Attachment 1 Spec 464-J.pdf

OCEAN ENGINEERING DIVISION

UNITED STATES COAST GUARD

WASHINGTON, D.C.

AUGUST 2011

SPECIFICATION FOR FABRICATION

OF

STEEL OCEAN BUOYS

SPECIFICATION NO. 464

REVISION J

Specification 464 J August 2011

1. SCOPE

1.1 Scope. This specification defines the requirements for the fabrication of steel ocean buoys for use as aids to navigation.

1.2 Buoy Classification. The Coast Guard uses a wide variety of ocean buoys. These buoys are classified as either lighted or unlighted. Lighted buoys and unlighted sound buoys are identified by their diameter and length, and various design attributes.

Unlighted buoys are identified by their shape (can or nun), class (1st through 5th in descending order of size), and various design attributes. The following tables list the designations corresponding to the buoy design attributes:

Lighted Buoys Unlighted Buoys

Designation Attribute Designation Attribute L Lighted R Radar Reflector R Radar Reflector C Can Shape Daymark B Bell N Nun Shape Daymark G Gong I Ice W Whistle S Special I Ice C Can Shape Daymark N Nun Shape Daymark

Thus, an “8x26LR” is an eight-foot diameter by twenty-six foot long lighted buoy with a radar reflector. 1NR is a first class nun radar reflective buoy, and 3CI is a third class can ice buoy. The following is a list of current Coast Guard steel ocean buoys:

Lighted Buoys and Unlighted Sound Buoys

Unlighted Buoys

9x35LWR 1NR 9x32LR 1CR 9x20BR 2NR 9x20GR 2CR 8x26LR 3NR

8x26LWR 3CR 8x21LR 3NI 7x20LIR 3CI 7x17LR 4NRS 6x20LR 5CRS

5x11LNR/LCR 5NR 3½x8LNR/LCR 5CR

5NI

5CI

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 following United States Coast Guard Office of Civil Engineering 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.

Specification Revision Date Title 357 D March 2000 Fabrication of Buoy Bells and Gongs 360 H June 2002 Fabrication of Buoy Bell and Gong Tappers 362 G March 2000 Fabrication of Buoy Bell and Gong Stands 374 E March 2000 Fabrication of Aluminum Radar Reflectors 460 I May 2010 Fabrication of Buoy Solar Battery Boxes

2.3 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.

SPECIFICATIONS

MIL-P-24647D(1) Paint System, Anticorrosive and Antifouling, Ship Hull 12 Jun 2006

QPL-24647-QPD Qualified Products List of Products Qualified Under Military 30 Nov 2010 Specification MIL-P-2464, Paint System, Anticorrosive and Antifouling, Ship Hull

MIL-PRF-24176C Military Specification, Cement, Epoxy, Metal Repair and Hull

14 OCT 2004 Smoothing

STANDARDS

FED-STD-595C Federal Standard Colors 31 Jul 2008

2.4 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.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A36-08 Standard Specification for Structural Steel

A48-03 Standard Specification for Gray Iron Castings

A285-03 Pressure Vessel Plates, Carbon Steel, Low and Intermediate Tensile Strength

A312-11 Seamless and Welded Austenitic Stainless Steel Pipes

A314-08 Standard Specification for Stainless Steel Billets and Bars for

Forging

A449-10 Standard Specification for Quenched and Tempered Steel Bolts and Studs

A666-10 Standard Specification for Annealed or Cold-Worked Austenitic

Stainless Steel Sheet, Strip, Plate, and Flat Bar.

A706-09b Standard Specification for Low-Alloy Steel Deformed Bars for

Concrete Reinforcement

A1008-11 Steel, Sheet, Carbon, Cold-Rolled, Structural High-Strength Low-

Alloy and High-Strength Low-Alloy with Improved Formability

A1011-10 Steel, Sheet and Strip, Carbon, Hot-Rolled, Carbon Structural

High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability

B209-10 Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

B221-08 Standard Specification for Aluminum and Aluminum-Alloy Bars, Rods, Wire, Profiles, and Tubes

C33-11 Standard Specification for Concrete Aggregates.

