IALAGUIDELINE

1006

PLASTICBUOYS

Edition3.1
December2013

DOCUMENTREVISION

RevisionstothisIALADocumentaretobenotedinthetablepriortotheissueofareviseddocument.

Date Page/SectionRevised RequirementforRevision

December2005 EntireDocument ReformattedtoreflectIALAdocumentationhierarchy

ReviewandupdateatIALAFloatingaids2008workshop
April2008 EntireDocument
andEEP11/12

ReferencestoGuideline1040deletedandreplacedby
December2013 Pages4,6,7,8and9
Guideline1077

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CONTENTS

1 INTRODUCTION...................................................................................................................................5
2 BACKGROUND.....................................................................................................................................5
2.1 Pointstobeconsideredwhenevaluatingplasticbuoys..........................................................................5
3 BUOYCONSTRUCTIONMATERIALS......................................................................................................6
3.1 POLYETHYLENE(ANNEXBFigure1,Figure2andFigure3)...................................................................6
3.1.1 General.......................................................................................................................................................................................6
3.1.2 Construction...............................................................................................................................................................................6
3.1.3 Repair&Maintenance................................................................................................................................................................7
3.1.4 Handling......................................................................................................................................................................................7
3.1.5 Recycling/Disposal....................................................................................................................................................................7
3.1.6 HealthandSafety.......................................................................................................................................................................7
3.2 GLASSREINFORCEDPLASTIC(GRP)(ANNEXCFigure4)........................................................................7
3.2.1 General.......................................................................................................................................................................................7
3.2.2 Construction...............................................................................................................................................................................7
3.2.3 RepairandMaintenance............................................................................................................................................................8
3.2.4 Handling......................................................................................................................................................................................8
3.2.5 Recycling/Disposal....................................................................................................................................................................8
3.2.6 Health&Safety...........................................................................................................................................................................8
3.3 POLYURETHANE/ELASTOMERCOATEDFOAM(ANNEXDFigure5)....................................................9
3.3.1 General.......................................................................................................................................................................................9
3.3.2 Construction...............................................................................................................................................................................9
3.4 ALLFOAM(ANNEXEFigure6andFigure7)..........................................................................................9
3.4.1 General.......................................................................................................................................................................................9
3.4.2 Construction...............................................................................................................................................................................9
4 DEFINITIONS......................................................................................................................................10
5 ACRONYMS........................................................................................................................................10
ANNEXA ADVANTAGESANDDISADVANTAGESOFPLASTICBUOYS...............................................................11
ANNEXB EXAMPLESOFPOLYETHYLENEBUOYS............................................................................................12
ANNEXC EXAMPLEOFGLASSREINFORCEDPLASTIC(GRP)BUOYS................................................................15
ANNEXD EXAMPLEOFPOLYURETHANE/ELASTOMERCOATEDFOAMBUOYS..............................................16
ANNEXE EXAMPLEOFFOAMBUOYS............................................................................................................17

ListofFigures
Figure1 SmallRotationallyMouldedBuoy...............................................................................................12
Figure2 AllPolyethyleneModularBuoy(exceptcastironballastandsteelmooringandliftingeyes)....13
Figure3 ModularBuoy..............................................................................................................................14
Figure4 LargeGlassReinforcedPlasticBuoy(PolyurethaneFoamFilled)................................................15
Figure5 Smallpolyurethane/elastomercoatedfoambuoy....................................................................16

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CONTENTS

Figure6 FoamBuoysfrom0.75mto1.6mdiameter...............................................................................17
Figure7 LargeModularfoambuoys.........................................................................................................18

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1 INTRODUCTION

Aplasticbuoymaybedefinedasafloatingaidwithatleastthehullbeingconstructedofaplasticmaterial.
Plasticbuoyshavebeeninproductionforovertwentyyears.Theyareproducedinvariousmaterialsanddesigns.
Initiallytheywereproducedinsmallsizes,butnowadaysthereareseveralmanufacturersproducingplasticbuoys
insizesuptoandinexcessof3mdiameter.

