1 TAO Insert Drawings.pdf

ISOMETRIC VIEW

SCALE 1 : 10

A A

B B

C C

D D

72B6 URETHANE FOAM 157324.996 in^3

6 POLYURETHANE OR POLYSULFIDE CAULK AR

5 1-1/2 OZ UNIDIRECTIONAL ROVING AR

42D3 CHOPPED REINFORCEMENT, BI-DIRECTIONAL ROVING AND/OR 24 OZ WOVEN ROVING AR

32D3 THIXOPUTTY OR DURAGLASS AR

23C2 7531PLATE, METAL, .25" x 48.00" x 144.00", 316 SST 305.832 in 13C5 18438PLATE, METAL, .50" x 24.00" x 24.00", 316/316L SST 742.500 in^2

PARTS LIST

ITEMZONEPART/SPEC. NO.NDBC CONT. NO.DESCRIPTIONNOTESVENDORQTY.

SHEET 1 OF 4

APPROVED

C.CARPENTER

F.LOSSETT

DWG NO

TAO-001102

TITLE

TAO BUOY HULL ASSEMBLY

SIZE

D

REV

F

NATIONAL DATA BUOY CENTER

John C. Stennis Space Center

Stennis Space Center, Mississippi 39529

UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN INCHES

TOLERANCES

DECIMALS ANGULAR

.XX +/- .05 +/- .5

.XXX +/-.010 .

DO NOT SCALE DRAWING

APPLICATION

-NO. HULL NO. NEXT ASSY. USED ON

NDBC PROJ. ENGINEER

NTSC ENGINEER

CHECKED

DRAWN

APPROVALS DATE

CONTRACT NO.

2/16/2011

11/4/2008

CONFIGURATION MGT. APPROVAL

ECP #

L.LEBLANC

QA133005CQ1035

S.YEADON 2/16/2011

P10-0007 2/16/2011

L.LEBLANC 2/16/2011

-001

-001

TAO

TAO

TAO-001100 TAO

TAO-001100 TAO FLUX

SCALE

NOTES:

BOLT INTERNAL METAL FRAMEWORK TO JIGS BEFORE GLASSING FRAMEWORK TO

FIBERGLASS SHELL.

VENDOR MUST ADHERE TO ALL DIMENSIONS AND TO THE SPECIFIED QUALITY OF

CONSTRUCTION. NO SUBSITUTIONS OF SPECIFIED MATERIALS WILL BE ACCEPTED.

VENDOR IS PERMITTED TO PROPOSE CONSTRUCTION TECHNIQUES, WHICH WILL BE

REVIEWED BY NDBC ENGINEERS.

VOID FILLED WITH URETHANE FOAM, ITEM 7 .

SHELL THICKNESS INCREASED TO .50 INCH AT INTERFACE BETWEEN TOP AND BOTTOM

HALF OF TOROID SHELL.

FIBERGLASS, ITEM 4 , AND "THIXOPUTTY OR DURAGLASS," ITEM 3 , USED TO

SECURE METAL BANDS TO THE BOTTOM TOROID SHELL TO FORM A RIGID STRUCTURE.

URETHANE FOAM NOT SHOWN FOR CLARITY.

SEE SHEET 4 FOR CONSTRUCTION DETAILS AND SOW.

2.

REVISION HISTORY

ZONE REV DESCRIPTION DATE APPROVED

GEN F

REPLACES WITH CHANGE TAO-001102.DWG REV E

PER ECP E15-0040. FOR PREVIOUS REVISIONS SEE

HISTORY. REDRAWN FROM AUTOCAD TO

INVENTOR. ADDED SHEET 4 AND FLAG NOTES 3, 4,

5, 6, 7, AND 8. UPDATED APPLICATION BLOCK,

PARTS LIST, NOTES, AND FIELD OF DRAWING.

CHANGED THE OVERALL HEIGHT OF THE INTERNAL

RING TO REFLECT AS-BUILT PART.

