PRODUCT CATALOGUEHIGHWAYOFF

YOUR PARTNER IN TOUGHTERRAIN

Sound solutions for your world 4How to control vibration 6

Vibration Theory 8

Assistance Guide 14MDS Mounting 16Metacone™ 18HydroMounting 26Compactor Shearmounting 27Cushyfloat™ Special 28Cab Mounting 302-piece CR Mounting 32EH 34Mushroom 36Suspension Systems 38Spherilastik™ 39Control Links 40Conical Bearing 41Suspension Spring 42Washers 43Trelleborg IAVS is a world leader in the design and manufactureof rubber to metal bonded components for anti-vibrationapplications and suspension systems. There are three main brands:TrellExtreme® in off-highway, Metalastik® is used in rail andmarine applications and Novibra® in industrial and powergeneration applications. The company`s head office, technicalcentre and research and develompment units are located inLeicester, UK while production is divided between Leicester andtwo Swedish factories at Trelleborg and Sjöbo. There are regionaloffices in Belgium, France, Germany, Italy, the Netherlands,Sweden and the United States. Trelleborg Industrial AVS isapproved to ISO 9001. The Trelleborg Group is a global groupwith 15 000 employees in 40 countries and an annual turnoverof 1 600 MEuro.

TrelleborgIndustrial AVSVibration TheoryProducts

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Trelleborg Industrial AVS is your partner in tough terrain. The company hasdeveloped the new TrellExtreme® range of isolators specifically for off-high-way vehicles – from the smallest skid steer loader and mini excavator to thelargest articulated dump truck. These superior vibration isolation systemswith motion control are designed to protect vehicle operators from the harm-ful and fatiguing effects of vibration and noise in extremeoff-highway conditions. With our new TrellExtreme®range and our specialized expertise in vibration control,we can help you find the optimum off-highway solution.

WORLDSOUND SOLUTIONSFOR YOUR

C O N T R O L L I N K

The primary function of Trelleborg Industrial AVS antivi-bration mountings is to eliminate harmful vibration andeffectively reduce structure-borne sound. Our mission is to beour customers’ preferred choice for engineered solutions inthe Industrial, Off-highway, Rail and Marine markets.

Unrivalled resourcesTrelleborg Industrial AVS has all the resources you wouldexpect from a global market leader:• An R&D centre and purpose-built, state-of-the-art manu-facturing plant at our Leicester head office in the UK,plus production facilities in Sweden.• Our own laboratories equipped with the very latest com-pound formulation, modelling and simulation technolo-gies for material and product development.• An advanced mixing facility to prepare compound on siteunder clean and rigorously controlled conditions.

Total solutionsTrelleborg Industrial AVS provides far more than optimumtechnical solutions based on computer-managed calcu-lations. Our overall approach to solving vibration problemsencompasses:• Education and training in vibration techniques to increaseunderstanding and knowledge of vibration problems.• World-class testing facilities including a comprehensiveprogram of static, dynamic and fatigue testing at our tech-nical centre in Leicester.• Advanced simulation techniques such as Finite ElementAnalysis (FEA) and multi body vibration analysis soft-ware to simulate the loads that products have to with-stand over a full service life.

Continuous developmentWe have developed the special TrellExtreme® range for theoff-highway market, but we don’t stop there:• We invest continuously in the development of our prod-ucts and the materials we use.• Our laboratories continually measure and control speci-fications of raw materials and finished products.• And, as a member of the Trelleborg group, Trelleborg

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Industrial AVS is in a position to fully control the com-plete production process and all vital raw materials.Environmental improvementOur aim is to exceed the requirements of current and futureenvironmental legislation and set a standard for others tofollow:

• We constantly review our manufacturing processes in thedrive for year-on-year environmental improvement.• Our strategy includes the continued elimination of sol-vents, significantly reducing emissions into the atmos-phere, water purification and decreasing notifiable waste.• In our industry we lead the way in the increased use ofaqueous metal degreasing methods, water-based bond-ing agents and protective finishes.

Overcoming complexityVibration problems are often complicated. We assist ourcustomers every step of the way:• Our technical department helps customers evaluatespring mass systems in order to achieve ideal solutionsto specific vibration problems.• The advanced computer programs we use are designed incooperation with technical universities.• Specialists in design engineering and product develop-ment work alongside customers to ensure a successfulproject outcome: products with outstanding performancebenefits.