2 BACKGROUND

Manytypesofplasticbuoysareavailableinthemarketplace,rangingfromsmallharbourorrivermarkers,to
largeoffshorebuoys.
Itissuggestedthatplasticbuoyshaveseveraladvantagesoverconventionalsteelbuoysincluding;lightweight
handling,corrosionresistance,lowmaintenance,andinsomecases,lowercosts.However,theseapparent
advantagesneedcarefulevaluation.
2.1 POINTSTOBECONSIDEREDWHENEVALUATINGPLASTICBUOYS

1 Lightweightbuoysneedcarefuldesigntoavoidhavingarapidrollingorpitchingmotiondetractingfrom
theirnavigationaleffectivenessinwaves,windandcurrent.
2 A wellmanufactured buoy using highquality pigment within IALA chromaticity standards, and virgin
material,shouldretainanacceptablesurfacecolourforthedesignlifeofthebuoy,whichcanbeinexcessof
15yearsinmostclimaticconditions.However,highultravioletexposurewillacceleratetheageingprocess.
3 Someplasticmaterialsmayhavebetterresistancetodensemarinefoulingthanotherbuoytypes.Plastic
buoys must be sufficiently robust to withstand weed being scraped off, or high pressure water jetting,
regularlyduringtheworkinglifeofthebuoy.
4 Thepurchasecostofplasticbuoysisdependentontheconstructiontechnology.Wholelifecostsmaybeless
thansteeltypes;howeverusersshouldcarefullyassesstheirrequirementswithcostsfactors.
5 Plasticbuoytechnologiesofferflexibilitytoincorporatenewdesigndevelopments.
6 Someplasticsparbuoysareparticularlyadaptabletocertainiceconditions.
7 Themooringeye(oreyes)willusuallybemetalandmustthusbefastenedormouldedintothebuoybysome
meanssuchthattheinternalstructuretocansafelytransmitloadsfromliftingeyestomooringeyesandto
distributemooringloads.
8 Handlingplasticbuoysmayrequirenewtechniques.Thesafeworkingloadonplasticbuoysmaybelessthan
steeltypes.
9 Majorserviceintervalsmaybegovernedbythelifeexpectancyofthemetalsusedinthebuoyassembly.
10 Seabased maintenance can be achieved on most plastic buoys, including jet washing and other normal
servicetasks.Variousmaintenanceproceduresaresuitablefordifferentplasticmaterials.Moreguidanceis
availableinIALAGuidelineNo.1077(TheMaintenanceofBuoysandSmallAidstoNavigationStructures).
11 Themetalcomponentswillrequireamoreintensivemaintenanceregime,thereforethegradeofsteelmust
beconsidered,dependingonenvironmentalconditions(e.g.themooringeye,eitherof316Lstainlesssteel
orhotdippedgalvanizedsteel).
12 Itmaybenecessarytoincorporateanearthingstraponlargeplasticbuoystopreventthebuildupofstatic
electricity,whichmaycauseshockordamageelectronicequipment.

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3 BUOYCONSTRUCTIONMATERIALS

Plasticbuoysmaybegroupedintofourbasictypeswhicharelistedwithcommentsontheirdesignand
construction:
Polyethylene;
GlassReinforcedPlastic(GRP);
Polyurethane/elastomercoatedfoam;
Allfoam.
3.1 POLYETHYLENE(ANNEXBFIGURE1,FIGURE2ANDFIGURE3)

