Buoy_Specifications_Combined.pdf

Atlas 3-Point Toroid Buoy with Solid Insert

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

Atlas Buoys

1. Provide all labor, materials and shipping to PMEL, Seattle, WA of 2.3 meter TAO oceanographic buoys as specified as indicated on attached drawings ATLAS-ATLAS Buoy_Solid Insert-X-X.

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

3. Upper and lower attachment points shall be made on jigs to ensure 120 degrees’ alignment, which will allow for the interchangeability of existing buoy towers and bridles onto buoys. The jigs and buoy molds shall be furnished to the contractor as Government Furnished Property. The contractor is responsible for shipping jigs and from, and returning them back to PMEL

4. Top and bottom jigs shall be securely bolted to the buoy attachment points using 1-inch

(x6) in the top and bottom jigs during all phases of fiberglass and foam fabrication. Bolts shall be tightened to approximately 90 ft-lbs. Jig shall remain so attached while fiberglass and foam cool to room temperature.

ATLAS Buoy Solid Insert Fiberglass:

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

2. A smooth surface inside mold shall be used to form the fiberglass skin within which the bulk of fiberglass shall be laid up. This shall be the required technique with the objective of producing buoys of consistent size and shape. Buoys with a surface finish consisting of dips or waves of greater than ¼ inch may be rejected. All transitions must be fully feathered.

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

Atlas Buoy Solid Insert Construction:

1. The Fiberglass shall have a maximum thickness of 3/8-inches and a minimum thickness of 5/16-inch, using alternate layers of chopped reinforcement, bi-directional and or 24-ounce woven roving. The framework is keyed so that it will fit in only one orientation on the jig. This the required procedure. After the framework is installed, attach the location jigs to the top and bottom pad eyes. Set the proper height of the frames to the inside of the shell. (The critical measurement here is the overall height of the buoy, i.e. 36-inches). All gaps between the internal bands and the lower fiberglass shell will be filled with thixo-puddy. Apply 3/8-inch alternating layer of mat and roving extending a minimum of 4-inches on each side of the band to secure the frame to the lower shell.

Remove the upper alignment jig to install the upper shell for the final assembly.

Reattach and tighten, (to approximately 90 ft-lbs.), the alignment jigs top and bottom.

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

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

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

5. THE UPPER AND LOWER JIGS SHALL REMAIN SECURELY ATTACHED USING 12

EACH, 1-INCH BOLTS DURING THE FOAMING PROCESS AND SHALL REMAIN

ATTACHED UNTIL FOAM HAS REACHED AMBIENT TEMPERATURE.

6. From the centerline up create four equal radial sections with painter’s tape. Two opposing sections shall be colored with three coats of international orange gel coat with surface agent added to the last coat. The orange gel coat shall surround only one of the stainless steel pad eyes. The two remaining sections shall remain white. All lines shall be straight and even.

ATLAS Buoy Solid Insert Urethane Foam:

Foam Type: Burtin Corporation, BUC 400-2.0. MIL-P-26514E Type II CLASS 1 and MIL-P-21929B or equal Foam shall have slow reactivity profile with low exotherm Free rise density: 1.8 – 2.2 PCF (ASTM-D-1622) Density within buoy: NTE 2.4 PCF Closed Cell (min): 90% (ASTM-D-1940)

Compressive strength: 26.0 PSI parallel to rise, min. 10 PSI perpendicular to rise at 72 deg. F. (ASTM-D-1621)

Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0% volume change at 158 degrees F. /100% RH.

(ASTM-2126)

The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam process equipment shall have the capability to fill each buoy with a single pour, which shall be the required foaming technique.

Solid Insert Fiberglass:

of producing buoys of consistent size and shape. Buoys with a surface finish consisting of dips or waves of greater than ¼-inch may be rejected. All transitions must be fully

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

4. An additional ¼-inch thickness of reinforcement must be applied to upper and lower seams (where buoy meets insert). Each ¼-inch thickness band shall be approximately 5-inches wide consisting of chop, two layers of 1-1/2 ounce mat and two layers of unidirectional roving. This additional thickness must be feathered into the adjacent areas not in excess of 3-inches on top and bottom to provide a smooth transition. All voids shall be filled with thixo-puddy and/or duraglass and covered with gel coat with surface agent then sanded to fair and re-gel coated as required.

