Attachment 08 - Spec. 450_G_Foam Buoys.pdf

United States Coast Guard

Shore Infrastructure Logistics Center

Waterways Operations Product Line

Specification for Fabrication of

Ionomer Foam Buoys

Specification No. 450

Revision G

December 2018

Specification 450G December 2018

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1. SCOPE

1.1 General. This specification describes the requirements for fabrication of lighted and unlighted ionomer foam buoys. The buoys will be used as aids to navigation in the navigable waters of the United States.

1.2 Buoy Classification. The buoys covered by this specification are classified as either lighted or unlighted. Lighted buoys are identified by their overall diameter and length and various design attributes. Unlighted buoys are identified by their class (2nd through 6th in descending order of size), shape, and design attributes. The type and description of the buoys covered by this specification are listed in Table I.

Table I Buoy Type and Description

Type Description 8x22LNFR 8x22 Lighted Nun Foam Radar Reflective 8x22LCFR 8x22 Lighted Can Foam Radar Reflective

6x16LNFR 6x16 Lighted Nun Foam Radar Reflective 6x16LCFR 6x16 Lighted Can Foam Radar Reflective

5x9LNFR 5x9 Lighted Nun Foam Radar Reflective 5x9LCFR 5x9 Lighted Can Foam Radar Reflective

2NFR 2nd Class Nun Foam Radar Reflective 2CFR 2nd Class Can Foam Radar Reflective

3NFR 3rd Class Nun Foam Radar Reflective 3CFR 3rd Class Can Foam Radar Reflective 3FWNFR 3rd Class Fast Water Nun Foam Radar Reflective 3FWCFR 3rd Class Fast Water Can Foam Radar Reflective

4NFR 4th Class Nun Foam Radar Reflective 4CFR 4th Class Can Foam Radar Reflective 4FWNFR 4th Class Fast Water Nun Foam Radar Reflective 4FWCFR 4th Class Fast Water Can Foam Radar Reflective

5NFR 5th Class Nun Foam Radar Reflective 5CFR 5th Class Can Foam Radar Reflective 5FWNFR 5th Class Fast Water Nun Foam Radar Reflective 5FWCFR 5th Class Fast Water Can Foam Radar Reflective

6NFR 6th Class Nun Foam Radar Reflective 6CFR 6th Class Can Foam Radar Reflective 6NTFR 6th Class Nun Tall Foam Radar Reflective 6CTFR 6th Class Can Tall Foam Radar Reflective

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2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are referenced in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification which are recommended for additional information or used as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3 and 4 of this specification, whether or not the referenced documents are listed here.

2.2 Coast Guard Documents. The latest revisions of the following United States Coast Guard Waterways Operation Product Line (WOPL) documents form a part of this specification to the extent referenced herein.

Specifications

374 Fabrication of Aluminum Radar Reflectors 393 High Intensity Retroreflective Films 460 Fabrication of Buoy Solar Battery Boxes

2.3 Government Documents. The latest revisions of the following Government documents form a part of this specification to the extent referenced herein.

Specifications

MIL-PRF-24647 Paint System, Anticorrosive and Antifouling, Ship Hull QPL-24647 Qualified Products List of Products Qualified Under Military

Standard

SAE-AMS-STD-595 Colors Used in Government Procurement

2.4 Industry Publications. The latest revisions of the following Industry documents form a part of this specification to the extent referenced herein.

American Society for Testing and Materials (ASTM)

A36 Standard Specification for Carbon Structural Steel A153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware A314 Standard Specification for Stainless Steel Billets and Bars for Forging A666 Standard Specification for Annealed or Cold Worked Austenitic

Stainless Steel Sheet, Strip, Plate and Flat Bar B209 Standard Specification for Aluminum and Aluminum-Alloy Sheet and

Plate B221 Standard Specification for Aluminum and Aluminum-Alloy Extruded

Bars, Rods, Wire, Profiles, and Tubes D1630 Standard Test Method for Rubber Property-Abrasion Resistance

(Footwear Abrader)

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D2240 Standard Test Method for Rubber Property-Durometer Hardness D3575 Standard Test Methods for Flexible Cellular Materials Made from

Olefin Polymers G155 Standard Practice for Operating Xenon Arc Light Apparatus for

Exposure of Non-Metallic Materials

American Welding Society (AWS)

ANSI/AWS D1.1 Structural Welding Code – Steel ANSI/AWS D1.2 Structural Welding Code – Aluminum

American Society for Quality (ASQ)

ASQ/ANSI/ISO Q9001 Quality Management Systems - Requirements

Steel Structures Painting Council (SSPC)

SSPC-SP-6/NACE No. 3 Surface Preparation-Commercial Blast Cleaning SSPC-SP-10/NACE No. 2 Surface Preparation-Near White Blast Cleaning

International Commission on Illumination (CIE)

CIE No. 15 Colorimetry, Third Edition

2.5 Drawings. The latest revisions of the following United States Coast Guard Waterways Operation Product Line (WOPL) drawings form a part of this specification to the extent referenced herein, and shall be referred to as “the drawings” throughout this specification.

