Specification 507_B_Steel Ocean Buoy Overhaul.pdf

UNITED STATES COAST GUARD

SHORE INFRASTRUCTURE LOGISTICS CENTER

WATERWAYS OPERATIONS PRODUCT LINE

APRIL 2020

SPECIFICATION FOR OVERHAUL

OF

STEEL OCEAN BUOYS

SPECIFICATION NO. 507B

Specification 507B April 2020

1. SCOPE

1.1 Scope. This specification defines the requirements for the overhaul of steel ocean buoys for use as aids to navigation (ATON).

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 Day mark B Bell N Nun Day mark G Gong I Ice W Whistle S Special I Ice T Tall C Can Shape Day mark N Nun Shape Day mark

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 7x17LR 6x20LR

3CI

5NR

5x11LNR 5CR 5x11LCR 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 latest revisions of the following United States Coast Guard documents form a part of this specification to the extent referenced herein.

Document # Title

357 Fabrication of Buoy Bells and Gongs 360 Fabrication of Buoy Bell and Gong Tappers 362 Fabrication of Buoy Bell and Gong Stands 374 Fabrication of Aluminum Radar Reflectors

Fabrication of Buoy Solar Battery Boxes Fabrication of Steel Ocean Buoys

2.3 Government Documents. The latest revisions of the following 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 Specification MIL-PRF-24647, Paint System, Anticorrosive and Antifouling, Ship Hull

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

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A36 Standard Specification for Structural Steel

A48 Standard Specification for Gray Iron Castings

A285 Pressure Vessel Plates, Carbon Steel, Low and Intermediate

Tensile Strength

A312 Seamless and Welded Austenitic Stainless Steel Pipes

A314 Standard Specification for Stainless Steel Billets and Bars for

Forging

A449 Standard Specification for Quenched and Tempered Steel Bolts and Studs

A666 Standard Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar.

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

Alloy and High-Strength Low-Alloy with Improved Formability

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

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

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

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

E165 Standard Practice for Liquid Penetrant Examination for General

Industry

E709 Standard Guide for Magnetic Particle Examination

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1 Structural Welding Code - Steel

AWS D1.2 Structural Welding Code - Aluminum

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

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

Practice

STEEL STRUCTURES PAINTING COUNCIL (SSPC)

SSPC-SP 1 Solvent Cleaning

SSPC-SP 10 Near White Blast Cleaning

SSPC-VIS 1 Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning

SSPC-Paint 36 Paint Specification 36

AMERICAN SOCIETY FOR QUALITY CONTROL (ASQC)

ANSI/ASQC Quality Management Systems - Requirements Q9001

SAE International

AMS-STD-595 Colors Used in Government Procurement

2.5 Drawings. The latest revisions of 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 drawings" throughout this specification:

Drawing No. Drawing Title 120316 Nun Shape Aluminum Radar Reflector 120777 120976

Buoy Whistle & Valve 7x20LI Ice Buoy

120990 5CI and 5NI Buoys 120994 Buoy Bells and Gongs 120998 Buoy Bell and Gong Stand 121009 24” Battery Rack Assembly 121024 Can Shape Aluminum Radar Reflector 121028 3CI and 3NI Buoy 121056 A/N Cover Plate for 9x35LWR Buoy 121100 Solar Buoy Battery Box 121102 Swing-bolt and Clevis Pin 121104 22” Battery Pocket Cover 121108 1988 Type First Class Nun Buoy (1NR) 121109 1988 Type First Class Can Buoy (1CR) 121110 1988 Type Second Class Nun Buoy (2NR) 121111 1988 Type Second Class Can Buoy (2CR) 121112 1988 Type Third Class Nun Buoy (3NR) 121113 1988 Type Third Class Can Buoy (3CR) 121129 1988 Type 7x17LR Buoy 121130 1989 Type 8x26LR Buoy 121131 1989 Type 8x26LWR Buoy 121132 1989 Type 9x32LR Buoy 121137 1990 Type 9x20R Buoy 121140 Buoy Lift Eyes 121143 24” Battery Pocket Cover 121145 1991 Type 8x21LR Buoy 121151 9x35LWR Buoy 121152 1992 Type 6x20LR Buoy 121153 Mooring Eye 121158 1992 Type 5x11LR Buoy 121159 Standard Buoy Tappers 121160 5x11LR & 3.5x8LR Pocket Covers 121162 22” and 24” Battery Pocket Conversion Kit 121163 1994 Type Fifth Class Nun Buoy (5NR) 121164 1994 Type Fifth Class Can Buoy (5CR) 121174 8x26LR/LWR Buoy Tower 121175 8x21LR and 9x20R Buoy Tower 121176 6x20LR and 7x17LR Buoy Tower 121182 7x20LIR Lantern Adapter Plate 121186 7x20LIR Battery Rack Assembly 121188 2010 Type 8x26LR Buoy 121190 2010 Type 8x21LR Buoy 121191 2010 Type 7x17LR Buoy 121192 2010 Type 6x20LR Buoy 121193 2010 Type 7x20LIR Buoy

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

Coast Guard Documents.