5. The entire finished surface of the buoy is to be coated with gel coat with an air inhibited polyester surface. To the top of the buoy and insert apply 40-mesh sand with gel coat to give a nonskid texture.

Solid Insert Urethane Foam:

Type II CLASS 1 and MIL-P-21929B or equal Foam shall have slow reactivity profile with low exotherm Free rise density: 1.8 – 2.2 PCF (ASTM-D-1622) Density within buoy: NTE 2.4 PCF Closed Cell (min): 90% (ASTM-D-1940)

Compressive strength: 26.0 PSI parallel to rise, min. 10 PSI perpendicular to rise at 72 deg. F. (ASTM-D-1621)

Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0% volume change at 158 degrees F. /100% RH.

(ASTM-2126)

The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam process equipment shall have the capability to fill each buoy with a single pour, which shall be the required foaming technique.

Atlas 3-Point Toroid Buoy without Solid Insert

Atlas Buoys

1. Provide all labor, materials and shipping to PMEL, Seattle, WA of 2.3 meter TAO oceanographic buoys as specified as indicated on attached drawings ATLAS-ATLAS Buoy-X-X.

onto buoys. The jigs and buoy molds shall be furnished to the contractor as

Fiberglass:

of producing buoys of consistent size and shape. Buoys with a surface finish consisting

Buoy Construction:

1. The Fiberglass shall have a maximum thickness of 3/8-inches and a minimum thickness of 5/16-inch, using alternate layers of chopped reinforcement, bi-directional and or 24-ounce woven roving. The framework is keyed so that it will fit in only one orientation on the jig. This is the required procedure. After the framework is installed, attach the location jigs to the top and bottom pad eyes. Set the proper height of the frames to the inside of the shell. (The critical measurement here is the overall height of the buoy, i.e.

36-inches). All gaps between the internal bands and the lower fiberglass shell will be filled with thixo-puddy. Apply 3/8-inch alternating layer of mat and roving extending a minimum of 4-inches on each side of the band to secure the frame to the lower shell.

Remove the upper alignment jig to install the upper shell for the final assembly.

Reattach and tighten, (to approximately 90 ft-lbs.), the alignment jigs top and bottom.

of chop, two layers of 1-1/2 ounce mat and two layers of unidirectional roving. This additional thickness must be feathered into the adjacent areas not in excess of 3-inches on top and bottom to provide a smooth transition. All voids shall be filled with thixo-puddy and/or duraglass and covered with a gel coat with surface agent then sanded to fair and re-gel coated as required. The entire finished surface of the buoy is to be surface agent added to the last coat. The orange gel coat shall surround only one of the

Urethane Foam:

Foam Type: Burtin Corporation, BUC 400-2.0. MIL-P-26514 Type II CLASS 1 and MIL-P-21929B or equal Foam shall have slow reactivity profile with low exotherm Free rise density: 1.8 – 2.2 PCF (ASTM-D-1622) Density within buoy: NTE 2.4 PCF Closed Cell (min): 90% (ASTM-D-1940)

Compressive strength: 26.0 PSI parallel to rise, min. 10 PSI perpendicular to rise at 72 deg. F. (ASTM-D-1621)

Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0% volume change at 158 degrees F. /100% RH.

(ASTM-2126)

The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam

DART-3_ETD Buoy

DART-3_ETD Buoys

1. Provide all labor, materials and shipping to PMEL, Seattle, WA of DART-3-ETD oceanographic buoys as specified as indicated on attached drawings {DART-3}{Buoy Hull}{1.5 M Buoy Hull Dwg}{X}.SLDDRW and {DART-3}{Buoy Hull}{Buoy Main Dwg}{X}.SLDDRW

2. The Buoy shall be fiberglass over foam, oceanographic buoy with galvanized steel framework.

3. The contractor is responsible for shipping jigs, NOAA supplied parts and molds from, and returning them back to PMEL.

DART-3_ETD Buoy Fiberglass:

1. A smooth surface inside mold shall be used to form the fiberglass skin within which the bulk of fiberglass shall be laid up. This shall be the required technique with the objective of producing buoys of consistent size and shape. Buoys with a surface finish consisting of dips or waves of greater than 1/8-inch may be rejected. All transitions must be fully feathered.