Drawing No. Title 120316 Nun Shape Aluminum Radar Reflector 121024 Can Shape Aluminum Radar Reflector 121100 Solar Buoy Double Battery Box 121148 1991 Type 5x9LCFR and 5x9LNFR Buoys 121166 2CFR and 2NFR Unlighted Foam Buoys 121167 3CFR and 3NFR Unlighted Foam Buoys 121168 4CFR and 4NFR Unlighted Foam Buoys 121169 5CFR and 5NFR Unlighted Foam Buoys 121170 5FWCFR and 5FWNFR Unlighted Foam Buoy 121171 6CFR and 6NFR Unlighted Foam Buoys 121181 6CTFR and 6NTFR Unlighted Foam Buoys 121184 2007 Type 6x16LFR Buoy 121185 2007 Type 8x22LFR Buoy 121187 4FWCFR and 4FWNFR Unlighted Foam Buoy 121202 3FWCFR and 3FWNFR Unlighted Foam Buoy 121204 2nd Class Foal Buoy Lantern Bracket 121205 2018 Type 5x9LCFR and 5x9LNFR Buoys

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2.6 Source of Documents. The documents may be obtained from the following sources:

Coast Guard WOPL Documents Commander U.S. Coast Guard Shore Infrastructure Logistics Center Waterways Operations Product Line 300 East Main Street Norfolk, VA 23510-9104

Government Documents Defense Printing Service Detachment Office Building 4 (NPM-DODSSP) 700 Robbins Avenue Philadelphia, PA 19111-5094 http://quicksearch.dla.mil/

Industry Publications American Society for Testing and Materials (ASTM) 100 Barr Harbor Drive P.O. Box 700 West Conshohocken, PA 19428-2959 https://www.astm.org/

American Welding Society (AWS) 8669 NW 36 Street, #130 Miami, FL 33166-6672 https://www.aws.org/

American Society for Quality Control (ASQ) 600 North Plankinton Avenue Milwaukee, WI 53203-2914 https://asq.org/

American Society for Non-Destructive Testing (ASNT) 1711 Arlingate Lane Columbus, OH 43228-4116 https://www.asnt.org/

Steel Structures Painting Council (SSPC) 40 24th Street, Suite 600 Pittsburg, PA 1522-4605 http://www.sspc.org/ http://quicksearch.dla.mil/ https://www.astm.org/ https://www.aws.org/ https://asq.org/ https://www.asnt.org/ http://www.sspc.org/

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United States National Committee of the CIE c/o Ronald B. Gibbons, Virginia Tech Transportation Institute 3500 Transportation Research Place Blacksburg, VA 24061 http://www.cie-usnc.org/

2.7 Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 General. The buoys shall be fabricated in accordance with the drawings and shall meet the requirements of this specification. The buoys shall be manufactured from ionomer foam and shall have steel and aluminum hardware.

3.2 Materials.

3.2.1 Ionomer Foam. Ionomer foam used in the buoys shall be made of Surlyn ionomer resin 9720 or 9721 (Surlyn is a registered trademark of the DuPont Company) or Iotek ionomer resin 7020 or 7030 (Iotek is a registered trademark of the Exxon Chemical Company). The ionomer foam shall consist of an expanded structure of individual non-connecting cells. The cells shall be closed, with the exception of those on the periphery of each foam piece that may be cut or broken during fabrication. The Contractor may use re-pelletized virgin ionomer foam (not to exceed 25%) in the fabrication of ionomer foam. The resultant ionomer foam shall be subjected to the entire battery of First Article Tests at the Contractor’s expense. Re-pelletized virgin ionomer foam material may be used in the buoys if the resultant ionomer foam passes all performance requirements as described in Table IV.

3.2.1.1 Method of Fabrication. The foam shall be extruded into colored sheets having a density of at least 4 pounds per cubic foot (pcf) and be between 1/8” and 3/8” thick. The extruded sheets shall be spirally wrapped into the cylindrical shapes as shown on the drawings. Each layer shall be continuously heat sealed onto the previous layer over the entire length and circumference of the shape. The conical upper portion of the nun buoys shall be made by trimming or cutting the cylinders into the required shapes shown on the drawings. The completed foam sections of the buoys shall be free from cracks, holes, gouges, and embedded foreign material.

