Floatex - OFFSHORE PRODUCTS

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OFFSHORE PRODUCTS

The knowledge and experience gained in the production of composed plastic materials and the laboratory extensive research, gives FLOATEX the capacity to fullfill the offshore industry requirements on special dedicated buoyancy materials.
Technique of resilient foam covered with a thick skin abrasion resistant elastomer, is widely utilised in the in-line production of fenders, bead floats, anchor pendant, pick-up and chain support buoys. Rotationally moulded technology is utilised for the production of hinged type deepwater floats manufactured in accordance with the latest OCIMF specifications and recommendations as well as special modules for the dredging industry.
FLOATEX internal laboratory facility enables independent inspection agencies to witness the test certificates issued.

PICK-UP BUOY TYPE ROTOMOULDED


The new generation of FLOATEX pick-up buoys have been designed to withstand the severe conditions associated with offshore operations.
The general construction scheme of in the inner part consist of shot blasted and galvanized steel structure.
The outer shell is obtained by means of a rotomoulding system, using high impact resistant polyethylene, the colour (on request) is imbedded in the plastic so that no painting is necessary for almost the whole pick-up buoy life time.
The material used for the foam filling is rigid monocellular polyurethane.

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POLYETHYLENE EXPANDED BUOY

Floats are high-quality buoys designed expressly for a marine environment.
The inner core of the floats is filled with a non-water absorbing closed-cell foam. This material is a rigid foam which permits the buoys to retain buoyancy even if submerged. The high quality buoys outer foam layer is semi-flexible and is specifically designed to absorb impacts. The foam is covered by a thick layer of reinforced elastomer specifically formulated for wear and abrasion resistance and for use in a marine environment. A heavy-wall steel pipe through the axis of the floats provides a high pull through load capability.

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CYLINDRICAL, SUPPORTING AND CHAIN BUOYS

All FLOATEX cylindrical, supporting and mooring buoys have been designed to withstand the severe operating conditions associated with offshore operations.
To achieve these characteristics the inner buoyancy core is realized applying spiral bending sheets of expanded cross-linked polyethylene.
The full closed-cell expanded Polyethylene used, guarantees the unsinkability of the buoy, also in case of accidental serious damages occurred during operations.
The outer Polyurethane skin provides the necessary abrasion and ultra-violet rays resistance to the buoy.
Standard outer colour is marine orange, but if requested, buoys can be manufactured in different colours.

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ANCHOR PENNANT BUOYS

This special type of buoy are produced by FLOATEX with the specific intent to provide a high degree of energy absorption and high resilience.
The general construction scheme consists of a central galvanized steel structure, a expanded rigid core, laminated resistant expanded PE around the inner core and a final elastomer PU cover. The outer elastomer cover will, in some cases, be reinforced by the application of special yarns blended into the layer, insuring a higher tear strength to the outer protective skin.
The heavy operating conditions foreseen for this type of buoy, can occasionally cause damages to the outer cover and to the floating expanded material. FLOATEX welcomes requests of repair on site, having developed a special portable equipment to regenerate damaged urethane covers and replace parts of broken expanded material.

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ROTATIVE ANCHOR PENNANT BUOY

This rotative type of buoy are produced by FLOATEX with the specific intent to provide a high degree of energy absorption and high resilience.
The general construction scheme consists of a central galvanized steel structure suitable to mount two separated floats made by laminated resistant expanded PE around the inner core and a final elastomer PU cover.The outer elastomer cover will, in some cases, be reinforced by the application of special yarns blended into the layer, insuring a higher tear strength to the outer protective skin.
The heavy operating conditions foreseen for this type of buoy, can occasionally cause damages to the outer cover and to the floating expanded material. FLOATEX welcomes requests of repair on site, having developed a special portable equipment to regenerate damaged urethane covers and replace parts of broken expanded material.


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MODULAR BUOYS

FLOATEX is specialised in production of Modular Buoys. The production of this type of buoys is based on our special know-how and technology. Therefore, we are able to offer a greater variety of sizes and dimensions for those models.
The FLOATEX MODULAR BUOYS are built for all offshore applications as oil rigs, supply vessels and other applications.
The Modular buoys are built up of interchangeable modules of plastic materials.
The materials used are sintermoulded cross-linked polyethylene and filled by polyurethane closed cell foam as core.
Modular Buoys range from a minimum 0,5 tons buoyancy up to any customers requirements.