2. Proper fiber glassing techniques shall be followed to prevent delamination during the

DART-3_ETD Buoy Construction:

1. The fiberglass shall be a polyester resin based and a maximum thickness of 0.10 inch and a minimum thickness of 1/16-inch. Due to weight considerations the optimal fiberglass thickness is 1/16-inch

2. Any voids or gaps that exist between the steel framework on the outside of the buoy and the fiberglass must be filled with polyester thixo-puddy or duraglass. A smooth bead or polyurethane or polysulfide caulk shall be applied to where the steel and fiberglass meet.

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

4. Sand the gel coat and apply a polyurea primer before over-spraying the buoys with a

1/8-inch thick layer of polyurea with battleship grey pigment.

5. The fully built buoy should weigh no more than 575 pounds. Over weight buoys may be rejected.

DART-3_ETD Buoy Urethane Foam (must be Coast Guard approved and be approved by NOAA engineers):

Foam Type: Burtin Corporation, BUC 400-2.0. MIL-P-26514E or MIL-P-21929B or equal Type II CLASS 1 and MIL-P-21929B or equal Foam shall have slow reactivity profile with low exotherm Free rise density: 1.8 – 2.2 PCF (ASTM-D-1622) Density within buoy: NTE 2.4 PCF Closed Cell (min): 90% (ASTM-D-1940)

Compressive strength: 26.0 PSI parallel to rise, min. 10 PSI perpendicular to rise at 72 deg. F. (ASTM-D-1621)

Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0% volume change at 158 degrees F. /100% RH.

(ASTM-2126)

The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam process equipment shall have the capability to fill each buoy with a single pour, which shall be the pCO2 3-Point Toroid Buoy pCO2 Buoys

1. Provide all labor, materials and shipping to PMEL, Seattle, WA of 2.3 meter pCO2 toroidial oceanographic buoys as specified as indicated on attached drawings pCO2_pCO2 Buoy_ATLAS pCO2 Buoy-X-X.

onto buoys. The jigs and buoy molds shall be furnished to the contractor as

(x6) in the top and bottom jigs during all phases of fiberglass and foam fabrication.

Bolts shall be tightened to approximately 90 ft-lbs. Jig shall remain so attached while pCO2 Buoy Fiberglass:

objective of producing buoys of consistent size and shape. Buoys with a surface finish consisting of dips or waves of greater than ¼ inch may be rejected. All transitions must be fully feathered.

pCO2 Buoy Construction:

1. The Fiberglass shall have a maximum thickness of 3/8-inch and a minimum thickness of 5/16-inch (unless specifically specified *See note #3 on drawing: pCO2_pCO2 Buoy_ATLAS pCO2 Buoy-X-X, ATLAS buoy sheet, Page 1) using alternate layers of chopped reinforcement, bi-directional and or 24-ounce woven roving. The framework is keyed so that it will fit in only one orientation on the jig. This the required procedure.

After the framework is installed, attach the location jigs to the top and bottom pad eyes.

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

of chop, two layers of 1-1/2 ounce mat and two layers of unidirectional roving. This additional thickness must be feathered into the adjacent areas not in excess of 3-inches on top and bottom to provide a smooth transition. All voids shall be filled with thixo-puddy and/or duraglass and covered with a gel coat with surface agent then sanded to fair and re-gel coated as required. The entire finished surface of the buoy is to be surface agent added to the last coat. The orange gel coat shall surround only one of the stainless steel pad eyes. The two remaining sections shall remain white. All lines shall be straight and even.

pCO2 Buoy Urethane Foam:

Type II CLASS 1 and MIL-P-21929B or equal Foam shall have slow reactivity profile with low exotherm Free rise density: 1.8 – 2.2 PCF (ASTM-D-1622) Density within buoy: NTE 2.4 PCF Closed Cell (min): 90% (ASTM-D-1940)

Compressive strength: 26.0 PSI parallel to rise, min. 10 PSI perpendicular to rise at 72 deg. F. (ASTM-D-1621)

Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0% volume change at 158 degrees F. /100% RH.