3.2.1.2 Protective Outer Skin. The entire circumference of each buoy shall have a protective outer skin. This outer skin shall be a denser composition of the inner foam layers. This skin shall be produced by “densifying” the outer surface of the buoy by extracting gas from the foam using a combination of pressure and heat. The resulting high density, pigment-rich outer skin shall have a minimum density of 30 pcf and a http://www.cie-usnc.org/

- 6 -thickness between 1/4” and 5/16”. The final diameter of the finished hull shall be as specified in the drawings.

3.2.1.3 Protective End Caps. The ends of the cylinders shall have a densified outer skin identical to that described in paragraph 3.2.1.2. This shall be accomplished by heat welding 4 pcf foam sheets to the top and bottom of the cylindrical shapes prior to densification. These sheets shall be cut to the pre-densified buoy diameter so that they are rolled over the circumferential edges to form a fortified shoulder during densification.

The end caps shall be identical in properties and color to the interior foam used to fabricate the cylindrical shapes and shall likewise have a density of 30 pcf with a thickness between 1/4” and 5/16”.

3.2.1.4 Final Densification. Final densification and heat compacting of all surfaces shall be performed to properly finish and fortify the ends, shoulders, and sides of the cylindrical shapes.

3.2.1.5 Color. The completed spirally wrapped foam parts shall be comprised of layers of foamed sheets conforming to the colors of SAE-AMS-STD-595 as shown in Table II.

Pigments shall be added to the foam during the sheet extrusion process and the colors shall be continuous throughout the entire volume of the foam. The colors shall be within the appropriate chromaticity region specified in Table III and shall remain within this region after continuous exposure to the sun for at least 8 years. Buoys with special color requirements are described in paragraph 3.3.7.

Table II SAE-AMS-STD-595 Colors

Red 11350 Coast Guard Buoy Red Green 14193 Coast Guard Green Dark Green 14062 Deep Green/Dark Green Yellow 13655 Blue Angels Yellow/OSHA Safety Yellow White 17875 Insignia White/ANA 515

Table III Chromaticity Regions

1 2 3 4 x y x y x y x y y

Red 0.690 0.310 0.595 0.315 0.569 0.341 0.655 0.345 10-15

Green 0.275 0.550 0.275 0.450 0.225 0.450 0.225 0.550 12-24

Dark Green 0.280 0.450 0.260 0.300 0.245 0.300 0.240 0.450 1-5

Yellow 0.522 0.477 0.470 0.440 0.427 0.483 0.465 0.534 48-60

White 0.350 0.360 0.300 0.310 0.290 0.320 0.340 0.370 80-95

Note: Coordinates shall be plotted on CIE 1931 color space. Make colorimetric measurements using 45/0 geometry, a 2 degree observer, and CIE standard illuminant D65. (CIE No. 15)

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3.2.1.5.1 Ultraviolet Stabilization. Ultraviolet stabilizers shall be added to the ionomer resin to enhance color retention and to protect the foam from degradation due to continuous exposure to the sun. These stabilizers shall provide ultraviolet protection for a minimum of 8 years.

3.2.1.6 Impact Resistance. The buoy shall be able to withstand the test described in paragraph 4.4.3.3 without sustaining any permanent damage such as cracks, tears, delaminations, separations, or gouges.

3.2.1.7 Colorfastness. After being subjected to the colorfastness test described in paragraph 4.4.1, the color of the foam shall remain within the appropriate chromaticity regions specified in Table III. The colorfastness test will be performed in accordance with ASTM G155, Table X 3.1, Cycle 7.

3.2.1.8 Density. Density of the foam shall be as specified in Table IV when tested in accordance with ASTM D3575, Suffix W, Method A.

3.2.1.9 Tensile Strength. Tensile strength of the foam, when measured in the horizontal, vertical, and radial directions, shall be as specified in Table IV when tested in accordance with ASTM D3575, Suffix T.

3.2.1.10 Tear Strength. Tear strength, measured in the horizontal, vertical, and radial directions, shall be as specified in Table IV when tested in accordance with ASTM D3575, Suffix G.

3.2.1.11 Compression Set. Compression set of the foam shall be as specified in Table IV when tested in accordance with ASTM D3575, Suffix B.

3.2.1.12 Compression Load Deflection. Compression load deflection of the foam shall be as specified in Table IV when tested in accordance with ASTM D3575, Suffix D.

3.2.1.13 Hardness. Hardness of the protective outer skin shall be as specified in Table IV when tested in accordance with ASTM D2240.

3.2.1.14 Abrasion Resistance. Abrasion resistance of the protective outer skin shall be as specified in Table IV when tested in accordance with ASTM D1630.

3.2.1.15 Water Absorption. Water absorption of the foam shall be as specified in Table IV when tested in accordance with paragraph 4.4.2.