United States Coast Guard Shore Infrastructure Logistics Center Waterways Operations Product Line 300 East Main Street

Norfolk, VA 23510-9104 http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-

Engineering-Logistics-CG-4-/Logistic-Centers/Waterways-Operation-Product- Line/

Government Documents.

Standardization Documents Order Desk Building 4, Section D 700 Robbins Avenue Philadelphia, PA 19111-5094 http://quicksearch.dla.mil/

Industry Publications.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

1916 Race Street Philadelphia, PA 19103-1187 https://www.astm.org/

AMERICAN WELDING SOCIETY (AWS)

550 NW LeJeune Road PO Box 351040 Miami, FL 33135 http://www.aws.org/

STEEL STRUCTURES PAINTING COUNCIL (SSPC)

4400 Fifth Avenue

Pittsburgh, PA 15213-2683 http://www.sspc.org/

AMERICAN SOCIETY FOR QUALITY CONTROL (ASQC)

310 West Wisconsin Avenue Milwaukee, Wisconsin 53203 http://asq.org/index.aspx

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

4153 Arlingate Plaza Columbus, OH 43228 http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-Engineering-Logistics-CG-4-/Logistic-Centers/Waterways-Operation-Product-Line/ http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-Engineering-Logistics-CG-4-/Logistic-Centers/Waterways-Operation-Product-Line/ http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-Engineering-Logistics-CG-4-/Logistic-Centers/Waterways-Operation-Product-Line/ http://quicksearch.dla.mil/ https://www.astm.org/ http://www.aws.org/ http://www.sspc.org/

SAE International

1200 G Street, NW Washington, DC 20005 http://www.sae.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.

http://www.sae.org/

3. REQUIREMENTS

3.1 General. Steel buoy standard overhaul consists of repairing damaged or worn areas, making required structural modifications, preparing the surface of the buoy, testing the watertight and structural integrity of the buoy body and battery pocket(s), and painting the buoy to final color choice. A standard overhaul consists of the requirements in Section 3.4.

If a buoy requires repair in excess of a standard overhaul, work shall not proceed without authorization from the Contracting Officer (KO). Repair in excess of standard overhaul shall be considered condition-based overhaul and is detailed in Section 3.5.

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 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.

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 Brass. All brass items shall be a standard commercial grade of brass.

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.

3.2.7 Sealant. Enamel sealant used to fill the void between the counterweight and the counterweight tube shall be hot applied asphalt enamel. The 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 Welding. All welding within this specification shall be In Accordance With (IAW) the following section. All welds shall be performed IAW the applicable drawings listed in paragraph 2.5.

3.3.1 Welding Procedures. Standard welding procedures and weld quality shall meet the requirements of AWS D1.1 and D1.2.

3.3.2 Welder Qualification. All welding shall be accomplished by trained welders who have been certified by the applicable regulatory code performance qualification procedures. Performance qualification procedures shall be IAW AWS or ASME.

Contractor continuity records must document the welder has been actively welding using a process IAW the applicable regulatory code.

3.4 Standard Overhaul. All work in section 3.4 is within the scope of a standard overhaul. If deficiencies are found during inspections that are outside of the parameters of the standard overhaul, the Contractor shall provide a Condition Found Report (CFR) with that hull’s associated Quality Assurance Inspection Form (QAIF) to the Contracting Officer’s Representative (COR) IAW paragraph 3.6. All applicable inspections and tests shall be performed IAW Section 4 of this specification.

3.4.1 Interference Removal. Remove all sound signal equipment, vent valves, top marks, solar panel bird springs, mooring gear, exterior battery boxes, battery pocket covers and RACON mounting hardware as needed. If components are in good condition and are not going to be reinstalled on the buoy, retain for future use as Government Furnished Property (GFP). This includes all sound signal equipment, top marks, and battery pocket covers.

3.4.2 Removal of Surface Contaminants. Oil, grease, dirt, and other contaminants on the surface of the buoy may become embedded in the steel during blasting, and will prevent proper adhesion of the coating system and cause premature failure in service.

In addition, chloride contamination of steel surfaces (from the buoy being immersed in salt water) is a well-known cause of premature coating failure. Prior to blasting, these surface contaminants shall be removed per SSPC-SP 1 by power washing the entire surface of the buoy at 3000-5000 psi with clean, fresh water. The buoy shall be allowed to dry to the degree that there is no visible moisture on the surface before blasting.