A.FINEOUT 7/7/15 L.RABALAIS 8/27/15

F

F

F

F

07/25/16

07/25/16

R. MOORE

C. KOHLER

TOP VIEW

NTS

SECTION A-A

NTS

SECTION B-B

NTS

DETAIL 4

SCALE 1 : 2

A A

B B

C C

D D

SHEET 2 OF 4

DWG NO

TAO-001102

SIZE

D

REV

F

SCALE

AA

B

B

91.00 - 1.00

.00+ OD

120°

120°

28.5625.03125

.345.035

R15.00 OD

4.00~

4.50 - .50 .00+~

2 3

F

F F

F

36.00

4.00~

7.00~

7.00~

3x

.25 FILLET, ALL AROUND

4.50 - .50 .00+~

FRONT VIEW

NTS FRONT VIEW

NTS

FRONT VIEW

NTS

SIDE VIEW

NTS

ISOMETRIC VIEW

NTS

SIDE VIEW

NTS

ISOMETRIC VIEW

NTS

SIDE VIEW

NTS

ISOMETRIC VIEW

NTS

A A

B B

C C

D D

SHEET 3 OF 4

DWG NO

TAO-001102

SIZE

D

REV

F

SCALE

2 3

.25 TYP

PADEYE

INTERNAL RING

29.132x OD

3.00

F F

F

3.00

17.565

3.00 .25

PADEYEWELDMENT

35.130

28.632x ID

.50 1.25

4.25 5.50

1.25

43.75 45.00

4x 1.00 THRU R.504x

F

F F

F

FF

4.94

22.50

14.57 14.57

A A

B B

C C

D D

SHEET 4 OF 4

DWG NO

TAO-001102

SIZE

D

REV

F

SCALE

ATLAS BUOY SPECIFICATIONS

BUOY CONSTRUCTION:

1. The Fiberglass shall have a maximum thickness of 3/8" and a minimum thickness of 5/16". Use alternate layers of chopped reinforcement, bi-directional and/or 24 OZ woven Roving. The framework is keyed so that it will fit in only one orientation on the jig.

This is the required procedure. After the framework is installed, attach the location jigs to the top and bottom pad eyes. Set the proper height of the frames to the inside of the shell. (The critical measurement here is the overall height of the buoy, i.e., 36 inches.) All gaps between the internal bands and the lower fiberglass shell shall be filled with thixoputty. Apply a 3/8" alternating layer of mat and roving extending a minimum of 4 inches on each side of the band to secure the frame to the lower shell. Remove the upper alignment jig to install the upper shell for final assembly. Reattach and tighten, (to approximately 90 ft-lbs.), the alignment jigs top and bottom.

2. An additional 1/8" thickness of reinforcement must be applied to the inner and outer seams. Each 1/8 inch thickness band shall be approximately 14 inches wide consisting of chop, two layers of 1-1/2 OZ mat and two layers of unidirectional Roving. This additional thickness must be feathered into the adjacent areas not in excess of 3 inches on top and bottom to provide a smooth transition. All Voids shall be filled with thixoputty, and/or duraglass, and covered with a gel coat with surface agent then sanded to fair and re-gel coated as required. The entire finished surface of the buoy is to be coated with gel coat with an air inhibited polyester surface. To the top of the buoy, apply an 18-inch wide strip of 40-mesh sand with gel coat to give a nonskid texture.

3. Any voids or gaps that exist between the stainless plates on the outside of the buoy and the fiberglass must be filled with polyester thixoputty or duraglass. A smooth bead of polyurethane or polysulfide caulk shall be applied to where the stainless and fiberglass meet.

4. Fill the buoy with a single pour of approved foam and re-fiberglass the foam holes and re-apply the nonskid.

5. THE UPPER AND LOWER JIGS SHALL REMAIN SECURLY ATTACHED, USING 12 EA, 1" BOLTS, DURRING THE FOAMING

PROCESS AND SHALL REMAIN ATTACHED UNTIL FOAM HAS REACHED AMBIENT TEMPERATURE.

6. The entire buoy shall be covered with three coats of OCEAN GRAY paint (Fed. Std. 595, FS Color 26173).

URETHANE FOAM:

Foam Type: Burtin Corporation, BUC 400-2.0. MIL-P-26514 E TYPE II CLASS 1 and MIL-P-21929B or equal.

Foam shall have slow reactivity profile with low exotherm.