(ASTM-2126)

The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam process equipment shall have the capability to fill each buoy with a single pour, which shall be the required foaming technique.

pCO2 Solid Insert objective of producing buoys of consistent size and shape. Buoys with a surface finish consisting of dips or waves of greater than ¼-inch may be rejected. All transitions must be fully feathered.

5-inches wide consisting of chop, two layers of 1-1/2 ounce mat and two layers of unidirectional roving. This additional thickness must be feathered into the adjacent areas not in excess of 3-inches on top and bottom to provide a smooth transition. All

5. The entire finished surface of the buoy is to be coated wit gel coat with an air inhibited polyester surface. To the top of the buoy and insert apply 40-mesh sand with gel coat to give a nonskid texture.

pCO2 Solid Insert Urethane Foam:

Type II CLASS 1 and MIL-P-21929B or equal Foam shall have slow reactivity profile with low exotherm Free rise density: 1.8 – 2.2 PCF (ASTM-D-1622) Density within buoy: NTE 2.4 PCF Closed Cell (min): 90% (ASTM-D-1940)

Compressive strength: 26.0 PSI parallel to rise, min. 10 PSI perpendicular to rise at 72 deg. F. (ASTM-D-1621)

Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0% volume change at 158 degrees F. /100% RH.

(ASTM-2126)

The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam pCO2_O-A Buoy pCO2_O-A Buoys

1. Provide all labor, materials and shipping to PMEL, Seattle, WA of pCO2_OA oceanographic buoys as specified as indicated on attached drawings {pCO2}{O-A Buoy Hull}{1.5 M Buoy Hull Dwg}{X}.SLDDRW and {pCO2-D-3 Buoy}{X}.SLDDRW

2. The Buoy shall be fiberglass over foam, oceanographic buoy with galvanized steel framework.

3. The contractor is responsible for shipping jigs, NOAA supplied parts and molds from, and returning them back to PMEL.

pCO2_O-A Buoy Fiberglass:

1. A smooth surface inside mold shall be used to form the fiberglass skin within which the objective of producing buoys of consistent size and shape. Buoys with a surface finish consisting of dips or waves of greater than 1/8-inch may be rejected. All transitions must be fully feathered.

2. Proper fiber glassing techniques shall be followed to prevent delamination during the

PCO2_O-A Buoy Construction:

1. The fiberglass shall be a polyester resin based and a maximum thickness of 0.10 inch and a minimum thickness of 1/16-inch. Due to weight considerations the optimal fiberglass thickness is 1/16-inch

2. Any voids or gaps that exist between the steel framework on the outside of the buoy and the fiberglass must be filled with polyester thixo-puddy or duraglass. A smooth bead or polyurethane or polysulfide caulk shall be applied to where the steel and fiberglass meet.

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

4. Sand the gel coat and apply a polyurea primer before over-spraying the buoys with a

1/8-inch thick layer of polyurea with battleship grey pigment.

5. The fully built buoy should weigh no more than 575 pounds. Over weight buoys may be rejected.

PCO2_OA Buoy Urethane Foam (must be Coast Guard approved and be approved by NOAA engineers):

Foam Type: Burtin Corporation, BUC 400-2.0. MIL-P-26514E or MIL-P-21929B or equal Type II CLASS 1 and MIL-P-21929B or equal Foam shall have slow reactivity profile with low exotherm Free rise density: 1.8 – 2.2 PCF (ASTM-D-1622) Density within buoy: NTE 2.4 PCF Closed Cell (min): 90% (ASTM-D-1940)

Compressive strength: 26.0 PSI parallel to rise, min. 10 PSI perpendicular to rise at 72 deg. F. (ASTM-D-1621)

Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0% volume change at 158 degrees F. /100% RH.