3.4.3 Abrasive Blasting. All exterior surfaces of the buoy hull, and the inside surfaces of whistle tubes and battery pockets, shall be blasted to near-white metal IAW SSPC-SP

10. The abrasive shall be steel shot or grit which contains no copper slag.

3.4.3.1 Surface Profile. The surface profile after blasting shall be 1.5 to 3.0 mils.

3.4.3.2 Post-Blast Surface Characteristics. Specific guidance is provided in SSPC-SP

10. After blasting and before paint application, the surface shall be free of all oil, grease, dust, dirt, mill scale, rust, coatings, oxides, corrosion products, and other foreign matter except for random staining. Per SSPC-SP 10, random staining may consist of light shadows, slight streaks, or minor discolorations caused by stains of rust, stains of mill scale, or stains of previously applied coatings on no more than 5% of the surface area. Examples of the visual appearance of a surface blasted to near-white metal can be found in SSPC-VIS 1.

3.4.4 Buoy Body Repair. Repairing damaged or worn areas is limited by the extent of total buoy body metal repair (clad weld, metal renewal, etc.) necessary to bring buoy back to its approximate original shape. The total repairs to buoy’s body (excluding tower and battery pockets, but including counterweight tube) shall be limited to no more than the square footage listed in Table 1 during a standard overhaul. Repairs in excess of these limits shall be reported on the QAIF IAW paragraph 3.6 and submitted via CFR to the COR for approval of additional square footage.

Table 1

ALLOWABLE BUOY SURFACE AREA REPAIR

Buoy Type SA (ft2) Buoy Type SA (ft2)

9X35LWR 12 1NR 8

9X32LR 10 1CR 10

9X20 R 8 2NR 5

8X26LR 8 2CR 6

8X26LWR 8 3NR 3

8X21LR 5 3CR 3

7X17LR 8 3CI 3

7X20LI 5 3NI 3

7X20LIR 5 5NR 3

6X20LR 5 5CR 3

5CI 3

5X11LR 5 5NI 3

3.4.4.1 Dents. Repair all dents or creases in the buoy body larger than 20 inches wide or 4 inches deep.

3.4.4.2 Cracks and Pits. Fill all cracks and pits deeper than 1/8 of an inch by welding.

Remove sharp edges of welds.

3.4.4.3 Plate Renewal. Crop and renew buoy body outer steel plating where any penetration, dent, pit, or crack is too extensive to be repaired, or where plating is wasted by 25 percent or more of original thickness. Ensure that the new plating is of equal thickness to original steel plating IAW the applicable drawings. The edges of the new plating shall not overlap the original shell and are faired into the original shape of the buoy.

3.4.4.4 Weld Repair. Grind or arc gouge all eroded, porous or otherwise defective welds to sound metal and weld as necessary to restore structural integrity of the buoy body shell.

3.4.5 Lifting Eyes. Inspect the lifting eyes for wear, damage and proper configuration IAW the applicable drawings. Record findings on the QAIF IAW paragraph 3.6 and repair as per below.

3.4.5.1 Abrasion. The surfaces of all lifting eyes shall be built up to the original dimensions IAW the drawing. Approved repairs to lifting eyes include welding or replacing the lifting eye. The junctions of the lifting eyes to the buoy body shall be closely inspected and tested IAW Section 4 of this specification as applicable and repaired if defective.

3.4.5.2 Bends or twists. Renew lifting eyes that are bent or twisted out of plane.

3.4.6 Mooring Attachments. Inspect/repair the mooring attachments for wear, damage and proper configuration IAW the applicable drawings. Record findings on the QAIF IAW paragraph 3.6.

3.4.6.1 Straightening Mooring Arms. Mooring arms that are bent to within three inches of the buoy counterweight shall be straightened to the original shape or replaced.

3.4.6.2 Pins and Ends. The mooring arm pin and the mooring arm shall be replaced when the clearance between them exceeds 5/8 inch. If the hole in the lower end of the mooring arm has worn by more than 1/2 inch in diameter, it shall be repaired by weld buildup or inserting sleeve bushings. The mooring arm support or doubler plate shall be built up to original size and shape or replaced. All inspection and tests shall be performed IAW Section 4 of this specification. Repair defects if found.

3.4.6.3 Mooring Arm Chafing Strip. The mooring arm chafing strip shall be built up to original size and shape or replaced.

3.4.6.4 Mooring Eyes. The surfaces of all mooring eyes shall be built up to the dimensions and shape detailed in the applicable drawings. Approved repairs to mooring eyes include welding, welding sleeve inserts in place or renewing the mooring eye. The junctions of the mooring eyes to the buoy body shall be closely inspected and tested IAW Section 4 of this specification. Repair defects if found.

3.4.7 Fenders. Fenders shall be replaced IAW the applicable drawings, regardless of condition. The steel bolts that hold the fenders in place shall be replaced when the new block is installed. All steel surfaces under the fenders shall be blasted and painted with required primer and antifouling coats prior to installation of the fenders.

3.4.8 Tower/Cages.

3.4.8.1 Radar Reflectors. Radar reflector plates and reflector bars bent more than three degrees from a right angle shall be repaired to a tolerance of plus or minus one degree.

Holes, pits, cracks and any other structural defects shall be repaired by welding. Any areas of the reflector or reflector bars that are badly corroded and cannot be repaired by welding shall be replaced IAW the applicable drawings. These components shall be installed to plus or minus one degree (±1º) tolerance on all right angle intersections.