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GIANT BUOY EXA 48/56-40

FLOATEX is specialised in production of Modular Buoys.
The production of this type of buoys is based on our special know-how and technology.
Therefore, we are able to offer a greater variety of sized and dimensions for this model.
GIANT MODULAR BUOYS are built for all offshore applications where great buoyancy capacity are required.
This modular buoys are built up of interchangeable modules of plastic materials able to be transported and shipped by container system to minimize logistic problems.
The materials used are rotomoulded polyethylene shells duly filled by polyurethane closed cell foam.

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CATAMARAN MOORING BUOY CAT 43/50

The CAT 43/50 is one of the giant buoy for mooring systems. This mooring buoy is designed for most of mooring projects.
These mooring buoys are built with interchangeable modules that are suitable to be transported and shipped into containers to reduce logistic problems.
We can also mount more modules to change the buoyancy and consequently the high of the floats.
The floats used for this buoy are made with rotomoulded polyethylene shells filled with polyurethane foam.
The metallic structure is made in galvanized steel, and has the important duty to support the modular floats and release the mooring hooks.
The production of this type of buoy is based on our special know-how and technology.

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HINGED BOLTED FLOATS

FLOATEX HINGED-BOLTED FLOATS are designed to provide buoyancy to submarine hose systems in order to maintain the required configuration.
The float consists two halves bolted together at one side, and hinged at the other one. The outer shell is obtained by means of a rotomoulding system, using high impact resistant polyethylene, orange coloured for surface use, and white coloured for underwater use.
The outer shell design allows also allows external steel or synthetic bands fastening if required, and the outer grooves give extra strength to the steel structure.
Special care is given to the filling of the float, applied by a computer controlled injection filling machine.
The material used is rigid monocellular PU foam and its density is determined by the operational depth of the floats.
Each float is clearly marked and registered as per required inspection procedure. Metal parts are realized in AISI 316 stainless steel, and the installation of the floats is very easy, also while the hose are under the water level.
Floats are duly tested following our Quality Control procedures, as per OCIMF specifications and requirements, and Test Certificates are issued after the satisfactory results.
Upon customer ‘s request, our floats can also be inspected by Qualified Inspection Agencies, such as R.T.D., Lloyd Register of Shipping, A.B.S., R.I.N.A., Bureau Veritas, etc.

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HINGED TURNBUCKLE FLOATS

FLOATEX HINGED-TURNBUCKLE FLOATS are designed to provide buoyancy to submarine hose systems in order to maintain the required configuration.
The float consists of two halves which are hinged together at one side, and fastened at the other side by means of an adjustable turnbuckle device. The outer shell is obtained by means of a rotomoulding system, using high impact resistant polyethylene, orange coloured for surface use, and white coloured for underwater use.
The outer shell design allows also external steel or synthetic bands fastening, if required, and the outer grooves give extra strength to the shell structure.
Special care is given to the filling of the float, applied by a computer controlled injection filling machine.
The material used is rigid monocellular PU foam and its density is determined by the operational depth of the floats.
Each float is clearly marked and registered as per required inspection procedure. Metal parts are realized in AISI 304 stainless steel, and the installation of the floats is very easy, even below water level.
Floats are duly tested following our Quality Control procedures, as per OCIMF specifications and requirements, and Test Certificates are issued after the satisfactory results.
Upon customer ‘s request, our floats can also be inspected by Qualified Inspection Agencies, such as R.T.D., Lloyd Register of Shipping, A.B.S., R.I.N.A., Bureau Veritas, etc.


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BEAD FLOATS AND INTEGRAL FLOATATION

Bead or ring floats and integral flotation for oil suction and discharge hoses have been in FLOATEX production program for a long time.
The ring floats are made of expanded cross-linked closed cell polyethylene foam, covered and protected by a layer of compact elastic polyurethane elastomer.
This flotation system is particularly useful for the application on gas-transport rubber hoses, allowing a high percentage of the hose outer surface to remain free for the natural gas transpiration through the rubber.
Rubber hose manufacturer’s requirements are enthusiastic about the application of ring floats, as FLOATEX is capable to fit all sizes, having a complete hose mandril set and a specific equipment for this type of work.
The same technology adopted to apply an integral flotation on O.S. & D. hoses has been successfully used for the rebuilding and repair of used oil hoses. This application can be of value to dredging industry.