3.1.1 GENERAL
Thiswellknowntechniquehasbeenwidelyusedtomanufacturemanytypesofbuoys,inrotationallymouldedor
extrudedpolyethylene.Somemanufacturersmaythenfillthebuoywithpolyurethanefoamorpolystyrenefoam.
Thepolyethylenematerialmaybelinear(low,mediumorhighdensity)orcrosslinked.Thelinearmaterialhas
theadvantagethatitcanbemeltedandhencerepairedbyhotfusionwelding.Thepolyethylenematerialusedin
buoymanufactureisusuallylinear.
Thepolyethyleneprovidespooradhesionforconventionalpaints,butspecializedhotplasticsprayingprocesses
areavailableandhavebeenusedsuccessfullyforblackorwhitecoatings.Whencolourismouldedin,pigments
mustbeofthehighestqualitysuitableformarineuseandUVexposure.
Therotomouldingprocessisalsousedtomanufacturebuoyancymoduleswhichareattachedtoastructuralcore
whichmaybeintheformofabuoyoraresilientbeacon.
Themanufacturingprocesshasbeendevelopedinrecentyearstoallowtheproductionoflargefloats(3m
diameter)withwallthicknessintheorderof1020mmwhicharenowbeingusedasthebuoyancyelementof
substantialbuoys.Thesefloatsmaybemanufacturedinfoursegmentstosimplifyhandingandtransportand
allowareserveofbuoyancyshouldonesegmentbedamaged.
Forsmallbuoys(<1mdiameter)theassembledweightofpolyethylenebuoyscanbeequalorhigherthanthin
skinsteelbuoys.
3.1.2 CONSTRUCTION
Manufacturerstypicallyconstructpolyethylenebuoysfromonepieceplasticmouldings,modularplastic,or
hybridmetal/plasticdesigns.Polyethylenematerialwillexpandandcontractabout3to5%,dependingonthe
colourandambienttemperature.Generally,smallbuoysaremadeinonepiece,whilelargertypesmaybe
modularorhybriddesigns.
Thewallthicknessofthebuoybodymustbeproportionaltothesizeofthebuoytobesufficientlyrobust.The
thicknessofthewalldependsonthefillingofthebuoy,i.e.foamfilledornot.Forexample,foamfilledtobe
between612mm,andnotfoamfilledbebetween630mm,notethatthisshouldbeproportionaltothe
diameterofthebuoybodyof500mmto3000mm.
Polyethylenematerialwillexpandandcontractwithchangesintemperature.Careshouldbetakeninthedesign
toensurecompatibilitybetweendifferentmaterials(e.g.elongatedoroversizedclearanceholes).
3.1.2.1 Filling
Topreventthebuoysinkingthebuoymaybedividedintoseparatewatertightsegments,whichmaybefilledwith
foam.Iffoamisused,itmustbeofthehighestqualityclosedcellspecificationtopreventwaterabsorption.
Fillingmaterialshouldbeofsufficientqualitytosurvivetheexpectedlifetimeofthebuoy.Somedisadvantages
mayexistintheuseoffilling.Somepolyurethanefoamtypesmaynotbepossibletorecycle.

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3.1.2.2 Fasteners/Mooringattachment
Inthemanufacturingprocess,careshouldbetakentoensurethatthreadedinsertsarefixedandalignedcorrectly
inthematerial,otherwisetheyshouldbeavoided.
Caremustbetakenwhenusingthreadedinsertstoavoiddetachmentoftheinsertwithinthepolyethylene.
Itisdesirabletousenoncorrosivefastenersincludinghotdippedgalvanizedsteel,marinegradealuminium,
marinegradestainlesssteelorbronze.
Itisimportantthatanyhighloadsaredistributedthroughoutthestructureofthebuoyandnotconcentratedin
smallareasoftheskin.Onesolutiontoavoidthesestressesmaybetointerconnectthemooringandlifting
pointswithastructuralcoremember.
3.1.2.3 QualityControl
Themanufacturingmaterialsmustbecarefullyspecifiedandcertificationobtainedfromthemanufacturerto
ensurethatcorrectqualityvirginmaterialsandUVstabilizers(inboththepigmentandthepolyethylene)have
beenused.
3.1.3 REPAIR&MAINTENANCE
linearpolyethylenecanbeeasilyrepairedbytrainedtechniciansusinghotfusionweldingequipmentin
requiredcolours;
maintenanceproceduresareoutlinedinIALAGuidelineNo.1077.
3.1.4 HANDLING
Therearenospecificrequirements.
3.1.5 RECYCLING/DISPOSAL
Linearthermoplasticscanberecycled,howeveritmustbepossibletoseparateanymetalcomponentsand
impurities(marinegrowth/paintetc.)fromtheplastic,andremoveanyinternalfilling.
3.1.6 HEALTHANDSAFETY
Referencetoavailablematerialdatasheetsshouldbemadepriortomakinganyrepairsorwhenhandlingany
polyurethanefillingmaterial(e.g.disposal,fusionwelding).
3.2 GLASSREINFORCEDPLASTIC(GRP)(ANNEXCFIGURE4)