3.4.8.2 Tower Legs and Members. Tower legs or feet broken away from the buoy body shall be re-attached by welding. Tower legs bent more than 1 inch from a straight line over a two foot length shall be straightened. If necessary, the tower shall be straightened so that the center line of the tower is not more than two degrees from perpendicular to the buoy top head.

3.4.8.3 Lantern Ring. The lantern ring (steel ring located at the top of a lighted buoy’s tower) shall be straightened if it obstructs a properly installed light. Any ring that is bent, broken, cracked, missing or damaged in any other way shall be repaired or replaced.

The buoy’s mounting plate for the light shall be inspected for any damage from corrosion or collision and repaired by welding, or replaced, if it will not support a standard Coast Guard light. Bent, broken or missing guano bars shall be repaired or replaced with 1/8 inch by 3/4 inch steel bars.

3.4.9 Bell or Gong Stand Support Plate and Stand. The bell and gong stand support pipe and plate shall be inspected for wear, corrosion, cracks and/or distortion. A bent or cracked support pipe or plate shall be repaired or replaced. If the bell and gong stand support pipe and plate are missing on a 9x32LR, 9x20R, 8x26LR, 8x21LR, 7x17LR and 6x20LR buoy, record the finding on the QAIF IAW paragraph 3.6.

3.4.10 Battery Pockets. If the buoy is equipped with battery pockets, inspect the battery pockets per the below standards. Record findings on the QAIF IAW paragraph 3.6.

3.4.10.1 Battery Pocket Cylinder Inspection. All battery pocket cylinders are to be inspected for pitting, cracks, holes or corrosion. The junction of the crossover tube to the battery pocket cylinder shall be inspected for the presence of excess slag or other welding material or defects that could impair the function of the crossover tube. All foreign matter shall be removed from the pocket prior to surface preparation and painting. This inspection is waived if the delivery order states that battery pockets are scheduled to be closed as per 3.5.2.

3.4.10.2 Battery Pocket Component Inspection. Battery pocket covers, stainless steel vent lines, flanges and associated components shall be inspected for breaks, pinched tubing, loose fittings, damaged hose, plugged tubes, cracks, pitting, warpage, defects, missing hardware and proper configuration IAW the drawings. Lighted buoys have been built with three different types of battery pocket flange closures- swing bolts, v-band and bolted. Identification of v-band or bolted closures (excluding 7x20LI / LIR buoys) shall be reported on the QAIF IAW paragraph 3.6. This inspection is waived if the delivery order states that battery pockets are scheduled to be closed as per 3.5.2.

3.4.10.3 Gaskets. Battery pocket cover gaskets shall be renewed as part of the standard overhaul and IAW the applicable drawings. (121104 or 121143). Gasket renewal is waived if the delivery order states that battery pockets are scheduled to be closed as per 3.5.2.

3.4.10.4 7x20LI/LIR Battery Pocket Flanges and Hardware. 7x20LI / 7x20LIR buoys shall have all mounting studs and battery pocket flanges inspected for cracks, pitting, broken/bent or stripped studs. Repair defects IAW the applicable drawings.

3.4.11 Air Test Fittings. All air test fittings including plugs and coupling inserts shall be inspected for damage or excess wear. Damaged air test fittings shall be repaired or replaced IAW the applicable drawings.

3.4.12 Air Test. After blasting and completion of standard and conditional repairs, but prior to the application of paint, the buoy body and battery pocket(s) shall be subjected to an air test IAW Section 4 of this specification.

3.4.13 Painting.

3.4.13.1 General. All painting shall be performed after the buoy has completed the required surface preparation, repairs and the buoy has successfully passed the required air test(s). All welding, machining, cutting, drilling, forming, or any other operation which would damage the coating system shall be performed prior to painting. The manufacturers' instructions for correct application of the coating system shall be followed. In addition, appropriate worker safety procedures for the application of the coating system shall be implemented, and procedures are strictly followed by the paint applicators.

3.4.13.2 Buoy Coating System. The buoy coating system consists of three components:

a high-build epoxy primer, an ablative antifouling paint, and a marine-grade aliphatic polyurethane topcoat. 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 applied to a given buoy shall be from the same manufacturer. This is to provide compatibility between coats, validate the manufacturers' warranties, and ensure the Coast Guard receives adequate technical support to correct problems and increase productivity.

3.4.13.3 Application. Follow the manufacturer's instructions for correct application of the coating system. This includes complying with temperature, humidity, and dew point restrictions; storage, mixing, and induction time requirements; and specific requirements related to equipment and application techniques. Record the paint application environmental readings and times listed above on the QAIF IAW paragraph 3.6.