Promoting insightTrelleborg Industrial AVS offers top-grade trainingand testing in its field:• Analysis using FFT technology – we cantake measurements, analyze the appli-cation and recommend the best solution.• Our technical centre’s advanced testingfacilities give Trelleborg IndustrialAVS an excellent platform forproduct development.• We conduct training andeducation courses for cust-omers and distributors toincrease awareness ofvibration issues andTrelleborg IndustrialAVS solutions.

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Causes and consequencesVibration is generated by all kinds of machinery, particularlyequipment with rotating or reciprocating movements. If sol-idly mounted, these generated motions are transmitted directlyto the foundations causing irritating noise in the immediatesurroundings of the machine installation. Noise may alsooccur in areas some distance away, transmitted through thestructure. This is normally referred to as structure-borne noise(structural noise). In addition to noise, the creation of vibra-tion can cause serious problems to sensitive machinery. Thehuman body, too, can be adversely affected and this manifestsitself in reduced working capacity, tiredness, and headachescaused by both high and low frequencies. Extremely low fre-quencies with considerable movement cause motion sicknessand seasickness.Combating the problemThe harmful effects of noise can be eliminated by:• Minimizing both imbalance in the machine and themachine’s natural vibrations by applying greater accuracyin manufacture, optimum design of engine balance, etc.

• Vibration-isolating the machine to prevent transmissionof vibrations.• Vibration-isolating the machine to prevent the effectof outside interference.• Sound-insulating the machine with suitable sound insu-lation and absorbing material to combat airborne noise.

HOWTO CONTROL VIBRATION

S P H E R I L A S T I K ™

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A cost-ef fective cureThe manufacturing costs related to accurate balancing ofmachines are very high and may rise quickly with increasedinner balancing. As vibration isolation of the entire machinemay still have to be considered, Trelleborg Industrial AVSantivibration mountings can be cost-effective by reducing theneed for intensive balancing.Rubber springs to the rescueVibration isolation is based on installing machinery on springsor resilient material of known stiffness and damping. The mostcommonly used spring materials are rubber and steel. Anotheralternative is air springs. However, the properties of rubbermake it particularly suitable as a spring material, as it has:

• A high load bearing capacity with an ability to accom-modate overload conditions without the catastrophic fail-ures associated with steel and other materials.• The ability to carry complex loadings more easily andeconomically than other alternatives. By bonding rubber

to a rigid material, a product can be created to accommo-date movement with no sliding or rotating surfaces thatrequire lubrication. This allows operation in many harshenvironments with substantially reduced maintenancerequirements.Components can be designed to integrate with the spacelimitations of the application and provide control in all sixmodes of freedom. Steel springs are normally used in the formof coil springs or leaf springs. Although steel springs permitrelatively high deflections, they provide very little damping.Consequently, excessive movement occurs when passingthrough the resonance range. Often special devices are installedin order to limit deflections. To allow their properties to beutilized in a satisfactory way, Trelleborg Industrial AVS rubbermountings are available in various hardness grades and polymertypes.

Rubber as anengineering materialCompared with other engineering materials,rubber is veryductile. In some cases,the elongation may be higher than1000%, and by far the highest proportion of this strain iselastic. Metals,on the other hand,have very small strains belowthe elastic limit. Compared with metals, the tensile strengthof rubber is low. The maximum level that can be achievedwith rubber is 25-30 MPa. However, because of the highstraincapability, rubber has a very large work absorption capa-city compared with the best grade of steel. If a material issubjected to a load below the elastic limit, the deformationwill, according to Hooke ´s law, be proportional to the load.This does not apply to rubber under tension or compression.This means that rubber does not have any constant tensileor compression modulus of elasticity. Rubber does not havea yield point, and the modulus is increased until there isabrupt failure.The most impor tantproper ties for rubber

High e las t ic i tyHigh elastic ductility is, therefore,the most pronouncedfeature of rubber. Just how easy it is to deform rubber is shownby the fact that the modulus of elasticity of compression forrubber within the normal hardness range, 30-80 °IRHD,

is between 2 and 12 MPa; while the modulus of elasticity ofsteel is 210 000 MPa. This means that rubber is about100 000 times softer than steel.Damping capaci tyDamping capacity is an additional important featureof compounded rubber.S ound-ins ulat ingAs sound-insulating material, rubber is one of the very best.The effect of sound insulation increases with the thickness ofthe rubber. Rubber is an excellent absorber of structure bornesound, which occurs in foundations, floors, buildings, etc.