3.2.1 GENERAL
GRPistheusualabbreviationforglassreinforcedplasticwhichinitsmostcommonformconsistsofglassmatt
bondedbypolyesterresin.
3.2.2 CONSTRUCTION
Complexshapescanbeeasilyproducedbylayingupresinandglassreinforcementintoamouldbyhand(orspray
machine).Thecylindricalbuoybodyisusuallyformedbyjoiningtwohalfbodyshapes.Itisimportanttonotethat
thejoinisoftentheweakestareaofthebody.
ThestrengthofGRPisbasicallydependentoftheratioofglassfibretoresinandthusthisisanotherareawhich
requiresdefinitionandqualitycontrol.Highstrength(requirediniceconditions)canbeachievedbytheuseof
carbonorKevlarfibres,buttheircostsmaybehigh.Thesefibresmaybeusedinspecificstressareasofthebuoy.
Theouterlayerofresin,thegelcoat,preventswaterabsorptionintotheglassreinforcementandmustbe
protectedfrommechanicaldamage.Thisisusuallyprovidedbysomeformoffendering.

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3.2.2.1 Filling
Intheeventofacollision,aGRPbuoymaywellcrackfromanimpactwhichwouldonlydentasteelbuoy.To
preventthebuoysinkingthebuoyshouldbedividedintoseparatewatertightcompartmentsorfilledwith
polyurethanefoamorpolystyrenefoam.Iffoamisuseditmustbeofthehighestqualityclosedcellspecification.
Ifthefoamisporousitmayabsorbwateroveralongperiodoftimeandincreasetheweightofthebuoytosuch
anextentthatitcannotbeliftedbytheservicingcraft,orthebuoymaysink.
3.2.2.2 Fasteners/Mooringattachment
CaremustbetakenwhenbondingmetalattachmentpointsintoGRPduetotheconsiderabledifferencein
thermalexpansionratesbetweenmetalsandplastics,andtheinherentflexibilityoftheGRP.Anotheroptionisto
usethroughboltedfixingswithgenerousbackingplatesandresilientwashersorcoatingsbetweenthemetaland
theGRP.
Itisdesirabletousenoncorrosivefastenersincluding;hotdippedgalvanizedsteel,marinegradealuminium,
marinegradestainlesssteelorbronze.
Similarproblemsmayexistwiththefasteningofliftingeyesandtowertypesuperstructures.Itisimportantthat
anyhighloadsaredistributedthroughoutthestructureofthebuoyandnotconcentratedinsmallareasofthe
skin.Onesolutiontothisproblemistoincorporateacentral(usuallysteel)spinetoconnectthemooringeyes,
liftingeyesandsuperstructure.
3.2.2.3 QualityControl
Asmanycommonlyavailabletypesofglassfibreandpolyesterresinhavelimitedresistancetoextended
immersioninwater,themanufacturingmaterialsmustbecarefullyspecifiedandcertificationobtainedfromthe
manufacturertoensurethatcorrectqualitymaterialshavebeenused.Confirmationmustalsobeobtainedthat
laminatingandcuringhastakenplaceinthecorrectenvironment.
3.2.3 REPAIRANDMAINTENANCE
GRPbuoyswillrequirecleaning,repaintingandanynecessaryrepairtothegelcoat.
RepairofGRPisusuallystraightforwardbutdoesrequirestandardsofcleanlinessandspecificworking
temperatures.Effectivedryingofdamagedlaminatesorfoamcoresmayalsobedifficultincoldclimates.Itmay
benecessarytouseheaterstowarmanddrydamageareasandtoensureeffectivecuringoftherepair.
ThefinalsurfacecolourofGRPbuoyscanbeincorporatedintothegelcoat.Ifthisnotthecaseorifacolour
changeisrequired,thenbuoyswillrequirenormalpaintingtoachievetherequiredsurfacecolours.
GRPbuoysmaybecleanedonsiteusingwaterjetting,howevercareshouldbetakentoensurepaintflakesand
surfacematerialsavoidpollutingthesurroundingenvironment.
TheareainwhichafoamfilledbuoysareusedmustbeconsideredasoilywaterinaroundthePortenvironment
couldpenetratethedamagedbuoys,makingtherepairofitverydifficult.
MaintenanceproceduresareoutlinedinIALAGuidelineNo.1077.
3.2.4 HANDLING
CareshouldbetakentoavoiddamagetotheGRPthroughimpactduetoitsrigidity.
3.2.5 RECYCLING/DISPOSAL
CrushedGRPmaybeusedasacomponentforroadconstruction.Therefore,itmaybeconsideredasarecyclable
material.
3.2.6 HEALTH&SAFETY
Theuseoflaminatingresinsandsolventsissubjecttoincreasingcontrolbyhealthandsafetyregulations.