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Table IV Performance Requirements

Parameter Test Method Required Value

Colorfastness G155, Table X 3.1, Cycle 7 As specified in Table III

Density D3575, Suffix W, Method A 4.0 ± 0.5 pcf

Tensile Strength D3575, Suffix T Vertical - 150.0 psi min Horizontal - 75.0 psi min Radial - 90.0 psi min.

Tear Strength D3575, Suffix G Vertical - 35.0 psi min Horizontal - 20.0 psi min Radial - 45.0 psi min.

Compression Set D3575, Suffix B 25.0% max.

Compression Load D3575, Suffix D Radial to 75% - 7.5 psi min

Hardness D2240 60 ± 5

Abrasion Resistance D1630 100 min.

Water Absorption Paragraph 4.4.2 15.0% max.

3.2.2 Steel. Steel bars, shapes, and plates shall meet the requirements of ASTM A36.

3.2.3 Stainless Steel.

3.2.3.1 Stainless Steel Sheet, Plate, Strip, and Bar. Stainless steel sheet, plate, strip, and bar, shall meet the requirements of ASTM A666, type 316 or 316L.

3.2.3.2 Stainless Steel Hardware. Stainless steel hardware (nuts, bolts, pins, swing bolts, etc.) shall meet the requirements of ASTM A314, type 316 or 316L.

3.2.4 Aluminum.

3.2.4.1 Aluminum Plate and Sheet. Aluminum plate and sheet shall meet the requirements of ASTM B209, Alloy 5086 H32.

3.2.4.2 Aluminum Rod. Aluminum rod shall meet the requirements of ASTM B221, Alloy 5086 H111.

3.3 Design and Construction.

3.3.1 Design, Dimensions, and Dimensional Tolerances. All portions of the buoy shall conform to the design, dimensions, and tolerances as shown in the drawings.

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3.3.2 Threads. The threads on all nuts and bolts shall be Unified Course Thread Series

(UNC).

3.3.3 Welding. The plates, bars, and shapes that form the various components of the buoy shall be fitted and faired prior to being welded in place. All welds shall be as indicated on the drawings.

3.3.3.1 Steel Welding. Shielded Metal Arc Welding (SMAW), Flux-Cored Arc Welding (FCAW), Gas Metal Arc Welding (GMAW), or Submerged Arc Welding (SAW) shall be used to weld the steel parts of the buoys. All welding procedures and weld quality for steel, shall meet the requirements of AWS D1.1. All welders employed for welding under this specification shall be qualified by the Contractor using procedures which meet the requirements of AWS D1.1.

3.3.3.2 Aluminum welding. Gas Metal Arc Welding (GMAW) shall be used to weld the aluminum parts of the buoys. All welding procedures and weld quality for aluminum, shall meet the requirements of AWS D1.2. All welders employed for welding under this specification shall be qualified by the Contractor using procedures which meet the requirements of AWS D1.2.

3.3.4 Buoy Serial Numbers. Each buoy shall be identified by its own unique serial number. The serial number shall be of the form 5X9LNFR-18-01-XX (or 2NFR-18-08- XX). The first group of characters represents the buoy type (see paragraph 1.2), the next two digits are the last two digits of the calendar year, the next digits are the sequential number of the buoy as manufactured, and the final two letters are the Contractor’s designation which will be furnished by the Contracting Officer after contract award. In addition, the letters "USCG" shall be applied to the buoy. All buoy bodies shall have the serial numbers engraved or melted into the foam on top of the buoy body (see paragraph 3.3.4.1). In addition the serial numbers being engraved it to the buoy body, the 8x22LFR, 6x16LFR, 5x9LFR; 2nd class; and 3rd class buoys shall have the serial numbers welded on to the center plate (see paragraph 3.3.4.2). Each type of buoy shall have its own sequential number series, (i.e., 2NFR buoys shall have a separate sequence of numbers from 2CFR buoys). For example, the eighth 2nd class nun foam buoy built in 2018 would be marked “2NFR-18-08-XX” and the eighth 2nd class can foam buoy built in 2018 would be marked “2CFR-18-08-XX”.

3.3.4.1 Engraved Serial Numbers. All foam buoys shall have the serial numbers engraved or melted into the foam on top of the buoy body. The characters shall be 2 inches tall and the depth of the markings shall be a minimum of 1/8 inch. Buoys shall be permanently engraved with two lines of alphanumeric characters. The first line shall be the letters “USCG”. The second line shall consist of the following serial number as described in paragraph 3.3.4. Below is an example:

USCG

5X9LNFR-18-01-XX

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3.3.4.2 Welded Serial Numbers. In addition to the serial number being engraved into the foam buoy body, the 8x22LFR, 6x16LFR, 5x9LFR; 2nd class; and 3rd class buoys shall have serial numbers welded on to the center plate. The characters shall be not less than 1” in tall and the weld bead shall be 1/8” high. The serial number shall be welded on to one corner of the steel top plate and “USCG” shall be welded on to the opposite corner.

