hook and nut used to remove bearing segments
56
APPENDIX 2
Bonding with TG-75 MIXING ADHESIVE COMPONENTS

TG-75 adhesive is a two-part system consisting of an
accelerator denoted as “TG-75A” and a resin “TG-75B”.
SURFACE PREPARATION
These two components should be mixed using the
The metal substrate and the Thordon material need to be following VOLUME ratio:
properly prepared. Poor substrate preparation may result in
Part A to Part B = 1:2
loss of bond strength and the possibility of the bearings
coming loose from their housings during operation.
Improper mixing ratios may result in failure of the adhesive
to cure (too little accelerator used, adhesive does not
METAL PREPARATION
harden) or it could cure too quickly (if too much
Metal surfaces should be machined not smoother than 3.0 accelerator is used) resulting in significantly reduced curing
micrometers Ra (125 microinches). The surface should be times. Using TG-75 cartridges not only ensures correct
gritblasted to increase adhesion. For metals exhibiting ratios, but the static mixer ensures proper mixing as well.
corrosion, the surface should be clean blast to obtain a
Near White Blast clean surface per Standard SSPC-SP No.
10/NACE No.2. Temperature of the materials at the time of mixing is also
very important for proper performance. For cartridges
stored in at low temperatures, the cartridge should be
NOTE: Bonding should take place within 2 hours of surface
allowed to return to room temperature (minimum
preparation and cleaning. For Aluminum and Stainless Steel,
reduce the exposure time to 30 minutes or less as an oxidation overnight) PRIOR to mixing of Components A&B. See
layer form very quickly after sandblasting in these materials. Storage guideline section for more information.
The surface to be bonded needs to be cleaned after Once mixed, the adhesive offers a maximum working
sandblasting with an organic solvent/degreaser such as time of 60 minutes at 23°C (73°F) and has a viscosity
Methyl Ethyl Ketone (MEK), isopropyl alcohol, or other of approximately 50,000cps. Increases in temperature
equivalent non-residue degreaser, to remove any will reduced the working time or pot life.
contamination prior to applying the TG-75 adhesive. Allow
the degreaser to completely evaporate without further
TG-75 adhesive is packaged in pre-measured tubes and each
contamination before bonding. Do not touch the cleaned
tube yields 450 ml (0.12 US gallons) of mixed adhesive.
parts – if the parts need to be handled, use NEW latex
Typical coverage for one tube is 7000 cm2 (1085 in2) at a
gloves to protect the clean surface from contamination
thickness of 0.25 mm (0.010 inches). Recommended
caused by oil in skin.
adhesive thickness ranges from 0.25 mm to 0.38 mm (0.010
in to 0.015 in). Exceeding the recommended adhesive
THORDON PREPARATION thickness reduces the bond strength. Consult with Thordon
Bearings if higher adhesive thickness values must be used.
The surface finish of the Thordon bearing to be bonded
should be between 3.0 to 6.0 micrometers Ra (125 to 250
microinches). Sandpaper can be used to roughen up the DISPENSING PROCEDURE A – PNEUMATIC GUN
area to be bonded.
a) Fully retract the pistons manually: The pneumatic gun
must be connected to the airline and the middle rod
It is recommended that the bearing surface be wiped with pulled back until the pistons are fully retracted.
a cloth or soft paper wetted with a small amount of
solvent – ensure that no residue from the paper is left
b) Insert the cartridge assembly: remove the “D” shaped
behind. A clean brush can also be used to clean the
plugs from the cartridge, keep in a safe place for re-
surface. Allow the solvent to dry completely before
storage. See figure 1. Place the open end of the
applying the adhesive. Note that the elastomeric bearing
cartridge assembly over the piston pads. Be careful to
should NOT be soaked in the solvent.
align the pads in the centre of the cartridge plungers.
If the pistons are not centred, the plungers may flip or
be pushed unevenly resulting in improper mixing and
57
APPENDIX 2
leaking. Snap the front end of the cartridge assembly Figure 3: Thumb release lever - shown with arrow
into position at the front of the gun. Manually push the
piston forward until they bottom out against the inside
of the cartridge plungers. See figure 2.
Figure 1: Plugs for TG-75 cartridge
b) Insert the cartridge assembly: remove the “D” shaped

plugs from the cartridge, keep in a safe place for re-
storage. Place the open end of the cartridge assembly
over the piston pads. Be careful to align the pads in
the centre of the cartridge plungers. See figure 4.
Figure 4: Plungers in manual gun