Environmental Condit ionsTrelleborg products are manufactured in a wide range of rubbercompound types. A range of hardnesses is available in eachcompound type to allow the required stiffness to be achieved.Each compound is carefully formulated to obtain the bestperformance for specific properties. The compound chosendepends upon the most important properties for theapplication’ requirement. Strength and fatigue requirements,operating temperature, environmental conditions and poten-8

THEORYVIBRATION

RUBBERSPRINGSTEELSPRINGFIG.3. Schematic difference between rubber spring and steel spring.

FIG.4. Resonance curve for spring material with different internal damping.

MAGNIFICATION FACTOR

Sub-critical range Sub-critical range

Interference frequencyNatural frequency

Tuning Z

Spring coef f icientsA rubber spring has different characteristics for static anddynamic conditions. A constant load causes a deflection, andthe inclination/deflection gives the static spring coefficient.When the spring at static equilibrium is loaded with a dynamicforce, the response is a higher spring coefficient.

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S tatic S t i f fnes sThe stiffness of a spring is a measure of applied force (P)againsta resulting Deflection (X). Measurements taken at a continuousfeed rate (usually in the order of 1mm/sec velocity)providestatic (or pseudo static)characteristic. The curves in fig. 7 showalternative methods of determining stiffness.

RANGE RANGE

FORCE FORCE

DEFLECTIONRANGERANGE

FORCE

FORCE

DEFLECTION

DEFLECTIONStifness = dP/dX at X.P

FIG.7. dP/dX at XP average gradient over P (or X) range (usually derived by least squares method of curve fitting).

Dynamic elasticityDynamic load

Static loadDeformationFIG.6. Schematic representation of the internal damping properties of rubber.The elliptical area indicates the loss of energy.

FIG.5. Response of single impact applied to steel and rubber springs.

tial contaminates must be considered. Most Trelleborg rubbercompounds are based on natural rubber compunds, offeringhigh strength and excellent performance characteristics. A rangeof synthetic rubber compounds is also available for special app-lications where resistance to continuous high temperatures(>60 °C) or other harsh environmental conditions is required.Anti-oxidants and anti-ozonants are included in manyformulations to provide resistance against ozone and ultra violetrays.

Dynamic Sti f fnessThe stiffness of a rubber spring changes when a dynamic forceis applied. This is known as the dynamic (or complex) stiffness.The dynamic stiffness is usually higher than the pseudo-staticstiffness, (the difference being referred to as the dynamic tostatic ratio) and is affected by several factors including changesin frequency, temperature and amplitude. See fig. 8. Thedynamic stiffness is considered to be unchanged between 5Hzand 80Hz under constant conditions. Above this frequencyrange, the dynamic stiffness of the spring will deviate fromthe ideal ‘massless ’spring stiffness. This is due to the masseffects of standing waves. “Wave effect ”changes of dynamicstiffness are generated when the rubber section dimensionsbecome comparable with multiples of the half wavelength ofthe propagated wave passing through the spring. Calculationsof the deviation from ideal “massless ” spring dynamic stiffnessdue to wave effect are complex and are normally obtained fromtest measurement. A typical stiffness curve for a large sectionrubber to metal bonded spring is shown below. In fig. 9.C reep Per fo rmanceWhen a rubber spring is subjected to a constant load, the re-sultant deflection continues to increase with time. An exampleof creep that occurs in a pair of inclined springs is shown onthe graph in fig.10. A typical creep characteristic for rubberused in antivibration mountings is 3-5% per time decade.

Joule ef fectChanges in temperature cause small changes in the deflectionof loaded rubber springs. This change in deflection, which isreversible with temperature, is known as the Joule effect. Forpairs of springs shown a 10 °C rise in temperature will causean increase in clearance by approximately 4.5% of thenominal static deflection. See fig. 11 and 12.