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3.3 POLYURETHANE/ELASTOMERCOATEDFOAM(ANNEXDFIGURE5)

3.3.1 GENERAL
Thesebuoystypicallyconsistofathick,flexiblemarinegradepolyurethaneelastomerskinonaflexibleclosedcell
foamcore.Theyhavetheadvantageofoverallflexibilityandresilience.Theflexibilitywillalsobeanadvantage
whenthebuoyhastobeliftedorservicedinroughweather.
3.3.2 CONSTRUCTION
Thebuoysareusuallymanufacturedbysprayingthepolyurethaneskinmaterialontoashapedfoamcoreandcan
thusbemadetoalmostanyrequiredshapewithouttheneedforanexpensivemould.
Inthemanufacturingprocess,particularattentionmustbemadetotheattachmentortheinterfacebetweenthe
flexibleskinandsteelmooringeyes.Thisrequiresverycarefuldesigntopreventwaterpenetrationintothefoam
ortearingoftheskin.
Thequalityoftheskinandfoammaterialsisoftheutmostimportance.Theconsequencesoffailureoftheskin
areselfevidentbutpoorqualityfoammayabsorbwaterthroughanapparentlysoundskinormaysimplyshrink,
resultinginawrinkledbuoywithaconsiderablelossofbuoyancy!
3.3.2.1 Fasteners/Mooringattachment
ThepointsnotedregardingmooringeyesonGRPbuoysapplyequallytothesebuoys.Theconceptofacentral
structuresteelspinebetweenthemooringandliftingeyesiscommonlyemployed.
3.3.2.2 Repair&maintenance
Polyurethanemayberepairedwithtwocomponentpouringortrowellingcompounds.Correctworking
conditionsarecritical(temperatureandhumidity)anddetailedhealthandsafetyprecautionsmustbeobserved.
3.3.2.3 Maintenanceprocedures
TheseareoutlinedinIALAGuidelineNo.1077.
3.3.2.4 Handling
Therearenospecificrequirements.
3.3.2.5 Recycling/Disposal
Polyurethaneproductsaredifficulttorecycle.
3.3.2.6 Heath&Safety
Themanufacturedpolyurethaneproductspresentnoparticularhealthandsafetyrisksinnormaluse,butare
hazardousifignited.
3.4 ALLFOAM(ANNEXEFIGURE6ANDFIGURE7)

3.4.1 GENERAL
Thelifeanddurabilityofthebuoyisentirelydependentonthequalityofthefoamused.Theflexibilityofthe
foamcanprovidegoodimpactresistancebutresistancetoaggressiveabrasionisnotgood.Thislastfactoris
importantforbuoyswhichwilldryoutonahardbottomatatidalsiteormaybesubjecttomovingiceconditions.
Afoambuoyhullcansustainconsiderabledamageorlossofmaterialwithoutsinking.Adamagedbuoymaybe
repairedorrecycledbythemanufacturer.Otheradvantagesoffoambuoysincludetheirlighterweightwhich
mayresultingoodperformanceinfastwater.
3.4.2 CONSTRUCTION
Thesebuoysareusuallyconstructedbywrappingclosedcellfoamaroundacentralstructuralcore,thelayersof
foambeingheatsealedtogetherduringthewrappingprocess.AmajorUSmanufacturerusesionomerfoam

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whichisproducedinsheetform.Theouterlayeroftherolledfoamshapescanbedensifiedthroughthe
applicationofpressureandheattomakeahard,smoothsurface.Pigmentsareusuallyincorporatedintothe
foamduringtheextrusionprocess,sothecolouriscontinuousthroughouttheentirehullanddaymark.The
buoysincludeastructuralsteelframework,steelliftingandmooringeyes,andstainlesssteelconnecting
hardware.Internalradarreflectorscanbemountedinthedaymarks.
Themanufacturingtechniqueparticularlylendsitselftotheproductionofoneoffdesignsasavarietyofbody
shapescanbemadewithouttheneedforamould.Buoysofthistypearesignificantlylighterthansteelbuoysof
thesamesize.
3.4.2.1 Fasteners/Mooringattachment
Pleaserefertothesectiononpolyurethane/elastomercoatedfoam(Section3.3refers).
3.4.2.2 Repairandmaintenanceprocedures
TheseareoutlinedinIALAGuidelineNo.1077.
3.4.2.3 Handling
Therearenospecificrequirements.
3.4.2.4 Recycling/Disposal
Theproductisgenerallyrecyclablethroughthemanufacturer.
3.4.2.5 HeathandSafety
Therearenospecificissues.