3.4.13.4 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-PRF-24647, Type II, Class 1, Grades A or B, Application 1, 2, or 3 and shall be listed in QPL-24647. Apply by spraying two coats, 5-7 mils dry film thickness each, using contrasting colors for each coat. Sharp corners, welds, edges, and other hard-to-coat areas shall be striped before each full coat is applied.

3.4.13.5 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-PRF-24647, Type II, Class 1, Grades A or B, Application 1, 2, or 3 and shall be listed in QPL-24647. Apply by spraying two coats, 5- 7 mils dry film thickness each, using contrasting colors for each coat (black followed by red). Commence application of the first coat of antifouling when the epoxy is tack-free (i.e., the epoxy can be lightly touched with no paint coming off on the fingertips) and no later than when the epoxy is still slightly soft to finger pressure. If the epoxy has cured too hard (no longer soft to finger pressure), apply another 1-2 mils wet film thickness of epoxy, following the manufacturer's specified recoat interval. Then, commence application of the antifouling as described above. Failure to apply the antifouling to the epoxy in this manner may result in loss of adhesion and premature failure of the coating system. Sharp corners, edges, and other hard-to-coat areas shall be striped before each full coat is applied.

3.4.13.6 Polyurethane Topcoat. All exterior surfaces above the waterline (with exception of battery pocket fastener threads, gaskets, bells, gongs and whistles) shall be coated with a marine grade of acrylic aliphatic polyurethane (waterlines for the purpose of painting are indicated in Figure 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 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; and 3) it shall meet the requirements of SSPC Paint Specification No. 36, Level 3. Apply by spraying one coat, 3-4 mils dry film thickness. Sharp corners, edges, and other hard-to-coat areas shall be striped prior to the full coating. Ensure vent valve openings are protected to prevent damage or blockage. The required colors shall be IAW SAE AMS-STD-595:

Color SAE AMS-STD-595 Red Federal Color 11350

Green Federal Color 14193 Black Federal Color 27038 Yellow Federal Color 13655 White Federal Color 27875 Blue Federal Color 15182

3.4.13.6.1 Preferred Channel Paint Scheme. When specified, 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 entire 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.

3.4.13.6.2 Isolated Danger Paint Scheme. When specified, a buoy shall be painted with an isolated danger paint scheme. The buoy shall be painted with three horizontal stripes above the water line. The stripes will be black/red/black. 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 3 shows the stripe configuration for various buoys.

3.4.13.6.3 Safewater Paint Scheme. When specified, 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 4).

When viewed from any angle around the buoy while the hull is in the vertical position, the right vane of the radar reflector and tower shall be red as seen in Figure 4. The interior surfaces of the tower legs, cross braces and the underside of the lower horizontal radar reflector panel can be painted solid white.

3.4.13.6.4 Mooring Buoy Paint Scheme. When specified, a buoy shall be painted with a mooring buoy paint scheme. Usually 2nd Class unlighted buoy hulls are used for mooring buoys (see Figure 5). Solid white color on all steel surfaces above the waterline. “Narrow” blue band painted horizontally around buoy midway between the buoy top and the waterline. The blue band shall be 17% to 20% as wide as the distance from the top head to the waterline. Example: As noted in Figure 1 below, a

2nd Class unlighted buoy has a standard water line of 36 inches. 17% to 20% of 36 inches is 6.12 to 7.2 inches.

Figure 1 Standard Waterlines for Steel Ocean Buoys

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

Buoy Waterline (in.)

Buoy Waterline (in.)

9X35LWR 24 1NR/1CR 60

9X32LR 30 1NT 152**

9X20BR/GR 18 1CT 108**

8X26LR 24 2NR/2CR 36

8X26LWR 24 3NR/3CR 24

8X21LR 24 3NI 60**

7X20LI/LIR * 3CI 54**

7X17LR 18 5NR/5CR 24

6X20LR 18 5NI 46**

5X11LR 12 5CI 33**

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

Standard Waterlines

Figure 2 Preferred Channel Paint Scheme

Figure 3 Isolated Danger Paint Scheme

½ X X

Figure 4 Safewater Paint Scheme

Figure 5 Mooring Buoy Paint Scheme

3.5 Condition-Based Overhaul. The following inspections/repairs shall be completed if activated on a delivery order. All inspections and tests shall be performed IAW Section 4 of this specification.

3.5.1 Battery Pocket(s) Repairs

3.5.1.1 Battery Pocket Component Repairs. Battery pocket cylinders, covers, stainless steel vent lines, flanges and closure devices/components with breaks, pinched portions, loose fittings, damaged hose, plugged tubes, warpage, defects and incorrect configuration shall be repaired IAW the applicable drawings. Cracks, pitting, holes or other defects in steel shall be repaired by welding. Any swing bolt or clevis pin that has damaged threads, is bent or cannot swing freely into position or pocket covers that are damaged beyond practical repair, shall be replaced IAW the applicable drawings. Cotter pins shall be replaced with stainless steel cotter pins. Clevis pin washers can be reused if in good condition and shall be made of stainless steel. This covers the repair of one battery pocket. This does not apply to 7x20 LI or LIR buoys since repair of 7x20 buoy battery pockets is addressed in section 3.4.10.4.