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FIG.8

LOAD

DEFLECTION

Ks = P1X1– X5

Kd = P3– P4X3– X4

FIG.9FREQUENCY (Hz)

HIGH FREQUENCY DYNAMIC STIFFNESS

dbref 1N/M

FIG. 10TIME - DAYS

CREEP - %

INCREACE

ON BASE D

EFLECTION

FIG. 11 FIG. 12

LADEN FREECLEARENCE

% CHANGE Deflection

% CHANGE Deflection

TempC˚ TempC˚

Gradient 4,5 %change in deflectionper 10˚C

Stif fnes of a rubber springWhen calculating compression characteristics of rubber, itshould be noted that the deflection is not directly proportio-nal to the load, as the modulus of elasticity in compressionincreases with the degree of stress. The modulus of shear,however, remains constant for normal stresses. The factor withthe most effect on stiffness is the ratio between loaded andfree surface area of rubber. This is the so-called shape factor(often designated S). With thin rubber sections,a very highmodulus of elasticity can be achieved. The stiffness of a rubberspring is also determined by the dimensions and the hardnessof the rubber. Fig. 13 illustrates the relationship between rubberhardness and shear modulus, and Fig.14 the dependence ofthe bulk modulus on the shape factor. The latter curve appliesat 10% deformation. The curves show that rubber at a shape

factor of 0.25 for shear i about 6-8 times softer thancompression for the same rubber hardness. Since only 3-4 timesthe stress value in compression can be considered, it may besaid that rubber is best used in shear to achieve large deflectionsand good isolation properties, particularly at low interferencefrequencies.Selection of antivibration mountingsThe principle relating to vibration isolation with springs isthat they are placed between source and receiving structures.To ensure effective isolation, the springs must be selectedcarefully, otherwise the result could be impaired performance.In favourable cases, the transmitted force can be reduced toonly 2 or 3% of that of a rigidly mounted machine. In suchcases, the vibrations are practically eliminated.

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Amplitude A (m) The magnitude of the displacement of a vibration deflection from the

mean position. The total vibration is thus twice the amplitude.Interference frequency f (Hz) Is essentially the same as the frequency of the rotational speed of the

machine or a harmonic.Natural Frequency fo

(Hz) The number of vibrations in a freely-oscillating system per unit of time.Mass m (Kg) The mass of the oscillating system.Spring force F (N) The force emanating from a spring on the machine or the reverse.Deflection d (m) The deformation of the spring from the neutral position.Static spring stiffness Kstat (N/m) The force required in Newtons to compress the mounting 1 m.Dynamic spring stiffness Kdyn (N/m) Spring stiffness when an alternating force is applied.Tuning ratio Z (-) The ratio between inter ference frequency f and natural frequency fo .Interference force F (N) The force transmitted to the base of an isolated machine.Impulse force F i (N) The force transmitted to the base of a rigidly mounted machine.Magnification factor B (-) The part of the impulse force which is transmitted as a vibration force.

Indicates the relation between the interference force F and impulse force F i .Level of isolation I (-) The part of the impulse force which is eliminated by the vibration isolation,

(1-B)or, if B is expressed as a percentage, (100-B).Damping coefficient c (Ns/m) The linear viscous damping coefficient.Critical damping c kr (Ns/m) The linear viscous damping coefficient at critical damping. A system is said to

be critically damped if it returns to its initial static position without any

over-oscillation after a displacement.Damping factor D (-) The ratio between c and ckr.Reduction R (dB) Isolation expressed in decibels.Deflection stat (mm) The static deflection for a spring.

S O M E V I B R A T I O N D E F I N I T I O N S

FIG.13 Relationship between rubber hardness and shear modulus. FIG.14 The dependence of the compression modulus upon the shape factor.

HardnessIRH

State shear modulus

60

Static E-modulus MPa

HardnessIRH

Shape factor, S

C alculat ion of deflect ionWhen calculating deflection the following formula shall beused.