4 DEFINITIONS

ThedefinitionoftermsusedinthisGuidelinecanbefoundintheInternationalDictionaryofMarineAidsto
Navigation(IALADictionary)athttp://www.ialaaism.org/wiki/dictionary.

5 ACRONYMS

GRP GlassReinforcedPlastic(fibreglass)
IALA InternationalAssociationofMarineAidstoNavigationandLighthouseAuthoritiesAISM
m metre
mm millimetre
PE polyethylene
US UnitedStates(ofAmerica)
UV UltraViolet(light)(10380nm)

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ANNEXA ADVANTAGESANDDISADVANTAGESOFPLASTICBUOYS

A1. ADVANTAGES
plasticdoesnotcorrode;
itiseasiertomaintain;onlyremovalofmarinegrowth,nopaintingonstation;
thecompletemaintenancecanbecarriedoutatseaifsuitablevesselsareavailable;
thereislessmaintenanceonshorefortheplasticcomponent(nogritblasting,nopaintingwiththeexception
ofGRP)thereforelessresourcesmaybeutilised;
plasticbuoysareoflowerweight(1/2to1/3massoftheequivalentdiametersteelbuoys).Therefore,the
servicemaybeabletousesmallerbuoytender;
wholelifecostsmaybelessthansteelbuoys;
FranceandTheNetherlands,amongstothers,havemorethanfifteenyearsexperienceofoperating
rotationallymouldedpolyethylene(PE)plasticbuoyssuccessfully;
thereareanumberofcommercialcompaniesofferinglargerotationallymouldedplasticbuoys;
mostplasticisrecyclable;
whereplasticbuoysareofmodularconstruction,itispossibletochangeindividualpartsorsegmentsifthey
aredamagedorneedrefurbishment;
largemodularbuoysareeasiertotransportandstore,aspartscanbedisassembledfortransit;
thenumberofspareparts(wholebuoysheld)canbereduced;
itispossibletoencasearadarreflectorwithinaplasticbuoyssuperstructure.

A2. DISADVANTAGES
duetothelighterweightofplasticbuoys,theremaybemoremotiononstation;however,thismaybe
mitigatedinthedesign;
itismoredifficulttochangethecolourofaplasticbuoy,asconventionalpaintingisnotreliableforplastic
surfaces;
oncurrentestimates,plasticbuoyshaveashorterlifetimethansteelbuoys;
plasticbuoycomponentswillbespecifictoeachmanufacturerandmaytherefore,notbeinterchangeable;
plasticbuoysarepoorradartargets,therebyrequiringaradarreflector,ifradarrecognitionisrequired;
GRPbuoysarepronetoimpactdamage,extremehotandcoldweatherdamageandagingwithprolongedUV
exposurewhichdegradesthesurfacefinish,whichcancausefibreglasssplintersinjuringservicingpersonnel.

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ANNEXB EXAMPLESOFPOLYETHYLENEBUOYS

Figure1 SmallRotationallyMouldedBuoy

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Figure2 AllPolyethyleneModularBuoy(exceptcastironballastandsteelmooringandliftingeyes)

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Figure3 ModularBuoy

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ANNEXC EXAMPLEOFGLASSREINFORCEDPLASTIC(GRP)BUOYS

Figure4 LargeGlassReinforcedPlasticBuoy(PolyurethaneFoamFilled)

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ANNEXD EXAMPLEOFPOLYURETHANE/ELASTOMERCOATEDFOAMBUOYS

Figure5 Smallpolyurethane/elastomercoatedfoambuoy

Note:Largepolyurethane/elastomercoatedfoambuoysarealsoavailable.

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ANNEXE EXAMPLEOFFOAMBUOYS

Figure6 FoamBuoysfrom0.75mto1.6mdiameter

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Figure7 LargeModularfoambuoys

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