C150-11 Standard Specification for Portland Cement

E165-09 Standard Test Method for Liquid Penetrant Examination

E709-08 Standard Guide for Magnetic Particle Examination

AMERICAN WELDING SOCIETY

AWS D1.1-08 Structural Welding Code - Steel

AWS D1.2-08 Structural Welding Code - Aluminum

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING

SNT-TC-1A-06 American Society for Nondestructive Testing Recommended

Practice

STEEL STRUCTURES PAINTING COUNCIL (SSPC)

SSPC-SP-10-01 Near White Blast Cleaning

AMERICAN SOCIETY FOR QUALITY CONTROL

ANSI/ASQC Quality Systems - Model for Quality Assurance in Production, Q9002-1994 Inspection, and Servicing

2.5 Drawings. The following United States Coast Guard Office of Civil Engineering drawings form a part of this specification to the extent referenced herein, and shall be referred to as "the drawing" throughout this specification:

Drawing Number

Revision Title

120316 F Nun Shape Aluminum Radar Reflector 120990 K 5CI and 5NI Buoys 120994 F Buoy Bells and Gongs 120998 F Buoy Bell and Gong Stand 121009 I 24” Battery Rack Assembly 121024 G Can Shape Aluminum Radar Reflector 121028 H 3CI and 3NI Buoy 121056 B A/N Cover Plate for 9x35LWR Buoy 121100 M Solar Buoy Battery Box 121102 G Swingbolt and Clevis Pin 121104 G 22” Battery Pocket Cover 121108 E 1988 Type First Class Nun Buoy (1NR) 121109 E 1988 Type First Class Can Buoy (1CR) 121110 E 1988 Type Second Class Nun Buoy (2NR) 121111 E 1988 Type Second Class Can Buoy (2CR) 121112 F 1988 Type Third Class Nun Buoy (3NR) 121113 F 1988 Type Third Class Can Buoy (3CR) 121129 G 1988 Type 7x17LR Buoy 121130 F 1989 Type 8x26LR Buoy 121131 F 1989 Type 8x26LWR Buoy 121132 F 1989 Type 9x32LR Buoy 121137 F 1990 Type 9x20R Buoy 121140 D Buoy Lift Eyes 121143 D 24” Battery Pocket Cover 121145 E 1991 Type 8x21LR Buoy 121151 F 9x35LWR Buoy 121152 F 1992 Type 6x20LR Buoy 121153 - Mooring Eye 121157 D 1992 Type 3½x8LR Buoy 121158 E 1992 Type 5xllLR Buoy 121159 D Standard Buoy Tappers 121163 B 1994 Type Fifth Class Nun Buoy (5NR) 121164 B 1994 Type Fifth Class Can Buoy (5CR) 121174 A 8x26LR/LWR Buoy Tower 121175 A 8x21LR and 9x20R Buoy Tower 121176 - 6x20LR and 7x17LR Buoy Tower 121182 C MVP LED Adapter Plate 121186 A 7x20LI Battery Rack Assembly 121188 2010 Type 8x26LR Buoy 121190 2010 Type 8x21LR Buoy 121191 2010 Type 7x17LR Buoy

Drawing Number

Revision Title

121192 2010 Type 6x20LR Buoy 121193 2010 Type 7x20LIR Buoy 121196 2010 Type 4CRS Buoy 121197 2010 Type 4NRS Buoy

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

Coast Guard Documents.

Commandant (CG-432B) U.S. Coast Guard Headquarters 1900 Half Street, SW Washington, D.C. 20593-0001 http://www.uscg.mil/hq/cg4/cg432/default.asp

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 WELDING SOCIETY (AWS)

550 NW LeJeune Road PO Box 351040 Miami, FL 33135

STEEL STRUCTURES PAINTING COUNCIL (SSPC)

4400 Fifth Avenue

Pittsburgh, PA 15213-2683

AMERICAN SOCIETY FOR QUALITY CONTROL (ASQC)

310 West Wisconsin Avenue Milwaukee, Wisconsin 53203

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

4153 Arlingate Plaza Columbus, OH 43228

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 First Article Testing. When specified (paragraph 6.1), buoys shall be subjected to first article testing in accordance with paragraph 4.3.

3.2 Materials.

3.2.1 Steel.

3.2.1.1 Steel Bars, Shapes, and Plates. Steel bars, shapes, and plates 3/16 inch thick or more shall meet the requirements of ASTM A36.