Figure 2: TG-75 cartridge properly inserted into
pneumatic gun
c) Phase the cartridge: use a pneumatic gun with a

maximum pressure of 0.70 MPa (100 psi), turn the
regulator knob counterclockwise to the stop. Hold the If the pistons are not centred, the plungers may flip or
cartridge tips over a disposable surface. Depress the be pushed unevenly resulting in improper mixing and
gun trigger and slowly open (turn the regulator knob leaking. Snap the front end of the cartridge assembly
clockwise) until compound extrudes evenly from the into position at the front of the gun. Manually push the
cartridge tips. Release the trigger. piston forward until they bottom out against the inside
of the cartridge plungers.
d) Dispensing: open the pressure regulator from the low-
pressure setting until the desired flow rate is obtained. c) Place the cartridge tips over a disposable surface and
The quantity of adhesive required should be squeezed squeeze the trigger handle slowly until compound
out onto a disposable surface and thoroughly mixed extrudes from both cartridge tips. Release the trigger
until the colour of the adhesive is completely uniform. handle and depress the thumb release lever.
DISPENSING PROCEDURE B – MANUAL GUN d) Maintain consistent pressure on the trigger handle as
a) Fully depress the thumb release lever and then retract you dispense the appropriate amount of material.
the piston carriage assembly. See figure 3. Depress the thumb release lever immediately after
dispensing or built up pressure in the cartridge will
result in additional compound extruding.
58
APPENDIX 2
ADHESIVE CURING ADHESIVE APPLICATION
Provided the material was mixed correctly, the cure time for As mentioned previously, for best results it is
TG-75 is dependent upon the temperature during the curing recommended to conduct the bonding installation at the
period. The recommended curing temperatures for TG-75 are: SAME temperature at which the bearing was machined. In
- Typical: 20 to 40°C (68 to 104°F) cold weather environments, it is important to maintain
the temperature above 10°C (50°F) for proper curing of
- Minimum: 10°C (50°F)
the adhesive.
Contact Thordon Bearings if TG-75 is being used at

SPLIT BEARINGS OR FLAT SURFACES
temperatures outside the range shown above.
a) Apply the adhesive to the prepared surface of the metal
and spread evenly with a spatula or a small notched
CURING TIMES AND TEMPERATURE trowel. See Figures 5 and 6.
Over 60% of the bond strength is attained in 8 hours at
23°C (73°F). Approximately 80% of the bond strength is
Figure 5: Adhesive being applied to split metal housing
achieved in 4 hours at 40°C (104°F). Full cure is reached
in 5 days at 23°C (73°F).
Insufficient curing time, particularly at low temperatures,

prior to water immersion will result in reduced bond strength
values. Water will stop further curing of the adhesive.
Note: For bearings with large OD [250 mm (9.4843 in) and up],
it is important to machine the bearing AND perform the bonding
installation at approximately the SAME temperature. Machining
the bearing at one temperature and installing it at a different
temperature may have significant effects on the optimal
adhesive thickness – see example.
After application of adhesive, keep bearing and carrier assembly Figure 6: TG-75 being applied to OD of split SXL bearing
at a constant temperature while the adhesive cures.
EXAMPLE
An SXL bearing is machined in the afternoon at 30°C
(86°F) to suit a housing ID of 250 mm (9.843 in). Based
on optimal adhesive thickness, the bearing OD is
machined to 250mm – 2 x 0.25mm = 249.50 mm (9.843
in -2 x 0.010 in = 9.823 in).
The bearing is to be installed the next day but note that