3.3.5 Radar Reflectors

3.3.5.1 Internal Radar Reflectors. The internal radar reflectors shall be Mobri Marine M3 or M4 or equivalent, as specified in the drawings. Radar reflectors shall be installed inside the buoy foam daymarks by inserting them into preformed slots of the appropriate size. The slots may be either cut or melted into the can or nun daymark, as shown on the drawings. A plug of foam shall be inserted to completely and snugly fill the gap between the bottom of the radar reflector and the outer surface of the buoy body.

3.3.5.2 External Radar Reflector. The external radar reflectors required for the 1991 Type 5x9LFR, 6x16LFR and 8x22LFR shall be manufactured in accordance with the drawings. The foam radar panels for the 6x16LFR and 8x22LFR shall be accomplished by heat welding 4 pcf ionomer foam sheets together with aluminum foil layered inside to provide the required radar reflectivity.

3.3.6 Retroreflective Material. Each buoy shall have retroreflective material attached as shown in the drawings and its color shall match the color of the buoy. The retroreflective material shall be applied in continuous sheets and shall not be spliced.

The retroreflective material shall meet the requirements of Coast Guard WOPL Specification No. 393.

3.3.7 Special Color Requirements.

3.3.7.1 Safe Water Buoy. A Safe Water Buoy shall consist of eight alternating red and white vertical stripes as described below. The retroreflective material shall be white.

3.3.7.1.1 Safe Water Markings for Radar Panel Buoys. The 6x16LFR and 8x22 LFR buoys shall have the ionomer foam radar reflector panels colored so that the vertical red and white segments bisect the 90-degree angle of the radar panels. The aluminum section of the buoy towers on the 6x16LFR and 8x22LFR shall be painted red. The buoy body shall consist of densified red and white foam segments covering 45 degrees of arc each. These segments shall cover the outer circumference of the buoy hull with the top surface of the buoy hull being white. The red and white sections of radar reflector and foam buoy body shall be aligned to show the same color.

3.3.7.1.2 Safe Water Markings for Foam Daymarks. The can shaped daymark shall be used for the unlighted safe water buoy. The buoy body and daymark shall consist of eight red and white foam segments covering 45 degrees of arc each. These segments

- 11 -shall cover the outer circumference of the buoy hull and daymark with the top surface of the hull and daymark being white. The red and white foam sections of buoy body and daymark shall be aligned to show the same color.

3.3.7.2 Preferred Channel Buoy. A Preferred Channel Buoy shall consist of three horizontal red and green bands as described below. The bands shall be either red/green/red or green/red/green with the top and bottom band designated the primary color and the middle band as the secondary color. The retroreflective material shall be of the primary color. The designation of the primary and secondary colors will be specified in the delivery order.

3.3.7.2.1 Preferred Channel Markings for Radar Panel Buoys. The 6x16LFR and 8x22LFR buoys shall be configured as follows: The top half of the ionomer foam radar reflector panels shall be colored the primary color; the bottom half of the ionomer foam radar reflector panels shall be colored the secondary color; the aluminum framing on the radar reflector tower section shall be painted to correspond with the ionomer foam color:

the primary color on the top half and the secondary color on the bottom half; the steel and aluminum sections above the foam buoy body (including the battery box) shall be painted the secondary color; and the foam buoy body shall consist of the primary color.

3.3.7.2.2 Preferred Channel Markings for Foam Daymarks. The buoy body shall consist of the primary color. The buoy daymark shall consist of two foam pieces heat welded together to form a single unit. On the nun-shaped daymark, the primary color shall extend from the top of the buoy to approximately 2” below the shoulder of the conical section. The secondary color shall consist of the remaining portion of the cylindrical section of the daymark. The can-shaped daymark shall consist of equivalent portions of primary and secondary color as that of the nun buoy, as shown on the drawings.

3.3.7.3 Special Markings. When specified in the delivery order, buoys shall be provided with special markings. These include symbols, legends, and retroreflective bands applied to the buoy top as described below. Examples of standard marking configurations are listed in Table V. The specific combination of symbols, legends, and retroreflective bands required for a given buoy will be specified in each delivery order.

3.3.7.3.1 Symbols. As specified in the delivery order, symbols shall be a circle, a diamond, or a diamond with a cross in the middle. The symbols shall be fabricated from sheets of retroreflective material meeting the requirements of Coast Guard WOPL Specification No. 393. The outlines of the symbols forming the shape of the circle and rectangle (and the cross within the rectangle) shall be 2 inches wide and orange in color (SAE-AMS-STD-595 color number 12197). The interior blank space of the symbols shall be white.

3.3.7.3.2 Legends. Legends shall consist of characters placed either above, below, or to the side of the symbols. The characters shall be black in color, upper case, and 3 inches in height with a bold Helvetica type font. The actual wording required for a given buoy will be specified in the delivery order.