3.2.1.2 Steel Sheets. Steel sheets less than 3/16 inch thick shall meet the requirements of ASTM A1008, Grade C, D, or E, or ASTM A1011, Grade 36, 40, 45, or 50.

3.2.1.3 Dished and Flanged Heads. The top and bottom buoy heads shall be steel meeting the requirements of ASTM A36 or any grade listed in ASTM A285.

3.2.1.4. Bars for Concrete Reinforcement (Rebar). Rebar shall meet the requirements of ASTM A706.

3.2.1.5 Steel Bolts and Nuts. Steel bolts and nuts shall be zinc-plated SAE Grade 5 and shall meet the requirements of ASTM A449.

3.2.2 Stainless Steel.

3.2.2.1 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.

3.2.2.2 Vent Pipe. Stainless steel vent pipe shall meet the requirements of ASTM A312, Grade TP316 or TP316L. The radius end of each vent pipe shall have a 3/4 inch NPT thread. The thread shall be a minimum of 1 inch in length and a maximum of 1-1/2 inches.

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

3.2.3 Aluminum.

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

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

3.2.4 Cast Iron. All cast iron counterweights shall meet the requirements of any class listed in ASTM A48.

3.2.5 Concrete. Concrete counterweights shall have a 28-day compressive strength of at least 3000 psi and a slump between 2 and 4 inches.

3.2.5.1. Cement. Cement used in the concrete mixture shall meet the requirements of ASTM C150, Type 1.

3.2.5.2 Coarse Aggregate. Coarse aggregate shall be uniformly graded from 1½ inch diameter to No. 4 sieve and shall meet the requirements of ASTM C33

3.2.5.3 Fine Aggregate. Fine aggregate shall be uniformly graded from No. 4 to No.

100 sieve and shall meet the requirements of ASTM C33.

3.2.5.4 Concrete Mix. The concrete mix shall be proportioned by volume as follows: 1 part cement, 2 parts fine aggregate, 4 parts coarse aggregate. Water shall be 6 gallons per 1 cubic foot (94 lb. sack) of cement.

3.2.6 Wood. Fenders shall be fabricated from wood. The wood shall be white oak or salt-treated white oak, red oak, ash, elm, hickory, maple, or walnut.

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.

3.3.2 Threads. The threads on all nuts and bolts shall be Unified Course Thread Series (UNC). The threads on all vent pipes, pipe couplings, nipples, elbows, unions, and pipe plugs shall be American Standard Taper Pipe Threads (NPT).

3.3.3 Counterweights. The finished weight of each counterweight and counterweight assembly shall be in accordance with the drawing. The actual weight of each counterweight shall be documented on the Quality Assurance Inspection Form as required in paragraph 3.7.2.

3.3.3.1 External Counterweights. The surface of the counterweight shall be free of any fused-on sand and shall be smooth (shall not cut skin or cloth). Runners, risers, fins, and other cast-on pieces shall be removed. Repairs to the surface of the counterweight shall be made by plugging or welding. The void between the counterweight and the counterweight tube shall be filled with a hot-applied asphalt enamel. Salient characteristics are: 20-30% filler, not more than 5% of which is calcium; 90% of the filler shall pass through a 200 mesh sieve; good adhesive qualities; shall not flow or sag from a vertical surface; and shall not become brittle.

3.3.3.2 Internal Counterweights. Internal concrete and cast iron counterweights shall be poured after the counterweight/mooring assembly has been fabricated. The concrete counterweights shall be poured after the rebar has been welded in place. The concrete shall be tamped to eliminate voids.

3.3.4 Fenders. After the antifouling paint (paragraph 3.6.1.2) has dried, wooden fenders shall be attached to the fender supports on 9x35LWR and 8x26LWR buoys.

Zinc-plated SAE Grade 5 hex bolts and nuts shall be used to secure the fenders in place. To prevent the loss of the fastener, the bolts shall be peened and the nuts tack welded.

3.3.5 Welding. The plates, bars, and other shapes forming the various components of the buoy shall be fitted and faired prior to being welded in place. All welds shall be performed as indicated on the drawings. Welds in and around the lifting eyes, mooring eyes, and tower feet shall be inspected using the magnetic particle method (paragraph 4.5.3.2).