3.5.1.2 Pocket Flange(s) and Closure Device Conversion. Lighted buoys have been built with three different types of battery pocket flange closures- Swing Bolts, V-band and Bolted. If directed in the delivery order, V-band or Bolted closures (excluding 7x20LI / LIR buoys) shall be replaced with a swing bolt flange per drawing 121102, 121104, 121143, 121160 or 121162 as applicable. This covers the conversion of both battery pockets.

3.5.2 Permanently Close Battery Pocket(s).

3.5.2.1 Permanently Close Battery Pockets on 8x26LR, 8x21LR, 7x17LR, or 6x20LR.

Remove the battery pocket covers, vent lines and all associated hardware. Both battery pocket wrappers shall be cut flush with the buoy top head. ¼ inch metal plates shall be inserted and welded in place as to not overlap while providing a smooth weld with the top head.

3.5.2.2 Permanent Close Battery Pocket on 5x11LR. Remove battery pocket cover and reflector stand pipe. Crop the radar reflector support stand and pipe stiffeners off the battery pocket cover. Retain reflector support stand. Crop/remove vent pipes, vent brackets, and associated hardware from support stand. The NPT coupling (Item 59, Drawing 121158) fitting shall remain as an air test fitting. Install an NPT pipe plug in the coupling. Weld vent pipe holes closed in radar reflector support plate (Item 5, Drawing 121158) and grind flush. Crop battery pocket swing bold mounts off the battery pocket flange and grind flush. Weld ¼ inch metal plate on top of the battery pocket wrapper/flange (item 12, drawing 121158) as to not overhang the battery pocket wrapper/flange. Cut or drill a 2 inch hole in the center of the new battery pocket cover plate to allow airflow during air tests. Weld previously retained radar reflector support stand and pipe stiffeners onto the new battery pocket cover plate over 2 inch hole.

Orient radar support stand pipe so radar plates align with the lifting eyes of the buoy.

Ensure the radar reflector support pipe is centered and perpendicular to buoy top head and the top of the radar reflector support plate (item 5, Drawing 121158) is 33-1/4 inch to 33-3/4 inch above the top head.

3.5.3 Cage/Tower Replacement. Crop and dispose any cage/tower remnants at the buoy body top and renew/install a new cage/tower, welding to the buoy body IAW the applicable drawings.

3.5.4 7x20LI Conversion to LIR. Crop and dispose of the non-radar reflective top between the buoy body and battery pocket assembly. Fabricate and install radar reflector assembly between buoy body and battery pocket assembly. Weld to sound metal and restore structural integrity of the buoy hull. Fabrication and positioning of reflector shall be completed as per drawing 121193.

3.5.5 Mooring/Lifting Eye Installation. This work item applies to renewal of one missing or improperly configured mooring/lifting eye. Crop out mooring/lifting eye if present, fabricate and install new mooring/lifting eye, welding to the buoy body IAW the applicable drawings.

3.5.6 Mooring Arm Installation. This work item applies to renewal of one missing or improperly configured mooring arm and associated components. Crop mooring arm, pin and retainer if present, repair damage to support or doubler plate by welding as necessary. Fabricate and install new mooring arm pin, mooring arm, and retainer welding to the buoy body IAW the applicable drawings.

3.5.7 Bell and Gong Support Plate and Stand. If not already installed on the buoy, fabricate and install a bell and gong stand support pipe and flange plate on a 9x32LR, 9x20R 8x26LR, 8x21LR, 7x17LR and 6x20LR buoy IAW the applicable drawings.

3.5.8 Counterweight Tube Replacement. If a counterweight tube or portion thereof is replaced, it shall be replaced with a pipe of equal thickness, diameter and length. If the counterweight tube being replaced was outfitted with gussets, the replacement tube shall also be outfitted with gussets of the same size and in the same location. The cast iron counterweight shall be removed from the damaged counterweight tube and installed on the new tube IAW Section 3.2.7. A new counterweight tube shall be equipped with chafing blocks if the one being replaced was so equipped. The location and manner in which the chafing block is installed shall be the same as on the original counterweight tube. Note that some counterweight tubes are of sealed construction and some are open. A counterweight tube shall be replaced with the same type of tube.

3.5.9 Serial Number Modification. If specified, a buoy’s serial number shall be modified.

As specified in a Task Order, grind off and/or add digits to a serial number. The serial number 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 number. The characters of the serial number 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.

3.5.10 Sound Signal Outfitting. If a sound signal is specified to be outfitted on a buoy, the following sections shall be completed after the application of the coating system.

3.5.10.1 Bell Installation. If specified, a buoy shall be outfitted with a bell. The bell shall be installed on its proper bell stand (85 lb bell stand or 225 lb bell stand). The bell and bell stand will be provided as GFP. 225 lb bells may be installed on 9x32LR, 9x20R, 8x26LR or 8x21LR buoys. 85 lb bells may be installed on 7x17LR and 6x20LR buoys.