the shop temperature has increased to 35°C (95°F). Using
the thermal coefficient of expansion for SXL [21.1x10-5
cm/cm/°C (11.7x10-5 in/in/°F)] and the temperature b) Position the Thordon component and clamp so that a
difference [5 °C (9°F)], the bearing OD at 35°C has small amount of the adhesive is extruded out from the
increased to 249.76 mm (9.833 in). The adhesive edges of the Thordon part. See Figure 7. Do not
thickness is reduced to 0.12 mm (0.005) with the machine or handle the bonded piece for a minimum of
temperature difference. Such thermal effects are even 8 hours at 23°C or 73 °F. Avoid smearing the
greater with larger bearings. adhesive during assembly.
59
APPENDIX 2
Figure 7: Clamping with slight force SXL to metal housing TROUBLE SHOOTING
a) If compound bypasses the plungers and leaks from the
backside of the cartridges, check that the plungers are
seated squarely against the cartridge plungers.
b) If the compound leaks around the retaining nut, ensure
that the nut is not cross-threaded and tighten it further.
c) The dispensed compound must be consistent in colour.
CLEAN UP
Scrape excess with a trowel then dampen a cloth with
solvent and carefully remove the remainder of the
adhesive from the bonded assembly edges. Do not
CYLINDRICAL BEARINGS contaminate the bond line with solvent.
a) The bearing should be sized to allow for a 0.25 to 0.38

mm (0.010 to 0.015 in) adhesive thickness. This is an STORAGE OF TG-75 & SHELF LIFE
allowance of 0.50 to 0.76 mm (0.020 to 0.030 in) on the TG-75 cartridges can be stored at room temperature
outside diameter. TG-75 will fill gaps up to a thickness (~20°C) with a shelf life of 15 months from time of
of 3.0 mm (0.125 in) but the shear strength of the delivery. To increase the shelf life of the material, the
adhesive decreases at thickness over 0.6 mm (0.025 in). cartridges can be placed in a fridge or freezer. The lower
temperature increases the shelf life of the unmixed
b) Apply the adhesive to both the metal and Thordon. components to 30 months from time of delivery.
Spread evenly with a spatula or small notched trowel.
Storage at lower temperatures (-10 to –20°C) may cause
c) Slide the bearing into the housing. Slight rotation of the the adhesive to crystallize or solidify, giving the product
bearing can help homogenize the adhesive layer, but do the appearance of a hazy liquid or waxy semi-solid.
not use excessive back-and-forth movements as this Crystallization is not an indication of material problems
could induce the creation of air bubbles within the layer. and does not affect the performance of the material.
However, Components A& B should not be mixed if it is
suspected to be crystallized.
d) Spacers can be used in situations where the bearing
cannot be held eccentrically with the housing and
This crystallization phenomenon is reversible by bringing
uneven adhesive thickness is an issue. Glass beads and
the materials back to room temperature. If time permits,
metal shims and wire can be used to ensure an even
allow the material to warm up naturally overnight. Gentle
thickness throughout the circumference – see Figure 8
warming (no direct heat or flame) of the cartridge and its
for suggested set up.
contents is acceptable. Bring the cartridge to 50°C
(120°F) for approximately 30 minutes. Allow to cool back
Figure 8: Wire used to keep bearing eccentric in housing - to room temperature prior to use.
drawing not to scale
If only a portion of a cartridge assembly is needed, it is
possible to store the remainder of the cartridge for later
use provided it is sealed properly. After completion of the
initial bonding procedure, place the “D” shaped end plugs
back into the cartridges. Store the used cartridge in a
freezer to preserve components.
NOTE: TG-75 does not contain volatile photochemical reactive

solvents. Produced CFC free.
60
WARRANTY
LIMITED WARRANTY AND LIMITATION OF LIABILITY