3.3.5.1 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 buoy. 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.

3.3.6.2 Aluminum Welding. Gas Metal Arc Welding (GMAW) shall be used to weld the aluminum parts of the buoy. All welding procedures and weld quality 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.

3.3.6 Watertightness. The buoy body and the battery pockets shall be watertight.

Watertightness shall be determined by the air test required in paragraph 4.5.2.

3.3.7 Serial Code. Each buoy shall be identified by a serial code. The serial code shall be of the form 8W-12-01-XX (or 1CR-12-01-XX). The first group of characters represents the buoy type, 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 opposite side of the buoy top head from the serial code.

3.3.7.1 Character Dimensions and Location. The serial code and "USCG" shall be a bead of weld not less than 1/8 ( 1/16) inch high by 1/4 ( 1/16) inch wide applied to the buoy top head 3 inches from, and parallel to, the outside edge of the head in the shapes of the characters that make up the serial code. The characters of the serial code shall be block digits with a maximum width of 1-3/4 ( 1/4) inches and a height of 2-1/2 ( 1/4) inches. The 3NI and 5NI ice buoys may have the serial code placed at the top of the upper conical section.

3.3.7.2 Buoy Identification Characters. The following characters shall be used as the first group of characters for identifying buoys in the serial code:

BUOY CODE BUOY CODE BUOY CODE

9x35LWR 9W 5x11LNR/LCR 5 3NI 3NI 9x32LR 9 3½x8LNR/LCR 3.5 3CI 3CI

9x20BR/GR 9S 1NR 1NR 4NRS 4NRS 8x26LR 8 1CR 1CR 4CRS 4CRS

8x26LWR 8W 2NR 2NR 5NR 5NR 8x21LR 8S 2CR 2CR 5CR 5CR 7x20LIR 7I 3NR 3NR 5NI 5NI 7x17LR 7 3CR 3CR 5CI 5CI 6x20LR 6

3.3.8 Weight. After painting, each buoy shall be weighed. This weight shall be recorded on the buoy’s Quality Assurance Inspection Form (paragraph 3.7.2) and DD form 250 (paragraph 3.7.4).

3.4 Additional Equipment.

3.4.1 Solar Battery Box. When specified in the delivery order, the Contractor shall delivery a lighted buoy with a solar battery box. The solar battery box shall be fabricated in accordance with 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 Cover Plate and Battery Rack. Each 9x35LWR buoy shall be delivered with one A/N cover plate (Drawing 121056) and one battery rack assembly (Drawing 121009).

The A/N cover shall be tied to the buoy tower with wire or a nylon cable tie. The battery rack shall be painted grey and shall be placed in one of the battery pockets.

3.4.3 Bell/Gong. As indicated in the delivery order, each 9x20R buoy shall be delivered with either a bell or gong. The bell, gong, bell stand, gong stand, and tappers shall be fabricated in accordance with the following Coast Guard drawings and specifications:

Item Specification No. Drawing No.

Bell and Gong 357 120994

Bell and Gong Stands 362 120998 Tappers 360 121159

3.4.3.1 Government Loaned Property. The bell and gong patterns will be provided to the Contractor as Government Loaned Property. Upon completion of the contract, the Contractor shall be responsible for reconditioning and shipping the patterns back to the Coast Guard Surface Forces Logistics Center (SFLC) in Baltimore, MD. The patterns shall be returned to the Coast Guard in the same condition as received.

3.4.4 Aluminum Radar Reflectors. As indicated in the delivery order, each 5x11LR and 3½x8 LR shall be delivered with an aluminum radar reflector. The reflectors shall be fabricated in accordance with Specification No. 374. Buoys specified in a delivery order as LCR shall be fitted with a "can" radar reflector shown in Drawing 121024. Buoys specified in a delivery order as LNR shall be fitted with the "nun" radar reflector shown in Drawing 120316. The stainless steel bolts connecting the radar reflector to the support stand shall be fitted with "top hats" or "isolation washers" to avoid contact between dissimilar metals.

3.5 Surface Preparation. All exterior steel surfaces, and the inside surfaces of whistle tubes and battery pockets, shall be blast cleaned to near-white metal in accordance with SSPC-SP-10. Prior to painting, all surfaces shall be free of contaminants such as oil, water, grease, dirt, blasting residue, weld spatter, slag, and flash rust.