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ANCILLARY EQUIPMENT FOR S.P.M. SYSTEM

Oil hose manufacturers and Oil terminals often refer to FLOATEX for the production and assembling of the various ancillary elements necessary to complete hoses strings for Single point Mooring System (S.P.M.).
Items like butterfly valves, Camlock coupling, ropes etc. not produced by FLOATEX are collected and then assembled with in house produced pick-up buoys, mooring buoys, blind flanges, winkerlights, diverters, etc.
This service is appreciated by clients desiring to group a number of small orders for different ancillary items for evident economical and practical reasons.

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DREDGING FLOATS

FLOATEX is specialised in production of dredging floats, to be applied on steel, polyethylene or rubber dredging pipes.
Floats can be realised in two different types of material:
Elastic closed-cell Polyethylene with external Elastomer Polyurethane cover, or Rotationally moulded Polyethylene shell filled with expanded closed cell foam.
Floats produced with these materials have more energy absorption capacity then fibreglass or steel floats and are easily reparable.
FLOATEX can also realises special floats outside the standard range and floats to be utilised to make floating valves and other accessories applied at the head of dredging line.


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FLOATING REDUCER AND “Y” PIECES

FLOATEX produces a full range of “Y” pieces and reducers for floating O.S. and D hoses strings, starting from 6’ inner diameter up to a 24”. The inner structure is made of galvanized steel while the outer floating body is made of expanded cross-linked polyethylene foam covered by a layer of elastomeric high impact resistant urethane. Below, a table shows the indicative dimensions and weight data for the whole range of floating reducers and “Y” pieces with a 25% minimum reserve buoyancy.


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EXPANDED POLYETHYLENE FENDERS

The FLOATEX expanded foam fenders have been developed to provide for maximum protection from damage by crushing apt to occur when operating under extremely difficult conditions such as side-by-side moorings in open sea or for cushioning off-shore oil platforms.
What these fenders offer in comparison with the alternative pneumatic rubber ones are the advantages of a major shock-absorbing capacity, a much more contained reaction force and full unsinkability.
The specific structure, being expanded foam covered with a relevant layer of polyurethane elastomer, for high abrasion resistance, requires a reduced turn off of interventions for maintenance.
A further asset is the use of different densities of expanded polyethylene for the core which enables FLOATEX to adjust the characteristics of energy absorption and reaction force to the specific technical requirements of individual circumstances.
The diagram below shows the behaviour of the expanded polyethylene when subject to compression and gives evidence of the very high performances offered by this product.
FLOATEX is also in a position to offer fenders shaped to customers’ specification, having available in-house the special equipment needed to manufacture pieces of different and complicated shapes.
Among the particular applications expected to occur are protection of mooring wharfs, vessels with special elements or parts to be cushioned, protection of lock entrances etc.
The cylindrical standard type of fenders are manufactured with an expanded polyethylene core wrapped up in overlapping and crossing layers, with a final covering of self pigmented polyurethane elastomer.
This type of construction ensures a notable resistance and reduces the frequent and burdensome number of interventions to a minimum.
According to customers’ requirements FLOATEX offers different types of attachment for their fenders: steel tube for mooring with heavy chain, with shackles, with flanges and double mooring eye.


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SPECIAL SUPPORTING FLOATS

FLOATEX has been requested to design and produce a special float to support steel pipes during launching operations.
This type of float is used to break down the immersion velocity, to avoid bendings over the designed limits of sealine pipes.
Fastened to the pipe by two bands (steel cable or nylon straps), the floats will be released by divers or by automatic self-releasing system allowing the buoyant element to recover the sea surface.
Particular attention has been given during the design to produce elements with dimensions to fit perfectly in a container to keep transport cost as low as possible.
Made of a hard polyethylene outer shell, these floats are filled with PU expanded rigid foams adjusted to guarantee an adequate resistance to the water depths foreseen for installation.

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