Ionomer_Foam_Hull_Spec.pdf

WxOP 3-M Foam Hull 1 of 9 10/27/2017

NDBC STANDARD SPECIFICATION FOR FABRICATION

OF IONOMER FOAM HULL

1.0 SCOPE

1.1 General. This specification describes the requirements for the fabrication of ionomer foam buoy hulls. The buoy will be used as an equipment platform to collect meteorological and oceanographic data for the National Data Buoy Center (NDBC) Weather Buoy Program. The contractor shall provide all the necessary labor, material, equipment, facilities and services to fabricate and deliver the hulls to NDBC.

1.2 Precedence. Any ambiguity or conflict between this specification and other applicable documents shall be resolved by the following order of precedence:

a) The issued contract with any amendments or modifications

b) This specification

c) The drawings listed in section 2.4

d) Other applicable documents listed in section 2.0

2.0 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 Government Documents. The following documents form a part of this specification to the extent referenced herein. Suffixes denoting the specific issue of each document are omitted from future references to the documents in this specification.

STANDARDS

MIL-P-21929C

15 January 1991 -

Plastic Material, Cellular, Polyurethane, Rigid, Foam-in-Place, Low Density (2 pounds per cubic foot)

FED-STD-595C

7 January 1994 - Federal Standard Colors

2.3 Industry Publications. The following documents of the issues specified form a part of this specification to the extent referenced herein. Suffixes denoting the specific issue of each document will be omitted from future references to the document in this specification.

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AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

D3575-2000 Standard Test Methods for Flexible Cellular Materials Made from Olefin

Polymers

AMERICAN SOCIETY FOR QUALITY

ANSI/ISO/ASQC Q9002-1994 Quality Systems

2.4 Drawings. The buoys shall be fabricated in accordance with the drawing referenced in procurement document.

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

Government documents Standardization Documents Order Desk Building 4, Section D 700 Robbins Avenue Philadelphia, PA 19111-5094

Industry publications

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

1916 Race Street Philadelphia, PA 19103-1187

AMERICAN SOCIETY FOR QUALITY (ASQ)

611 East Wisconsin Avenue Milwaukee, WI 53202

AMERICAN SOCIETY FOR NON-DESTRUCTIVE TESTING (ASNT)

4153 Arlington Plaza Columbus, OH 43228

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3.0 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 polyvinyl chloride (PVC) hardware.

3.2 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 repelletized 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. Repelletized virgin ionomer foam material may be used in the buoys if the resultant ionomer foam passes all performance requirements as described in Table II.

3.2.1 Method of Fabrication. The foam shall be extruded into colored sheets having a density of at least 4.4 pounds per cubic foot (pcf), not greater than 4.6 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 completed foam sections of the buoys shall be free from cracks, holes, gouges, and embedded foreign material.

3.2.2 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 thickness between 1/4” and 5/16”.

The final diameter of the finished hull shall be as specified in the drawings.

3.2.3 Color. The completed spirally wrapped foam parts shall be comprised of layers of foamed sheets conforming to the colors of FED-STD-595, yellow 13655. Pigments shall be added to the foam during the sheet extrusion process and the color shall be continuous throughout the entire volume of the foam. The color shall be within the appropriate chromaticity region specified in Table I and shall remain within this region after continuous exposure to the sun for at least 8 years.

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Table I 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

Light 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

3.2.4 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.

3.2.5 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.

3.2.6 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 I. The colorfastness test will be performed in accordance with ASTM G155-05a, Table X3.1, Cycle 7.

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

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

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

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

3.2.11 Compression load deflection. Compression load deflection of the foam shall be as specified in Table II when tested in accordance with ASTM D3575, Suffix D.

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

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

3.2.14 Water absorption. Water absorption of the foam shall be as specified in Table II when tested in accordance with paragraph 4.4.2.

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Table II Performance Requirements

Parameter Test Method Required Value

Colorfastness G155-05a, Table X3.1, 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 Deflection 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.

3.3 Material Certification. In addition to records required by ASQ Q9002, the Contractor shall maintain and provide access to the material certifications from the manufacturer or certified independent testing laboratories which show that all of the materials used in the first articles and production buoys meet the requirements of this specification.

3.4 NDBC Waiver. NDBC reserves the right to waive or reduce portions of the contractor requirements.

4.0 QUALITY ASSURANCE

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 Q9002 and the Contractor shall maintain and adhere to these requirements throughout the length of the contract. The Contractor DOES NOT have to be Q9002 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 Q9002. These documents shall describe the Contractor’s quality control organization, the inspections and tests which the Contractor

WxOP 3-M Foam Hull 6 of 9 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:

4.2.1 Material certifications as specified ins section 3.3

4.2.2 The ionomer foam samples listed in Table III for the test described in section

3.2.4 through 3.2.14.

Table III First Article Foam Samples

Test Size Density Quantity

Colorfastness 6” x 6” x 0.25” 30 pcf 2 yellow

Density 1” x 1” x 1” 4 pcf

30 pcf

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

4 pcf 3 - horizontal direction 3- vertical direction 3 - radial direction

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

4 pcf 3 - horizontal direction 3- vertical direction 3 - radial direction

Compression Set 2” x 2” x 1” 4 pcf 3 Compression Load Deflection

4” x 4” x 1” 4 pcf 3

Hardness 2” x 2” x 0.25” 30 pcf 3 Abrasion Resistance 1” x 1” x 0.25” 30 pcf 3 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:

1. First article inspection (section 4.4)

2. Contractor production inspection (section 4.5)

3. NDBC production inspection (section 4.6)

4.4 First article inspection. The Contractor shall conduct tests on the first article 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 3.2.4 through 3.2.14, 4.4.1, and 4.4.2.

4.4.1 Colorfastness. Samples shall be prepared in accordance with the test procedure described in paragraph 3.2.6 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.

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Parameters for the test cycle shall be as follows:

Filters: Quartz Inner and Type S Borosilicate Outer Irradiance: .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)

Samples that do not meet the requirements of paragraph 3.2.5 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 Buoy Inspection. First article inspection and testing of the completed buoy shall be at the Contractor’s facility and will be witnessed by the Contracting Officer’s Technical Representative (COTR). Upon completion of the impact resistance test and heat seal inspection, the buoy shall meet the requirements of paragraph 3.2.5 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 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.

4.4.3.3 Heat Seal Inspection. Once the buoy passes the impact resistance test above, the Contractor shall disassemble the buoy and, at the discretion of the COTR, 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.

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 3.3 shall be maintained at the contractor’s plant and be available for review by the COTR. First articles that do not meet the material requirements of this specification will be

WxOP 3-M Foam Hull 8 of 9 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 material certifications required by section 3.3.

4.5 Contractor Production Inspection. The Contractor shall perform all the inspections and tests as specified in paragraphs 4.5.1 and 4.5.2 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 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 COTR as required in section 3.3.

4.6 NDBC Production Inspection. NDBC will periodically verify quality of production buoys by performing the inspections described in paragraphs 4.6.1 through 4.6.3.

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, part alignment, and surface preparation.

4.6.2 Material Certification Inspection. The COTR will review the material certifications required by paragraph 3.3 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.

4.6.3 Foam Sample Inspection. At the COTR’s discretion, NDBC will perform the tests described in paragraphs 3.2.4 through 3.2.14, taking test samples from production buoys. NDBC 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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5.0 DELIVERABLES

All deliverables shall be shipped to the following address:

National Data Buoy Center Attn: Property Officer Building 3203 Stennis Space Center, MS 39529