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3.3.7.3.3 Retroreflective Bands. When specified in the delivery order, two continuous bands of 2-inch wide orange retroreflective material shall be placed around the circumference of the buoy, once below and one, above the legend and symbol. The retroreflective material shall meet the requirements of Coast Guard WOPL Specification No. 393, and the color shall be SAE-AMS-STD-595 number 12197.

Table V Special Markings – Standard Configurations

Symbols Legends

Orange Circle CONTROLLED AREA

Orange Diamond HAZARD WARNING

Orange Diamond with Cross RESTRITED AREA/EXCLUSION

Orange Diamond DANGER SHOREWARD

Orange Diamond with Cross COAST GUARD SECURITY ZONE KEEP OUT

3.4 Additional Equipment.

3.4.1 Solar Battery Box. When specified in the delivery order, the Contractor shall delivery an 8x22LFR or 6x16LFR with a solar battery box. The solar battery box shall be fabricated in accordance with Coast Guard WOPL Specification No. 460 and Drawing 121100. The solar battery box shall be painted the same color as the buoy it is to be attached too. The solar battery box shall be attached to the bell stand after the buoy has been painted

3.4.2 LED Lantern Bracket. When specified in the delivery order, the Contractor shall delivery a 2nd Class buoy with a LED lantern bracket. The LED lantern bracket shall be fabricated in accordance with Coast Guard WOPL Drawing 121204.

3.5 Surface Preparation. All metal surfaces shall be cleaned of contaminants such as oil, water grease, dust, dirt weld splatter and slag to achieve surface profile of 1.5 to 2.5 mils.

3.5.1 Steel Surface Preparation. All steel surfaces shall be blast cleaned to near white metal in accordance with SSPC-SP-10.

3.5.2 Aluminum Surface Preparation. All aluminum surfaces shall be blast cleaned in accordance with SSPC-SP-6. The Contractor shall:

Use non-metallic abrasive such as aluminum oxide or garnet. Blasting aluminum with steel grit will create galvanic issues.

Coat the aluminum within 6 hours of blasting, otherwise aluminum oxide formations will begin.

3.6 Coating System. The buoy coating system shall consist of a protective finish for the steel and aluminum components plus an antifouling paint (when specified) for the

- 13 -underwater portion of the buoy. The steel and aluminum components shall be coated as described below.

3.6.1 Hot-Dip Galvanizing. All steel parts (with the exception of stainless steel bolts and threaded rods) on the 4th, 5th, 6th class and all fast water buoys shall be hot-dip galvanized in accordance with ASTM A153.

3.6.2 Painting. All steel surfaces (with the exception of stainless steel bolts and threaded rods) on the 8x22LFR, 6x16LFR, 5x9LFR, 2nd class, and 3rd class buoys shall be painted with the epoxy primer described in paragraph 3.6.2.1. All steel surfaces above the waterline shall be coated with the marine grade acrylic aliphatic polyurethane described in paragraph 3.6.2.2. In addition, when specified in the delivery order, an ablative antifouling paint shall be applied below the water line as described in paragraph

3.6.2.3. All painting shall be performed after the buoy has been cleaned as specified in paragraph 3.5. The paints in the coating system are commercial products available from a variety of manufacturers. However, they shall be applied as a complete system;

i.e., all of the paints used on any given buoy (primer, topcoat, and antifouling) shall be from the same manufacturer. The Contractor shall follow the manufacturer’s instructions for mixing, induction, application, and curing of the paint. Sharp corners, edges, and other hard-to-coat areas shall be striped before each full coat is applied.

3.6.2.1 Epoxy Primer. The epoxy primer shall meet the requirements of MIL-P-24647, Type I, Class 1A, Grade A or B, Application 1 or 2, and shall be listed on the latest edition of QPL-24647. The colors shall be haze gray, off-white or buff (manufacturers’ standard colors are acceptable). Apply by spraying two coats, 5 mils dry film thickness each, using contrasting colors for each coat (e.g. off-white or buff followed by haze gray).

3.6.2.2 Polyurethane Topcoat. This paint shall meet the following requirements: it shall have a Volatile Organic Compound (VOC) content of no more than 340 g/L (2.8 lb./gal), a lead content of less than 0.06% by weight, and a chromium content of less than 0.06% by weight. The required colors (as specified in the delivery order) shall be in accordance with SAE-AMS-STD-595 as shown in Table II. Apply by spraying one coat, 3 mils dry film thickness.