3.5.1 Epoxy Repair Compound. After all surfaces have been blasted clean, any weld containing porosity shall be filled with an epoxy repair compound meeting the requirements of DOD-C-24176B. The epoxy repair compound shall only be used to fill porosity discontinuities that are within the allowable maximums stated in table 6.1 of

AWS D1.1.

3.6 Painting. Buoys shall be painted with the coating system outlined below. All painting shall be performed after the buoys have been cleaned in accordance with paragraph 3.5 and have successfully passed the air test required by paragraph 4.5.2.

All welding, machining, cutting, drilling, forming, or any other operation which would damage the coating system shall be performed prior to painting. The Contractor shall follow the manufacturers' instructions for correct application of the coating system. In addition, the Contractor shall be responsible for implementing appropriate worker safety procedures for the application of the coating system, and for ensuring that the procedures are strictly followed by the paint applicators. When buoy towers are purchased alone (i.e. not part of a complete buoy), they shall be primed only.

3.6.1 Coating system. The buoy coating system includes epoxy primer, ablative antifouling paint, and polyurethane topcoat paint as described below. The paints in the coating system are commercial products available from a variety of manufacturers.

However, the paints shall be applied as a complete system; i.e., all of the paints used on any given buoy (primer, antifouling, and topcoat) shall be from the same manufacturer.

3.6.1.1 Epoxy primer. All exterior steel surfaces, the exterior counterweights, and the inside surfaces of whistle tubes and battery pockets shall be coated with epoxy primer.

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 in QPL-24647. The colors required are haze gray and off-white or buff (manufacturers' standard colors are acceptable). Apply by spraying two coats, 5 mils minimum dry film thickness each, using contrasting colors for each coat (haze gray followed by off-white or buff). Sharp corners, edges, and other hard-to-coat areas shall be striped before each full coat is applied.

3.6.1.2 Ablative antifouling paint. All exterior surfaces below the waterline and the inside surfaces of whistle tubes shall be coated with ablative antifouling paint (waterlines for the purpose of painting are indicated in Figure 1). 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 (manufacturers' standard colors are acceptable). Apply by spraying two coats, 5 mils minimum dry film thickness each, using contrasting colors for each coat (black followed by red). Sharp corners, edges, and other hard-to-coat areas shall be striped before each full coat is applied.

3.6.1.3 Polyurethane topcoat. All exterior steel surfaces above the waterline shall be coated with a marine grade of acrylic aliphatic polyurethane (waterlines for the purpose of painting are indicated in Table 1). This paint shall meet the following requirements:

1) it shall be a commercial product from the same manufacturer that supplies the epoxy primer and ablative antifouling paints; 2) 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; 3). The required colors (as specified in the delivery order) shall be in accordance with FED-STD-595: red (Federal Color 11350), green (Federal Color 14193), dark green (Federal Color 14062) white (Federal Color 27875), and yellow (Federal Color 13655). Apply by spraying one coat, 3 mils minimum dry film thickness. Sharp corners, edges, and other hard-to-coat areas shall be striped before the full coat is applied.

3.6.1.3.1 Preferred Channel Marks. When specified in a delivery order, a buoy shall be painted with a preferred channel paint scheme. The buoy shall be painted with three horizontal stripes above the water line. The stripes will be red/green/red or green/red/green. All lighted buoys with radar towers shall have the top radar panels painted in the primary color, the bottom radar panels and tower legs painted in the secondary color, and the buoy top head to the water line painted in the primary color.

For unlighted buoys, the radar reflector shall be painted in the primary color. The top head to the water line shall be split in half with the upper half being painted with the secondary color and the lower half being painted with the primary color. Figure 2 shows the stripe configuration for various buoys

3.6.1.3.2 Safewater Paint Scheme. When specified in a delivery order, a buoy shall be painted with a safewater paint scheme. Eight alternating red and white vertical segments shall be applied to all steel and aluminum surfaces above the water line. The vertical segments shall be arranged to bisect the 90 degree angle of the radar reflector (see Figure 3).