FOR THORDON BEARINGS INC. (‘TBI’)
(a) Basic Terms. TBI provides a limited warranty on the Goods 1. The Goods are operated with any accessory, equipment or
of its own manufacture sold by it to the Buyer thereof, against part not specifically approved by TBI
defects of material and workmanship and not manufactured by TBI or to TBI’s design and
(the “Limited Warranty”). specifications, unless the Buyer furnishes reasonable
evidence that such installation was not a cause of
the defect; provided, that this provision shall not
(b) Coverage. This Limited Warranty covers the repair apply to any accessory, equipment or part, the use
or replacement or the refund of the purchase price, of which does not effect the safety of the Goods;
as TBI may elect, of any defective products regarding
which, upon discovery of the defect, the Buyer has given 2. The Goods shall not be operated or maintained in
immediate written notice. TBI does NOT warrant the accordance with TBI’s written instructions as delivered to
merchantability of its product and does NOT make any warranty the Buyer, at any time or from time to time,
express or implied other than the warranty contained herein. unless the Buyer furnishes reasonable evidence
that such operation or maintenance was not a cause
of the defect;
(c) Third Party Products. Accessories, equipment and 3. The Goods shall not be operated or maintained under
parts not manufactured by TBI are warranted or normal industry use, unless the Buyer furnishes reasonable
otherwise guaranteed only to the extent and in the manner evidence that such operation was not a cause of the
warranted or guaranteed to TBI by the actual manufacturer, and defect;
then only to the extent TBI is able
to enforce such warranty or guarantee. 4. The Goods shall have been repaired, altered or modified
without TBI’s written approval or, if the Goods shall have
been operated subsequent to its involvement in an
(d) Limited Liability. TBI’s liability for any and all claims, accident or breakdown, unless
damages, losses and injuries arising out of or relating to its the Buyer furnishes reasonable evidence that such repair,
performance or breach of any contract of sale of goods and the alteration, modification, operation, accident
manufacture, sale delivery, re-sale, repair, or use of any goods, or breakdown was not a cause of the defect; provided,
shall NOT exceed the agreed price of such Goods. The Buyer’s however, that this limitation insofar as it relates
remedy shall be at TBI’s option, the replacement or repair of the to repairs, accidents and breakdowns, shall NOT be
Goods. This shall be the Buyer’s sole, exclusive and only remedy applicable to routine repairs or replacements or minor
against TBI. IN NO EVENT SHALL TBI BE LIABLE FOR INCIDENTAL, accidents or minor breakdowns which normally occur
SPECIAL OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT in the operation of a machine, if such repairs or
LIMITED TO LOSS OF PROFITS, BUSINESS, GOODWILL, INCURRING replacements are made with suitable materials and
OF MACHINERY DOWNTIME, DESTRUCTION OR LOSS OF ANY according to standard practice and engineering;
CAPITAL GOODS, LIABILITY FOR PERSONAL INJURY, DEATH, 5. The Buyer does not submit reasonable proof to TBI that the
PROPERTY DAMAGE AND ANY OTHER TYPE OF DAMAGES WHETHER defect is due to a material embraced within TBI’s Limited
SIMILAR TO OR DIFFERENT FROM THIS LISTING. Warranty hereunder.
(g) Warranty Term. This Limited Warranty made by TBI
(e) Latent Defects. In cases of defects in materials or contained in these Terms and Conditions, or contained in any
workmanship or defects arising from the selection of material or document given in order to carry out the transactions
processes of manufacturer, such defects contemplated hereby, shall continue in full force and effect for
must be apparent in the Goods within three (3) months, after the benefit of the Buyer, save and except, no warranty claim
delivery and acceptance of the Goods to the Buyer. may be made or brought by the Buyer after the date which is
twelve (12) months following delivery and acceptance of the
Goods pursuant to this Contract.
(f) Exclusions. TBI shall, as to each aforesaid defect, be
relieved of all obligations and liability under this Limited (h) Expiration and Release. After the expiration of this Limited
Warranty if: Warranty’s period of time, as aforesaid, TBI shall
be released from all obligations and liabilities in respect
of such warranty made by TBI and contained in this Contract or
in any document given in order to carry out the transactions
contemplated hereby.
61
Customer Focused To Support
Your Immediate And Future Needs
Supply and Service: Geared to provide Manufacturing: Thordon’s modern Quality: Thordon Bearings Inc. is a
quick response to customer needs, Thordon polymer processing facility is staffed with Canadian company manufacturing to ISO
Bearings understands the importance of experienced and dedicated employees. 9001:2000 Quality System requirements.
fast delivery and reduced down time. Bearings up to 2.2 m (86") in diameter have With over 35 years experience in polymer
Thordon marine and industrial bearings can been supplied and bearings up to 1.5 m bearing design, application engineering
be designed, produced to the exact (60") O.D. can be machined in-house. and manufacturing, Thordon marine and
requirements of the customer and shipped industrial bearings are recognized world-
quickly. wide for both quality and performance.
Distribution: With Thordon bearings Research and Development: Thordon
specified all around the world, an extensive bearings are being continuously tested by
distribution network has been established our Bearing Test Facility. The Facility
in over 70 countries. Inventories of common evaluates new designs and applications
bearing sizes are stocked by local Thordon before they are put into service. Ongoing
Distributors and are backed up by large testing not only allows for design
regional and head office Thordon stocks. refinements, but ensures quality and
Application Engineering: Thordon performance after installation. Our polymer
Bearing’s engineers work closely with laboratory evaluates new and modified
customers to provide innovative bearing polymers in a continuing quest to improve
system designs that meet or exceed the Thordon bearing performance and searches
technical requirements of the application. for new polymer bearing solutions.
Your local Thordon Distributor
3225 Mainway, Burlington, Ontario L7M 1A6 Canada