3.6.2.3 Ablative Antifouling Paint. When specified, an ablative antifouling paint shall be applied below the waterline to the foam hull section on all classes of buoy plus the underwater steel components on the 8x22 LFR, 6x16 LFR, 5x9 LFR, 2nd class, and 3rd class buoys. This ablative antifouling paint shall meet the requirements of MIL-P- 24647, Type I, Class 1A, Grade A or B, Application 1 or 2, and shall be listed in QPL- 24647. The colors required are red and black (manufactures standard colors are acceptable). Apply by spraying two coats, 5 mils dry film thickness each, using contrasting colors for each coat (black followed by red). This anti-fouling paint shall not be applied to the galvanized steel components on the 4th, 5th, 6th class and all fast water buoys.

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3.7 Documentation.

3.7.1 Material Certifications. When requested by the Contracting Officer’s Representative (COR), the Contractor shall furnish material certifications, either from the material manufacturers or an independent testing laboratory, to the effect that all of the material described in paragraphs 3.2.2 through 3.2.4 have been tested and found to meet the requirements of the applicable sections of this specification. Each material certification shall be assigned a reference number by the Contractor.

3.7.2 Material Inspection and Receiving Report (DD Form 250). A form DD-250 shall be used as a certification of product quality assurance, as a packing list, and as a certification of acceptance. A separate DD-250 shall be prepared by the Contractor for each shipping lot. Prior to shipment, the DD-250 must be signed by the COR.

4. VERIFICATION

4.1 General. The Contractor shall establish a quality assurance program prior to commencing production of buoys. This quality assurance program shall conform to the requirements of ASQ Q9001 and the Contractor shall maintain and adhere to these requirements throughout the length of the contract. The Contractor DOES NOT have to be Q9001 certified.

4.1.1 Quality Manual. The Contractor shall maintain a Quality Manual and provide access to the procedures, instructions, records, and test results required by ASQ Q9001. These documents shall describe the Contractor’s quality control organization, the inspections and tests which the Contractor intends to perform, and the methods by which the Contractor will identify and correct defects in the buoys and in the buoy production process.

4.2. First Articles. The Contractor shall provide the following as first articles for inspection:

a. Material certifications as specified in paragraph 3.7.1.

b. One 3NFR buoy, complete with all steel members and fasteners.

c. The ionomer foam samples listed in Table VI for the tests described in paragraphs 3.2.1.7 through 3.2.1.15.

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Table VI First Article Foam Samples

Test Size Density Quantity Colorfastness 6” x 6” x 0.25” 30 pcf 2 red

2 yellow 2 dark green 2 light green 2 white

Density 1” x 1” x 1” 4 pcf 30 pcf

Tensile Strength 6” x 1.6” x 0.13” (die A cut)

4 pcf 5 - horizontal direction 5- vertical direction 5 - radial direction

Tear Strength 6” x 1.6” x 0.13” (die C cut)

4 pcf 5 - horizontal direction 5- vertical direction 5 - radial direction

Compression Set 2” x 2” x 1” 4 pcf 5

Compression Load Deflection

4” x 4” x 1” 4 pcf 5

Hardness 2” x 2” x 0.25” 30 pcf 5

Abrasion Resistance 1” x 1” x 0.25” 30 pcf 5

Water Absorption Cylinder 6” x 1.5” x 12”

4 pcf 30 pcf outer skin

4.3 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. First article inspection (paragraph 4.4)

b. Contractor production inspection (paragraph 4.5)

c. Coast Guard production inspection (paragraph 4.6)

4.4 First Article Inspection. The Contractor shall conduct tests on the first article 3NFR buoy as described in paragraph 4.4.3 (and all associated subparagraphs). The Contractor shall employ an independent testing laboratory to conduct tests on the first article foam samples as described in paragraphs 3.2.1.7 through 3.2.1.15, 4.4.1, and 4.4.2.

4.4.1 Colorfastness. Samples shall be prepared in accordance with the test procedure described in paragraph 3.2.1.7 and exposed for the required period of time in a weatherometer. The weathering cycle shall be 40 minutes of light, followed by 20 minutes of light with front water spray, 60 minutes of light, followed by 60 minutes of dark with front and back water spray.

Parameters for the test cycle shall be as follows:

Filters: Quartz Inner and Type S Borosilicate Outer Irradiance: 0.55 W/m2 @ 340 nm Black Panel Temperature: 70°C (light cycle), 38°C (dark cycle) Dry Bulb Temperature: 47°C (light cycle), 38°C (dark cycle) Relative Humidity: 50% (light cycle), 95% (dark cycle)

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Samples that do not meet the requirements of paragraph 3.2.1.5 after 2000 hours of testing will be considered to have failed.

4.4.2 Water Absorption Test. The two cylindrical samples shall be weighed and then completely submerged in water for a continuous period of 72 hours. All portions of the samples shall be at least six feet below the surface of the water. The samples shall then be recovered, dried off, and re-weighed within two hours of recovery from the water. The weight gain shall be no greater than 15 percent of the original dry weight.