3.7 Documentation.

3.7.1 Monthly Status Report. The Contractor shall prepare and deliver a monthly status report to the Contracting Officer’s Technical Representative (COTR). This report shall be typewritten on standard (i.e., 8½x11 inch) white paper. The report shall be prepared in the Contractor's format and shall be legible, in English, and suitable for reproduction.

The reporting period shall start on the first day and end on the last day of each month of the year.

3.7.1.1 Report Content. At a minimum the report shall include:

a. The Contractor's name and address, the contract number, the date of the report, the period covered by the report.

b. A list of active delivery orders.

c. A description of progress made for each active delivery order during the reporting period.

d. A description of any problems encountered during the reporting period. Problem areas are any aspects of contract performance which prevent the contractor from meeting:

1. technical requirements

2. delivery schedule requirements

3. quality assurance provision requirements In addition, problems with subcontractor, vendor, and supplier-provided products and services shall be specifically noted.

e. Results, positive and negative, obtained from resolving problems discovered during the reporting period or for previously identified problems. A description of the action taken or a recommendation shall be provided for each problem.

f. Record of significant telephone calls and meetings and any commitments or action items made as a result of such telephone calls or meetings.

g. The identification and status of Engineering Change Proposals (ECPs) which have been proposed, approved, or are being implemented.

h. A brief description of planned activities for the next reporting period.

i. Authentication by the responsible company official preparing the report. This shall include the person's name, signature, date signed, and telephone number.

j. Any necessary tables, references, photographs, illustrations, charts, or drawings shall be included as appendices.

3.7.2 Quality Assurance Inspection Form. The Contractor shall develop and provide a Quality Assurance Inspection Form (QAIF). The QAIF shall be used to document the inspections and tests performed on every buoy throughout its fabrication process. The form shall be typewritten on standard (i.e., 8½x11 inch) white paper. Inspection results may be handwritten on the form. The form shall be prepared in the Contractor's format and shall be legible, in English, and suitable for reproduction. The form shall be delivered to the COTR for review along with the DD-250 (paragraph 3.7.4) prior to any shipment.

3.7.2.1 QAIF Content. At a minimum the QAIF shall include:

a) Buoy classification and serial number.

b) Material certification reference numbers (paragraph 3.7.3).

c) Date of test or inspection.

d) Test or inspection to be performed (list every test and inspection require by section 4.0).

e) Result of test or inspection.

f) Accept/Reject criteria for each test or inspection.

g) Notes.

h) Initial or signature of Contractor’s test personnel.

3.7.3 Material Certifications. When requested by the COTR, 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 3.2.1 through 3.2.6 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. When any material is used in the fabrication process of a buoy, the material certification reference number shall be documented in the QAIF (paragraph 3.7.2.1). The material certifications shall be stored by the Contractor for the life of the contract.

3.7.4 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 COTR.

FIGURE 1

STANDARD WATERLINES FOR STEEL OCEAN BUOYS

Noted below are the standard waterlines (line between color coat and antifouling paint).

BUOY W/L (IN.) BUOY W/L (IN.)

9x35LWR 24 1NR/1CR 60 9x32LR 30 2NR/2CR 36 9x20R 18 3NR/3CR 24 8x26LR 24 3NI 60** 8x26LWR 24 3CI 54** 8x21LR 24 4NRS/4CRS 24 7x20LI * 5NR/5CR 24 7x17LR 18 5NI 46** 6x20LR 18 5CI 33** 5x11LR 12 3½x8LR 9

Note: * Located at largest diameter of the buoy ** Measured from the top horizontal surface

Waterline Reference

FIGURE 2

PREFERRED CHANNEL PAINT SCHEME

FIGURE 3

SAFEWATER PAINT SCHEME

½X

X

4 VERIFICATION

4.1 General. The Contractor's quality assurance program shall meet the requirements of ANSI/ASQC Q9002. However, the Contractor DOES NOT have to be Q9002 certified.

4.2 Classification of Inspections. The inspections required by this section are not intended to supplant any controls, examinations, inspections, or tests normally employed by the Contractor to ensure product quality. The inspection requirements specified herein are classified as follows:

a. First Article Inspection (see paragraph 4.3)

b. Conformance Inspection (see paragraph 4.4)

4.3 First Article Inspection. When first article samples are required (see paragraphs 3.1 and 6.1), the Contractor shall perform a First Article Inspection. This inspection shall include the tests and examinations listed in paragraphs 4.5.1 through 4.5.6.