Free rise density: 1.8-2.2 PCF (ASTM D-1622) Density within buoy: NTE 2.4 PCF Closed Cell (min): 90% (ASTM D-1940) Compressive strength: 26.0 Psi parallel to rise, min 10 Psi perpendicular to rise at 72 deg. F. (ASTM-D-1621) Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0 % volume change at 158 degrees F. /100% R.H. (ASTM-2126) The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam process equipment shall have the capability to fill each buoy with a single pour, which shall be the required foaming technique.

ATLAS BUOY SPECIFICATIONS

STATEMENT OF WORK:

The contractor shall furnish the necessary personnel, material, equipment, services, shipping and facilities (except as otherwise specified), to perform the following statement of work/specifications.

BUOYS:

1. Provide all labor, materials and shipping to NDBC, Stennis Space Center, MS of 2.3 meter TAO oceanographic buoys as specified below and as indicated on attached drawings: TAO-001102.

2. The Buoy shall be fiberglass over foam, oceanographic buoy with type 316 L stainless steel framework and three (3) attachment points on top and bottom of buoy.

3. Upper and lower attachment points shall be made on jigs to ensure 120 degrees alignment, which will allow for interchangeability of existing buoy towers and bridles onto buoys.

4. Top and bottom jigs shall be securely bolted to buoy attachment points using 1" hardware (6x) in the top, and bottom jigs during all phases of fiberglass and foam fabrication. Bolts shall be tightened to approximately 90 lft-lbs. Jigs shall remain so attached while fiberglass and foam cool to room temperature.

FIBERGLASS:

1. The fiberglass lay-up shall be layered with a combination of bulk fiberglass, applied by chopper gun, and 24 OZ Roving. Equal bi-directional plus, minus, 45-degree strand material may be substituted for 24 OZ Roving. Resin to glass ratio shall be approximately 65 to 35.

2. A smooth surface inside mold shall be used to form the fiberglass skin within which the bulk of the fiberglass shall be laid up. This shall be the required technique with the objective of producing buoys of consistent size and shape. Buoys with a surface finish consisting of dips or waves of greater than 1/4" may be rejected. All transitions must be fully feathered.

3. Proper fiber glassing techniques shall be followed to prevent delamination during the lifetime of the buoy.

FRONT VIEW

SCALE 1 : 10

TOP VIEW

SCALE 1 : 10

ISOMETRIC VIEW

TOP RIGHT

SCALE 1 : 10

BOTTOM VIEW

SCALE 1 : 10

SECTION A-A

SCALE 1 : 10

TOP VIEW

SECTION CUT

SCALE 1 : 10

ISOMETRIC VIEW

SECTION CUT

SCALE 1 : 10

ISOMETRIC VIEW

BOTTOM RIGHT

SCALE 1 : 10

A A

B B

C C

D D

41D5C83-4581 FIBERGLASS, ROVING, 24 oz./yd.² x 50" FIBERGLASS SUPPLYAR 31C3BPL 4045-2 URETHANE FOAM BURTIN POLYMER LABORATORIES10623.815 in^3 23D7,3B75359T19 SHEET, METAL, .1875" x 36.00" x 96.00", 316 SST McMASTER-CARR1254.429 in^2

11D5526-A FIBERGLASS, CHOPPER GUN ROVING FIBRE GLASTAR

PARTS LIST

ITEMZONEPART/SPEC. NO.NDBC CONT. NO.DESCRIPTIONNOTESVENDORQTY.

A

A

SHEET 1 OF 4

APPROVED

ERIC GAY

NLS

LLOYD RABALAIS 8/28/2015

DWG NO

TAO-001411

TITLE

TAO FIBERGLASS BUOY INSERT

SIZE

D

REV

NATIONAL DATA BUOY CENTER

John C. Stennis Space Center

Stennis Space Center, Mississippi 39529

UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN INCHES

TOLERANCES

DECIMALS ANGULAR

.XX +/- .02 +/- 1°

.XXX +/-.002 .

DO NOT SCALE DRAWING

APPLICATION

-NO. HULL NO. NEXT ASSY. USED ON

NDBC PROJ. ENGINEER

NTSC ENGINEER

CHECKED

DRAWN

APPROVALS DATE

CONTRACT NO.