The bell and bell stand shall be attached to the buoy bell stand support plate with stainless steel hardware using lock washers and locking nuts. Isolation pads shall be inserted between the bell and stand IAW applicable drawings. Each bell shall have four properly adjust tappers. Each tapper ball shall be adjusted so that the ball’s centerline is located 1-1/4 inch above the lower edge of the bell.

3.5.10.2 Gong Set Installation. If specified, a buoy shall be outfitted with a gong set.

The gong set shall be installed on the gong stand. The gong and gong stand will be provided as GFP. Gong sets shall only be installed on 9x32LR, 9x20R, 8x26LR or 8x21LR buoys. The gong set and gong stand shall be attached to the buoy’s gong stand support plate with stainless steel hardware using lock washers and locking nuts. Each gong set shall have four properly adjust tappers. Each tapper ball shall be adjusted so that the ball’s centerline is located 1-1/4 inch above the lower lip of the gong. On three gong sets the lowest gong shall have two tappers mounted on opposite sides of the buoy tower. One tapper shall be adjusted to the middle gong and one tapper to the top gong. Four gong sets shall have one tapper adjusted to strike each individual gong.

3.5.10.3 Tappers. Tappers on all sound buoys shall be inspected for condition and proper operation. Metal hinge tappers shall be replaced when the hinge bar is worn to 3/4 inch diameter, or the hinge support ring is worn to a thickness of 1/16 inch. The tapper must swing freely on its hinge or be repaired. Tappers bent more than 3 inches from a straight line over a 2 foot distance shall be straightened. On tappers with adjustable balls, the tapper ball shall be turned to an unworn area. When it can no longer be turned to an unworn area, the ball shall be replaced. When installing tapper hinge plate to the cage, flat washers made of stainless steel shall be placed under both the head and the nut of the bolt. When the tapper has been properly adjusted, a tack weld shall be made on the tapper to prevent the lower adjusting nut from backing off.

Rubber tapper stops shall be mounted on the buoy towers as shown in the applicable drawings.

3.5.10.4 Whistle and Whistle Valve. If specified, a buoy shall be outfitted with a whistle and whistle valve. Whistles and whistle valves will only be installed on 9x35LWR or 8x26LWR buoys. Install a cast bronze whistle and associated whistle valve, using stainless steel hardware; replace all gaskets, broken or missing studs and the four rubber-coated balls in the valve. The flange on the whistle valve shall be wrapped with a minimum of three layers of packing flax to prevent air from escaping between the flange and the whistle valve housing.

3.5.11 Disposal. The government may designate buoys for disposal based on findings of inspections. If approved and activated by the Contracting Officer, the Contractor shall stop further repair work on the buoy being disposed of, remove all sound signal equipment, tower, vent valves, top marks and RACON hardware (if their condition warrants future use as GFP). All removed components shall be added to the GFP inventory and retained at Contractor’s facility. Contractor shall update the QAIF IAW paragraph 3.6 and forward to the COR. Contractor can then dispose of the buoy as scrap.

3.6 Quality Assurance Inspection Form. The overhaul facility shall develop and provide a Quality Assurance Inspection Form (QAIF). The QAIF shall be used to document the standard overhaul inspections and tests performed on every buoy throughout its overhaul process. The form shall be printed on standard (i.e., 8½x11 inch) white paper.

Inspection results may be handwritten on the form. The form shall be prepared in the facility’s format and shall be legible, in English, and suitable for reproduction. The form shall be provided to the COR upon request or when reporting buoy condition and discrepancies via CFR.

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

a) Buoy classification and serial number.

b) Date of test(s) or inspection(s).

c) Test or inspection to be performed (list all tests and inspections required by section 3 and 4).

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

e) Results of tests or inspections to include metal wastage, pitting depth, total square footage of buoy body repair, description of significant damage, paint application environmental readings, etc.

f) Any photographs requested by COR needed to properly evaluate discrepancies.

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

g) Notes.

h) Printed name and signature of test personnel.

4. VERIFICATION

4.1 General. The quality assurance program shall meet the requirements of ANSI/ASQC Q9001. However, program does not have to be Q9001 certified.

4.2 Tests and Inspections.

4.2.1 Visual Inspection. All buoys shall be visually inspected upon start and completion of overhaul for conformance to this specification and the applicable drawings. The visual inspection shall include checks of dimensional conformance, mechanical fit, and alignment of parts, defects and workmanship. Any deficiencies shall be recorded on the

QAIF.

4.2.2 Air Test. Each buoy body and battery pocket shall be subjected to an air test as applicable 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. All air tests shall be conducted after the buoy has been blasted. 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.

4.2.2.1 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 to include inside battery pockets shall be checked for leaks by applying a soapy water solution. An air test shall be considered a failure if either a drop in pressure occurs or a leak is detected by the presence of bubbles after applying soapy water.