Tel: (905) 335-1440 Fax: (905) 335-4033
E-mail [email protected]
MBIB 2008.1 01/08 2,000BC ISO 9001:2000
CGSB
PRINTED IN CANADA www.thordonbearings.com Registration #93649

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SYMBOLS & UNITS

THORDON MARINE BEARING INSTALLATION MANUAL

FREEZE FIT COOLANT TEMPERATURES

METRIC CONVERSION TABLE

Thordon elastomeric bearings are available in four grades

1.1.2 BEARING LENGTH

The number of staves required for an installation will vary with

Figure 4: Thordon STAXL Stave Dimensions

STAXL Staves (1000mm, 39 inches length)

NOTE 1: The number of staves is rounded up to the next whole

1.4 GRADE SELECTION

Figure 9: Thordon Composite Bearing Profile

A pumped flow of water to a Thordon strut bearing is not

2.1 GENERAL Thordon rudder bearings are normally supplied in rough

3.6 MATING SURFACES - FINISH

3.7 CORROSION PROTECTION

3.9 CATHODIC PROTECTION – CATHODIC CHALK

3.10 ANTI ROTATION DEVICES

Figure 12: Radial Pin or Screw

Grub screws are not accepted as anti rotation devices.

Figure 17: Tapered Keyset

Figure 19: Maximum Wear is I.D. of Retaining Ring

3.11 MAXIMUM CLEARANCES

It is important to check that the housing is round and has

Prior to calculating bearing dimensions, the housing

The recommended procedure is to calculate the machined

4.4.2 BEARING INSIDE DIAMETER (I.D.) 4.4.2.4 THERMAL EXPANSION

4.6.3 INTERFERENCE CALCULATION

For Thordon SXL, XL and Composite propeller shaft

4.6.7 ENCAPSULATED KEEPER STRIPS

The I.D. of the Thordon dovetail stave assembly must

Use the Thordon Bearing Sizing Calculation Program to

NOTE: See figure 30 on the next page

NOTE 2: Grooves must always be machined before fitting the

Clearances, as specified using the design information in

NOTE 2: Cutting lubricants are not required and are not

Step Machining Tool Bit

A thin wall tube I.D. can also be machined by first

To machine the I.D. of a thin wall tube, the O.D. should

5.2.5 MACHINING LUBRICATION GROOVES

NOTE: Lubrication grooves must always be machined before the

5.2.7 MACHINING LARGE BEARINGS

5.4 Machining ThorPlas

5.3.2 MACHINING SPEEDS AND FEEDS

A - Bearing OD Machining Tolerances C - Bearing LENGTH Machining Tolerances

5.4.4 STEP-BY-STEP MACHINING PROCESS

Figure 42: Dimensions for Machining Chamfers

Step 4 - Proceed to machine bearing I.D. using the tool

Step 5 - Machine the bearing O.D. using the

NOTE: Cutting feeds for rough turning are 0.38 to 0.50mm

Step 7 - Include chamfers on the end of the bearings to

NOTE: Measure the ID of the bearings at the temperature at

5.5.1 SPLITTING A THORDON BEARING USING A SAW BLADE

A horizontal boring mill with an indexed rotating table is

Begin cutting the split line. Position the spindle to make

Line the spindle of the machine to the split line indicated on

5.5.2 SPLITTING A THORDON BEARING USING A KNIFE

Rotate bearing180 degrees, and support the bearing so that

5.6 DIMENSIONAL AND SURFACE FINISH