2/2/2016

1/2/2006

CHAIR, ENGINEERING REVIEW BOARD

CHANGE ORDER #

R. MOORE

EA133W-12-CN0050

E15-0033 3/17/2016

C. KOHLER 3/17/2016

TAO-001100 TAO

SCALE

NOTES:

BREAK ALL SHARP EDGES AND DEBURR EXPOSED WORK.

VENDOR MUST ADHERE TO ALL DIMENSIONS, AND TO THE SPECIFIED QUALITY OF

CONSTRUCTION. NO SUBSTITUTION OF SPECIFIED MATERIALS WILL BE ACCEPTED.

VENDOR IS PERMITTED TO PROPOSE CONSTRUCTION TECHNIQUES, WHICH WILL BE

REVIEWED BY NOAA ENGINEERS.

IMPORTANT: INSERT MUST FIT INTO TAO BUOY, TOP AND BOTTOM (2x/BUOY.)

.3125" MIN .375" MAX THICKNESS FIBERGLASS.

INSERT FIBERGLASS SHELL SECURED TO THE "REMOVABLE INSERT WELD ASSEMBLY"

PER "SOLID INSERT FIBERGLASS" (SHEET 4).

FILL VOID WITH URETHANE FOAM PER "SOLID INSERT URETHANE FOAM" (SHEET 4).

CABLE PASS THRU SHALL BE CENTERED ON BUOY PADEYE.

WELDING ROD SHALL BE TYPE 316L.

ENSURE AN ADDITIONAL .25 INCH FIBERGLASS REINFORCEMENT IS ADDED AT SEAMS

CONNECTING FIBERGLASS PIECES PER "SOLID INSERT FIBERGLASS" #4 (SHEET 4).

1.

2.

28.30

1.4

1 4

1.50

16.25~

7.402x ~

51.25 OD

1 2

27.76

7.502x ~

R15.08

3 6

1.30

5.00

1.30

5.00

10.00

17.633

(13.63) 17.33

11.50

R14.50

.50

3.50

BOTTOM VIEW

SCALE 1 : 4

ISOMETRIC VIEW

SCALE 1 : 4

FRONT VIEW

SCALE 1 : 4

A A

B B

C C

D D

SHEET 2 OF 4

DWG NO

TAO-001411

SIZE

D

REV

SCALE

120°

TYP

TYP

2 3

2 3

120°

REMOVABLE INSERT WELD ASSEMBLY

1 2

3x

31.50

TYP

TYP

SHEET METAL VIEW

HOLE AND SLOT PATTERN

SCALE 1 : 4

TOP VIEW

SCALE 1 : 4

ISOMETRIC VIEW

SCALE 1 : 4

SHEET METAL VIEW

MAJOR CUTS

SCALE 1 : 4

END VIEW

SCALE 1 : 4

SIDE VIEW

SCALE 1 : 4

ISOMETRIC VIEW

SCALE 1 : 4

A A

B B

C C

D D

SHEET 3 OF 4

DWG NO

TAO-001411

SIZE

D

REV

SCALE

17.00 ID THRU

23.00 OD

2 3

2 3

STEEL INSERTS

INTERNAL METAL RING

5.205.25 6.50

24.20 28.56

31.56

1.252x THRU PER SLOT

2 SLOTS TOTAL

1.00 THRU

.1875

.1875

8.63

2.803.00

7.37

11.00

8.50 11.50

14.75

R13.00

R16.00

R8.00 R11.00

R.254x

28.56 32.81

3.00

A A

B B

C C

D D

SHEET 4 OF 4

DWG NO

TAO-001411

SIZE

D

REV

SCALE

TAO BUOY SOLID INSERT SPECIFICATIONS:

SOLID INSERT FIBERGLASS:

1. THE FIBERGLASS LAY-UP SHALL BE LAYERED WITH A COMBINATION OF BULK FIBERGLASS, APPLIED BY CHOPPER GUNS, AND 24 OZ ROVING. EQUAL BI-DIRECTIONAL PLUS, MINUS, 45 STRAND MATERIAL MAY BE SUBSTITUTED FOR 24 OZ ROVING. RESIN TO GLASS RATIO SHALL BE APPROXIMATELY 65 TO 35.