Samples that do not meet this requirement will be considered to have failed the test.

4.4.3 First Article 3NFR Buoy Inspection. First article inspection and testing of the completed buoy shall be at the Contractor’s facility and will be witnessed by the COR.

Upon completion of the impact resistance test and heat seal inspection, the buoy shall meet the requirements of paragraph 3.2.1.6 or it will be considered to have failed the inspection.

4.4.3.1 Visual Inspection. Prior to conducting the impact resistance test and heat seal inspection described below, the buoy shall be visually inspected for quality workmanship and conformance to this specification and the drawings. The inspection shall include surface finish of the foam, dimensions, marking, mechanical fit, part alignment, surface preparation, and painting.

4.4.3.2 Welds. Welds shall be visually inspected for quality in accordance with AWS D1.1 and D1.2. Weld inspections shall be performed prior to hot-dip galvanizing or application of paint.

4.4.3.3 Impact Resistance Test. The first article buoy shall be dropped onto a paved surface from a height of ten feet in both a horizontal and diagonal orientation. The test shall be performed twice in the horizontal and twice in the diagonal orientation.

4.4.3.4 Heat Seal Inspection. Once the buoy passes the impact resistance test above, the Contractor shall disassemble the buoy and, at the discretion of the COR, cut it into various sections radially, vertically, or horizontally. The buoy shall then be inspected for quality of the heat seals, integrity of the lamination, and adhesion of the foam layers.

The Contractor may re-use the metal hardware for future production buoys.

4.4.4 Material Certifications Inspection. The Contractor shall ensure that all materials used in the first articles meet the requirements of this specification. Material certifications required by paragraph 3.9 shall be maintained at the Contractor’s plant and be available for review by the COR. First articles that do not meet the material requirements of this specification will be considered to have failed the inspection.

4.4.5 First Article Test Report. The Contractor shall submit a test report after the completion of first article tests and inspections. The report shall include the results of all first article tests and inspections required by this specification, as well as copies of the

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4.5 Contractor Production Inspection. The Contractor shall perform all the inspections and tests as specified in paragraphs 4.5.1 through 4.5.3 to ensure conformance to this specification. The Contractor shall provide space, personnel, and test equipment to conduct all inspections and tests as required. The inspections required by this specification are not intended to supplant any controls, inspections, or tests normally used by the Contractor to assure product quality.

4.5.1 Visual Inspection. All buoys shall be visually inspected for quality of workmanship and conformance to the specification and drawings. The inspection shall include surface finish of the foam, dimensions, marking, mechanical fit, part alignment, surface preparation, and painting.

4.5.2 Welds. Welds shall be visually inspected for quality in accordance with AWS D1.1 and D1.2. Weld inspections shall be performed prior to hot-dip galvanizing or application of paint.

4.5.3 Material. The Contractor shall ensure that all materials used in the production buoys conform to the requirements of this specification, and shall maintain material certifications for review by the COR as required in paragraph 3.7.1.

4.6 Coast Guard Production Inspection. The Coast Guard will periodically verify quality of production buoys by performing the inspections described in paragraphs 4.6.1 through 4.6.4.

4.6.1 Visual Inspection. All buoys shall be visually inspected for quality of workmanship and conformance to the specification and drawings. The inspection shall include surface finish of the foam, dimensions, marking, mechanical fit, part alignment, surface preparation, and painting.

4.6.2 Welds. Welds shall be visually inspected for quality in accordance with AWS D1.1 and D1.2. Weld inspections shall be performed prior to hot-dip galvanizing or application of paint.

4.6.3 Material Certification Inspection. The COR will review the material certifications required by paragraph 3.7.1 for conformance with this specification. If any material fails to meet the requirements of this specification, each item made from the material will be rejected.

4.6.4 Foam Sample Inspection. At the COR’s discretion, the Coast Guard will perform the tests described in paragraphs 3.2.1.7 through 3.2.1.15, taking test samples from production buoys. The Coast Guard will bear the costs of these foam inspections. If the foam fails any of the tests described, the entire lot will be rejected and shall not be resubmitted. The term “lot” shall refer to all buoys made from the same batch of ionomer resin.

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5. PACKAGING.

5.1 Packaging. Packaging requirements are specified in Section D, Part I, Contract Schedule.

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Specification for Fabrication of Ionomer Foam Buoys

Specification No 450G

December 2018

Prepared by: Reviewed by:

Sean McEvoy LT Rudy Bowis Asset Line Engineer Asset Line Manager Waterway Operations Product Line Waterway Operations Product Line Fixed and Floating Asset Line Fixed and Floating Asset Line

Approved:

_____________________________ 10 December 2018___________________ Mr. Wayne Danzik Date Deputy Manager Waterway Operations Product Line