4.2.2.2 Battery Pocket Air Test. Seal the battery pockets with the appropriate pocket covers and cap the vent pipes. Vent lines shall be tested as part of the air test of the battery pockets. 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. While the battery pocket is pressurized, all new welds on the battery pocket shall be checked for leaks by applying a soapy water solution. An air test shall be considered a failure if either a drop in pressure occurs or a leak is detected by the presence of bubbles after applying soapy water.

4.2.2.3 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 one percent (1%) accuracy at the test pressure. The gauge shall have a 1 psi sensitivity.

4.2.3 Weld Inspections. All weld inspections shall be performed after a buoy has been blasted and prior to the application of the epoxy primer.

4.2.3.1 Visual Weld Inspection. All welds shall be visually inspected for quality IAW AWS D1.1 and AWS D1.2.

4.2.3.2 Non Destructive Testing (NDT). Welds in and around the lifting eyes, mooring eyes, mooring arm pins, tower feet and sound signal stand shall be inspected using either the magnetic particle testing method or liquid dye penetrant method. The procedures and technique for magnetic particle testing shall be IAW ASTM E709. The procedures and technique for liquid dye penetrant testing shall be IAW ASTM E165.

4.2.3.3 NDT Personnel Qualifications. Only personnel qualified for NDT Level II IAW SNT-TC-1A may perform the nondestructive testing.

4.2.4 Surface Profile Inspection. After the buoy has been blasted and 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.

4.2.5 Paint Inspection. Ensure that each buoy was painted IAW paragraph 3.4.10 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 (section 3.6).

4.2.6 Certifications Review. When requested by the COR, Contracting Specialist (KS), or KO, material certifications shall be provided for review.

5. DELIVERY

5.1 Shipping. Buoys shall ship fully assembled (with exception of 5x11 buoys) on a truck or trailer (e.g. flatbed, step-deck or double-drop trailer) that facilitates unloading buoys with a small crane or forklift. Buoys shall not be shipped in containers or "box" trailers. Vent tubes shall be capped to prevent water intrusion. Buoys outfitted with bells or gongs shall have tapper arms secured to the tower to prevent damage. Buoys shall be properly supported and protected from damage, including the paint, during shipment.

Lighted buoys shall be shipped horizontally (with exception of 5x11 and 6x20 buoys).

Towers and counterweights shall be appropriately supported. Chocks shall be used to support the buoy body. 5x11 LCR / LNR buoys are shipped vertically with their radar reflector detached at the radar reflector support plate or battery cover. Radar reflectors shall be shipped on the same trailer as their associated buoys. 6x20 LR buoys are shipped with their counterweight in contact with the trailer deck, chocked and secured in place. This allows the tower of an adjacent buoy to be positioned over the previous buoy’s counterweight allowing 3 hulls per 53’ trailer.

5.2 Loading. Following combinations can be hauled on a 53’ flatbed trailer. This is not an all-inclusive list of buoy combinations. Multiple types of buoys can be shipped on one truck:

Item Buoys Per 53’ Trailer

Diameter X Length

(ft. X ft.)

Shipping Weight Per Buoy

(lbs.)

9x35LWR * 1 9 X 35 18,500 9x35LR * 1 9 X 35 18,500 9x32LR * 1 9 X 32 17,500

9x20BR Bell * 2 9 X 20 8,000 9x20GR Gong * 2 9 X 20 8,000

8x26LR 2 8 x 26 11,800 8x26LWR Buoy 2 8 x 26 12,100

8x21LR 2 8 X 21 13,900 7x20LIR Buoy 3 7 X 20 6,500 7x17LR Buoy 3 7 X 17 7,800 6x20LR Buoy 3 6 X 20 6,500

5x11 LCR Buoy** 8 5 X 12 3,150 5x11 LNR Buoy** 8 5 X 12 3,150

1CR Buoy 3 5 X 19 6,100 1NR Buoy 3 5 X 20 6,000 2CR Buoy 6 4 X 14 2,800 2NR Buoy 6 4 X 15 2,600 3CR Buoy 8 3 X 9 1,200 3NR Buoy 8 3 X 10 1,175 3CI Buoy 12 3 X 13 1,550 3NI Buoy 12 3 X 14 1,550 5CR Buoy 12 2 X 9 710 5NR Buoy 12 2 X 10 710 5CI Buoy 12 2 X 8 700 5NI Buoy 12 2 X 9 700

* Indicates buoys that require a wide load certification.

SPECIFICATION NO. 507B -- OVERHAUL OF STEEL OCEAN BUOYS

MARCH 2020

Reviewed by:

LT Tyler Vieira Asset Line Manager

Waterways Operations Product Line

Approved by:

Wayne Danzik Deputy Manager Waterways Operations Product Line

Updated by:

CWO Paul Dalton Floating ATON Project Officer Waterways Operations Product Line

Reviewed by:

Sean McEvoy Asset Line Engineer Waterways Operations Product Line