2. A MOLD WITH A SMOOTH SURFACE SHALL BE USED TO FORM THE FIBERGLASS SKIN ON WHICH THE BULK OF THE FIBERGLASS SHALL BE LAID UP. THIS SHALL BE THE REQUIRED TECHNIQUE WITH THE OBJECTIVE OF PRODUCING PLATES OF CONSISTENT SHAPE AND SIZE. PLATES WITH A SURFACE FINISH CONSISTING OF DIPS OR WAVES OF GREATER THAN

.25 INCH MAY BE REJECTED. ALL TRANSITIONS MUST BE FULLY FEATHERED.

3. PROPER FIBER GLASSING TECHNIQUES SHALL BE FOLLOWED TO PREVENT DELAMINATION OF THE INSERT DURING THE LIFETIME OF THE BUOY.

4. AN ADDITIONAL .25 INCH THICKNESS OF REINFORCEMENT MUST BE APPLIED TO UPPER AND LOWER SEAMS (WHERE BUOY MEETS INSERT). EACH .25 INCH THICKNESS BAND SHALL BE APPROXIMATELY 5 INCH WIDE CONSISTING OF CHOP, TWO LAYERS OF 1.5 OZ MAT AND TWO LAYERS OF UNIDIRECTIONAL ROVING. THIS ADDITIONAL THICKNESS MUST BE FEATHERED INTO THE ADJACENT AREAS NOT IN EXCESS OF 3 INCHES ON TOP AND BOTTOM TO PROVIDE A SMOOTH TRANSITION. ALL VOIDS SHALL BE FILLED WITH THIXOPUTTY, AND/OR DURAGLASS, AND COVERED WITH A GEL COAT WITH SURFACE AGENT THEN SANDED TO FAIR AND RE-GEL COATED AS REQUIRED.

5. THE ENTIRE FINISHED SURFACE OF THE BUOY INSERT IS TO BE COATED WITH GEL COAT WITH AN AIR INHIBITED POLYESTER SURFACE. TO THE TOP OF THE BUOY AND INSERT, APPLY 40 MESH SAND A WITH GEL COAT TO GIVE A NON-SKID TEXTURE.

6. ANY VOIDS OR GAPS THAT EXIST BETWEEN THE STAINLESS PLATES ON THE OUTSIDE OF THE SOLID INSERT AND THE FIBERGLASS MUST BE FILELD WITH POLYESTER THIXOPUTTY OR DURAGLASS. A SMOOTH BEAD OF POLYURETHANE OR POLYSULFIDE CAULK SHALL BE APPLIED TO WHERE THE STAINLESS AND FIBERGLASS MEET.

7. THE ENTIRE INSERT SHALL BE COVERED WITH THREE COATS OF OCEAN GRAY PAINT (FED. STD. 595, FS COLOR 26173).

SOLID INSERT URETHANE FOAM:

FOAM TYPE: MIL-PRF-83671 CLASS 1 AND MIL-P-21929 OR EQUAL.

FOAM SHALL HAVE SLOW REACTIVITY PROFILE WITH LOW EXOTHERM.

FREE RISE DENSITY: 1.8-2.2 PCF (ASTM D-1622)

DENSITY WITHIN BUOY: NTE 2.4 PCF

CLOSED CELL (MIN): 90 (ASTM D-1940)

COMPRESSIVE STRENGTH: 26.0 PSI PARALLEL TO RISE, MIN 10 PSI PERPENDICULAR TO RISE AT 72 DEG. F. (ASTM-F-1621)

WATER ABSORPTION: 0.05 LBS POUNDS PER CUBIC FOOT

DIMENSIONAL STABILITY: MAX 8.0 VOLUME CHANGE AT 158 DEGREES F. /100 R.H. (ASTM-2126)

THE ENTIRE INSERT SHALL BE FILLED WITH A HOMOGENEOUS FOAM MIXTURE WITH NO VOIDS. FOAM PROCESS EQUIPMENT SHALL HAVE THE CAPABILITY TO FILL EACH BUOY WITH

A SINGLE POUR, WHICH SHALL BE THE REQUIRED FOAMING TECHNIQUE.