C alculat ion o f

is o lat ion degreeThe following formulas are used for calculating the isolationdegree for a given spring.The natural frequency:

Tuning: Z = f/f0

Magnification factor:

The factor D depends on the internal damping of the springmaterial. In rubber D has the value 0.04-0.1 depending onhardness of the rubber. The term 4D2.Z2 can generally beneglected completely except in the resonance range,that is,whenZ=1. If Z=1,that is, the machine speed (rpm) = the naturalvibrations of the system, it is said that there is resonance, andthe vibrations will be infinitely large if there is no damping.Here, then, a rubber spring has a distinct advantage over asteel spring, which has minor internal damping and in whichthe amplitude, in theory, grows to a very high value in theresonance point. Refer to fig. 4 on page 10.Isolation degree I= (1-B) or as percentage, I= (1-B) x 100Reduction in dB R=20log(1/B)The relative magnitude of the transmission of force dependsprimaeily on the tuning ratio Z. If Z is high, the force trans-mission percentage will be small. As can be seen in fig.15,B atZ= √2 has dropped to 100% and when Z is further increased,B drops rapidly. Vibration isolation is therefore of significancefirst when the operating frequency considerably exceeds thenatural frequency. For practical applications, Z should bebetween 3 and 5, which means that 88 to 96 % of interferenceforces are eliminated. Generally, the operating speed of amachine (interference frequency) is given. If the system´snatural frequency can be modified, and influence Z, it ispossible to change the force transmitted.This is exactly what

happens when vibration isolation is achieved. The low elasticityand shear moduli of rubber are used to achieve a low naturalfrequency.To summarize, transmission of vibration forcescan be effected in three ways:1. Rigidly mounted machines transmit vibration forces inunchanged form to the base, which is therefore forced tobe a part of the movement of the machine. The magnifi-cation factor can be regarded a being 100%.2. In the case of an unsuitable spring system, the magnificationfactor will increase considerably and may amount to severalhundred percent.3. The force transmission percentage is reduced substantiallyby correct calculation and suitable mountings beinginstalled between the machine and base. Typical reductionscan be from 100 down to 10%, but in favourablecircumstances can be as low as 2%.

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FIG.15 Resonance curve.

Shock isolationShock is usually described as a transient phenomenon as opp-osed to a vibration, which is a contin uous process. A shockpulse can normally by described by parameters such as maxi-mum amplitude (acceleration, for example), duration (inmilliseconds, for example), and the shape of the pulse. Thepulse may be a half sine wave, rectangular, saw tooth or othershape of wave. The basic principle for achieving good shockisolation is to mount the machine on mountings that are softenough to give a low natural frequency, and which can offerrelatively large mounting deflections. If the duration of a shockpulse is • seconds, and the natural frequency of the set up isf˚ Hz, then the product must be • f˚ <approx. 0.25 if the isola-tion is to provide protection against the shock. The value 0.25is not an absolute value but depends on the shape of the shockpulse.MovementsGenerally, softer suspension systems give a lower NaturalFrequency and more static deflection than stiff mountingsystems. A low system Natural Frequency will give good vi-bration isolation performance, but the high deflections mayresult in undesired excessive movements of the mountedequipment under normal working conditions. One solutionto decrease undesired movement is to increase the stiffness ofthe mounting, but then it becomes a compromise betweenlow Natural Frequency (isolation performance) and accepta-

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ble equipment movements. An alternative option is to installa buffer system to reduce the movement in the direction thatcauses a problem. If in doubt please don´t hesitate to contactlocal sales office.StorageThere may be changes in appearance and physical propertiesof rubber products during storage, particularly if adversecondition apply. BS3574 provides an ideal guide to the mostsuitable storage conditions, including:• Moderate temperature (ideally 20°- 30°).• Low humidity.• Protection from intense light, radiation andhigh ozone concentrations.• It is recommended that the storage perioddoes not exceed five years.

Unit conversionMultiply by to obtainfeet 0.30480 metersinches 25,4 millimeterspounds 0.453 kilogramspound/force 4.4482 Newtonsfeet second 0.3048 meters/secondinches/second 0.0254 meters/secondfeet/second2 0.3048 meters/second2inches/second2 0.0254 meters/second2