(ASTM-2126)

The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam process equipment shall have the capability to fill each buoy with a single pour, which shall be the

TFLEX 3-Point Toroid Buoy

TFLEX Buoys

1. Provide all labor, materials and shipping to PMEL, Seattle, WA of 2.3 meter TFLEX toroidal oceanographic buoys as specified as indicated on attached drawings {ATLAS}{TFLEX}{ Buoy}{X}.

onto buoys. The jigs and buoy molds shall be furnished to the contractor as

TFLEX Buoy Fiberglass:

of producing buoys of consistent size and shape. Buoys with a surface finish consisting

TFLEX Buoy Construction:

1. The Fiberglass shall have a maximum thickness of 3/8-inch and a minimum thickness of 5/16-inch (unless specifically specified *See note #3 on drawing:

{ATLAS}{TFLEX}{Buoy}{x}.SLDDRW, ATLAS buoy sheet, Page 1) using alternate layers of chopped reinforcement, bi-directional and or 24-ounce woven roving. The framework is keyed so that it will fit in only one orientation on the jig. This the the required procedure. After the framework is installed, attach the location jigs to the top and bottom pad eyes. Set the proper height of the frames to the inside of the shell. (The critical measurement here is the overall height of the buoy, i.e. 36-inches). All gaps between the internal bands and the lower fiberglass shell will be filled with thixo-puddy.

Apply 3/8-inch alternating layer of mat and roving extending a minimum of 4-inches on each side of the band to secure the frame to the lower shell. Remove the upper alignment jig to install the upper shell for the final assembly. Reattach and tighten, (to approximately 90 ft-lbs.), the alignment jigs top and bottom.

of chop, two layers of 1-1/2 ounce mat and two layers of unidirectional roving. This additional thickness must be feathered into the adjacent areas not in excess of 3-inches on top and bottom to provide a smooth transition. All voids shall be filled with thixo-puddy and/or duraglass and covered with a gel coat with surface agent then sanded to fair and re-gel coated as required. The entire finished surface of the buoy is to be surface agent added to the last coat. The orange gel coat shall surround only one of the

TFLEX Buoy Urethane Foam:

Type II CLASS 1 and MIL-P-21929B or equal Foam shall have slow reactivity profile with low exotherm Free rise density: 1.8 – 2.2 PCF (ASTM-D-1622) Density within buoy: NTE 2.4 PCF

Closed Cell (min): 90% (ASTM-D-1940) Compressive strength: 26.0 PSI parallel to rise, min. 10 PSI perpendicular to rise at 72 deg. F. (ASTM-D-1621) Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0% volume change at 158 degrees F. /100% RH.

(ASTM-2126)

The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam process equipment shall have the capability to fill each buoy with a single pour, which shall be the required foaming technique.

TFLEX Solid Insert of producing buoys of consistent size and shape. Buoys with a surface finish consisting

5-inches wide consisting of chop, two layers of 1-1/2 ounce mat and two layers of unidirectional roving. This additional thickness must be feathered into the adjacent areas not in excess of 3-inches on top and bottom to provide a smooth transition. All

5. The entire finished surface of the buoy is to be coated wit gel coat with an air inhibited polyester surface. To the top of the buoy and insert apply 40-mesh sand with gel coat to give a nonskid texture.

TFLEX Solid Insert Urethane Foam:

Type II CLASS 1 and MIL-P-21929B or equal Foam shall have slow reactivity profile with low exotherm

Free rise density: 1.8 – 2.2 PCF (ASTM-D-1622) Density within buoy: NTE 2.4 PCF Closed Cell (min): 90% (ASTM-D-1940)

Compressive strength: 26.0 PSI parallel to rise, min. 10 PSI perpendicular to rise at 72 deg. F. (ASTM-D-1621)

Water absorption: 0.05 pounds per square foot Dimensional stability: Max 8.0% volume change at 158 degrees F. /100% RH.

(ASTM-2126)

The entire buoy shall be filled with a homogeneous foam mixture with no voids. Foam