4.4 Conformance Inspection. The Conformance Inspection, to be performed by the Contractor, shall include the tests and examinations listed in paragraphs 4.5.1 through 4.5.6.

4.5. Tests and Inspections.

4.5.1 Visual Inspection. Buoys shall be visually inspected for conformance to this specification and the drawings. The visual inspection shall include checks of dimensional conformance, mechanical fit, alignment of parts, and workmanship.

4.5.2 Air Test. Each buoy body and battery pocket shall be subjected to an air test to determine its watertight integrity. Separate air tests shall be performed on the buoy body and on the buoy battery pockets. At no time during testing shall both the buoy body and the battery pockets be under pressure at the same time. Air tests shall not be conducted within 1 hour after any hot work (i.e. welding, grinding, etc.) has been performed on the buoy. All welding to the hull shall be completed prior to the air testing.

Any welding completed after air tests have been conducted shall require all air tests to be repeated.

4.5.2.1 Buoy Body Air Test. The buoy body shall be pressurized to 3 psi and the air source shall be secured. The pressure shall not change over a period of 10 minutes.

While the buoy is pressurized, all welds on the buoy body shall be checked for leaks by applying a soapy water solution with a soft brush. An air test should be considered a failure if either (a) drop in pressure occurs or (b) leak is detected by the soapy water application.

4.5.2.2 Battery Pocket Air Test. The battery pockets shall be sealed by closing the pockets cover and plugging the vent pipes prior to testing. The crossover pipe between the battery pockets shall not be obstructed during this test in order that both pockets may be equally pressurized at the same time. The battery pockets shall be pressurized to 2 psi and the air source shall be secured. The pressure shall not change over a period of 5 minutes. An air test shall be considered a failure if any drop in pressure occurs.

4.5.2.3 Pressure Gauges. The pressure gauge range shall be selected such that a test pressure of 2.0 psi is not less than 20% of the scale of the gauge. The gauge shall have a 1 percent accuracy at the test pressure. The gauge shall have a 1 psi sensitivity.

4.5.3 Weld Inspections. All weld inspections shall be performed prior to the application of the epoxy primer.

4.5.3.1 Visual Weld Inspection. All welds shall be visually inspected for quality in accordance with section 6.9 of AWS D1.1.

4.5.3.2 Non Destructive Testing (NDT). Welds in and around the lifting eyes, mooring eyes, and tower feet shall be inspected using the magnetic particle testing method. The procedures and technique shall be in accordance with ASTM E709.

4.5.3.3 NDT Personnel Qualifications. Only personnel qualified for NDT Level II in accordance with SNT-TC-1A may perform the nondestructive testing.

4.5.4 Surface Preparation. Prior to the application of the epoxy primer, all exterior surfaces and the inside surfaces of whistle tubes and battery pockets shall be inspected to ensure conformance with SSPC-SP-10.

4.5.5 Paint Inspection. The Contractor shall ensure that each buoy was painted in accordance with paragraph 3.6 and all sub-paragraphs. Paint thickness shall be gauged at no fewer than six different random locations on the buoy. The ambient temperature, humidity, induction, and cure times shall be documented on the QAIF (paragraph 3.7.2).

4.5.6 Certifications Review. When requested by the COTR, material certifications required by section 3.7.3. shall be provided for review.

5. PACKAGING.

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

6. NOTES

6.1 First Article Inspection. First article inspection shall be performed by the Contractor and at the Contractor’s facility. The first articles shall consist of fully assembled buoys with written certifications in accordance with this specification. The first article shall be inspected and tested for requirements in this specification and those tests and inspections listed in paragraphs 4.5.1 through 4.5.6. The following buoys shall be inspected: 8x26LR with solar battery box; 7x20LI; and 2NR. These buoys must pass the first article tests before the Coast Guard will place any production orders.

6.2 Packaging. The buoys shall be shipped fully assembled. The ends of the vent pipes shall be covered with a heavy tape to protect them from damage and to prevent water from entering the battery pockets. The buoys shall be properly supported and protected from abrasive wear to prevent damage to the buoy, including paint, during shipment. The lighted buoy towers and counterweights shall be supported to prevent vibration during shipment.