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CONSTRUCTION EQUIPMENTC O N S T R U C T I O N E Q U I P M E N T

MDS MOUNTING ENGINE, C AB 16METACONE™ ENGINE, C ABIN, RADIATO R 18HYDROMOUNTING C AB 26COMPACTOR SHEARMOUNTING V IBRATO RY C O MPAC TO RS 27CUSHYFLOAT™ SPECIAL ENGINE 28CAB MOUNTING ENGINE, C AB 302-PIECE CR MOUNTING ENGINE , C AB 32EH ENGINE , C AB, RADIATO R 34MUSHROOM ENGINE, C AB, RADIATO R 36SPHERILASTIK™ S U S PENS IO N 39CONTROL LINK S U S PENS IO N 40CONICAL BEARING S U S PENS IO N 41SUSPENSION SPRING S U S PENS IO N 42

AGRICULTUREA G R I C U L T U R E

MDS MOUNTING ENGINE, C AB 16METACONE™ ENGINE, C AB, RADIATO R 18HYDROMOUNTING C ABIN 26

P R O D U C T P A G E

P R O D U C T P A G EA P P L I C A T I O N

A S S IS TA NAS S I S TAN C E G U I D E W H E N C H O O SA P P L I C A T I O N

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CABMOUNTING ENGINE, C AB 302-PIECE CR MOUNTING ENGINE , C AB 32EH ENGINE, C AB, RADIATO R 34MUSHROOM ENGINE, C AB, RADIATO R 36SPHERILASTIK™ S U S PENS IO N 39CONTROL LINK S U S PENS IO N 40CONICAL BEARING S U S PENS IO N 41

MDS MOUNTING ENGINE 16METACONE™ ENGINE, C AB, RADIATO R 18HYDROMOUNTING C AB 26CUSHYFLOAT™ SPECIAL ENGINE 28CAB MOUNTING ENGINE, C AB 302-PIECE CR MOUNTING ENGINE , C AB 32EH ENGINE , C AB, RADIATO R 34MUSHROOM ENGINE, C AB, RADIATO R 36SPHERILASTIK™ S U S PENS IO N 39

MATERIAL HANDLINGM A T E R I A L H A N D L I N G

P R O D U C T P A G EA P P L I C A T I O N

NC E GUIDES I N G A N T I V I B R AT I O N M O U N T I N G

CHOICEA SAFE

ALL OVER THE WORLD

Head OfficeTrelleborg Industrial AVS1 Hoods Close, LeicesterLE4 2BN, EnglandTel: +44 116 267 0300Fax: +44 116 267 0301industrialavs.uk@trelleborg.com

Trelleborg Industrial AVS USA, Inc.1431 East Algonquin Road,Arlington Heights, Illinois 60005 USATel: +1 847-357 1600Fax: +1 847-357 1701industrialavs.usa@trelleborg.comTrelleborg Industrial AVS Italyc/o Trelleborg Wheel Systems SpaVia V. De Vizzi, 60I-20092 Cinisello Balsamo (MI), ItalyTel: +39 02 660 393 80Fax: +39 02 660 393 81industrialavs.italy@trelleborg.com

S A L E ST E C H N I C A L C E N T E RP R O D U C T I O N

BranchesTrelleborg Industrial AVS Belux(p/a) Trelleborg Wheel Systems Belgium NVBrugsesteenweg 7BE-9940 Evergem, BelgiumTel: +32 9 258 10 94Fax: +32 9 253 61 80industrialavs.belgium@trelleborg.comTrelleborg Industrial AVS Netherlands BVZeemanstraat 71-73NL-2991 XR Barendrecht, HollandTel: +31 10 292 7414Fax: +31 10 479 7079industrialavs.holland@trelleborg.comTrelleborg Industrial AVS France SASMini Parc du Verger, Bâtiment G1, rue de Terre NeuveFR-91940 Les Ulis, FranceTel: +33 1 64 86 42 60Fax: + 33 1 64 86 42 69industrialavs.france@trelleborg.com

www.trellextreme.com

Trelleborg Industrial AVS SwedenP O Box 9020SE-15 109 Södertälje SwedenTel: +46 8 550 34 490Fax: +46 8 550 34 494industrialavs.sweden@trelleborg.comTrelleborg Industrial AVS SwedenSE-231 81 Trelleborg, SwedenTel: +46 410 510 00Fax: +46 410 193 70industrialavs.sweden@trelleborg.comTrelleborg Industrial AVS Germany GmbHDudenstrasse 27 - 35DE-68167 Mannheim, GermanyTel: +49 621 484 650Fax: +49 621 484 6565industrialavs.germany@trelleborg.com