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Division 3 - Construction & Installation.

Chapter 1 - General.

3100. This Chapter assumes that all construction, fabrication and installation complies with drawings, specifications and other relevant data provided by the design organization, and which has been approved.

3101. All construction, fabrication and installation operations shall be performed or supervised by persons holding appropriate and valid qualifications, licenses or permits. All welding shall be performed by persons holding current certificates issued by a recognized organization valid for the welding operation being performed.

3102. No departure shall be made from design data or drawings provided by the design organization without reference to the designer, who shall review and if necessary re-issue the data or drawings.

3103. All fabrication processes and treatments shall be performed under appropriately controlled conditions, using materials and correctly adjusted equipment as required to provide the specified product.

3104. Recognized standards appropriate to the work being performed shall be employed unless specifically authorized otherwise by the design organization.

3105. The installation of any equipment or component shall comply with any special instructions provided by the equipment manufacturer.

3106. All fluid-carrying pipes shall be identified as to contents and function (e.g. fuel vent; hydraulic oil return) at each end and at intervals where servicing or maintenance operations require identification.

3107. All electrical wires and cables shall be marked to identify their circuit or service.

3108. Electrical connections requiring soldered assembly shall be made using non-corrosive solder.

3109. All electrical connectors shall be installed to provide accessibility for inspection and maintenance.

3110. All connections in electrical circuits associated with essential services shall be positively secured.

Chapter 2 - Tests during Construction. ^

3200. Rigid Structure.

The manufacturer shall make arrangements for suitable testing of structural samples of fabricated structure to confirm structural properties assumed in design calculations. Tests shall be conducted according to an approved method, and the selection of sample locations may require to be approved.

3201. In addition to the structural testing required by section 3200, the manufacturer may be required to arrange for non-destructive testing of selected sections of the vehicle structure or assemblies. The selection of such test requirements will be related to results of the structural tests, and to the design structural analysis.

3202. Fire Safety.

The manufacturer shall submit a full-scale specimen of each type of boundary intended to be installed to provide structural fire protection of a Designated Fire Zone. The specimens shall be not less than 4.65 square metres in surface area, and shall have one axial dimension at least 2.44 meters in length. The specimen shall be fully representative, including all treatments and finishes to be installed integral with the boundary, and shall include representative joints and fire-resistant penetrations. The fire test shall be the standard fire test as defined in Division 1 Section 1002(c) of these Standards, and shall be performed by a recognized fire testing agency.

3203. The manufacturer may be required to submit representative samples of any deck, bulkhead, deck-head, trim or furnishing fabric, and of electrical wiring for appropriate fire safety testing by a recognized fire testing agency.

3204. Upon completion of the prototype vehicle, all electrical supply and distribution circuits and mechanical devices associated with fire detection and extinguishing shall be tested for each Designated Fire Zone to establish electrical continuity and correct functioning. Where the vehicle design includes fixed remote-controlled fire extinguishing systems, the vehicle system shall be used to demonstrate the satisfactory discharge and retention of the fire extinguishing used in a Designated Fire Zone. Where Designated Fire Zones or fire extinguishing discharge arrangements are significantly different, satisfactory demonstration of each arrangement may be required.

3205. The testing required by section 3204 shall be arranged to provide a record of fire extinguishing penetration and retention within the Designated Fire Zone, and shall be conducted with the assistance of a recognized fire protection specialist agency.

3206. Flexible Structures.

The manufacturer shall provide satisfactory evidence of such testing of flexible structure joints or bonds as may be required and agreed. Destructive testing by recognized test methods shall be performed to determine tensile, adhesion or peel strength as appropriate, on representative coupons made during manufacture of the flexible structure. These tests shall be performed under temperature conditions paying due regard to the environmental envelope of the vehicle for which certification is sought.

3207. Buoyancy spaces.

All structural spaces and all tanks, bladders or cells designed to contribute to buoyancy, and for which buoyancy credit is claimed, shall satisfactorily complete a pressure test. The testing medium shall be air or an inert gas, and the initial test pressure shall be not less than 1.5 times the theoretical draft of the space when the vehicle is floating in water at the maximum weight for which certification is sought. The test will be satisfactory if, at the end of 30 minutes, the pressure has not decreased by more than 10% of the initial value.

3208. No pressure testing of buoyancy spaces, tanks, bladders or cells shall be performed for the purposes of approval until all fabrication and installation which requires penetration of water-tight boundaries, or adjacent work which may affect water-tight integrity, has been completed.

3209. In designs where buoyancy spaces have common boundaries, each space shall be tested individually.

3210. Fuel Tanks and Fuel Tank Bays.

Fuel tanks which are integral structural spaces of the vehicle, designed to contain fuel or a bladder containing fuel, shall satisfactorily complete a pressure test, arrangements being made to blank any pipes or openings not normally subjected in service to fuel pressure. The test medium shall be air or an inert gas, and the initial pressure shall be a water head of not less than 1.5 times the maximum depth of the tank, or 1.5 times the maximum pressure to which the tank may be subject in service, whichever is the greater. The test will be satisfactory if, at the end of 30 minutes, the pressure has not decreased by more than 10% of the initial value.

3211. All rigid fuel tanks which do not form part of the vehicle structure shall comply with the pressure testing requirements of section 3210.

3212. All flexible bladder fuel tanks shall comply with the pressure testing requirements of section 3210. The manufacturer may submit for consideration that testing of bladders contained within a structural space may be integrated with the testing of that space as required by section 3210.

3213. No pressure testing of structural spaces designed to contain fuel, or of any tank or bladder designed to contain fuel, shall be performed for the purposes of approval until all connections and installation work have been completed.

3214. Hull Openings.

Any vents, discharges or openings in the hull below 76 mm. above the floating waterline in the damaged condition arising from any damage considered in Chapter 3 of Division 1 of these Standards at maximum weight for which certification is sought shall be tested for water-tight integrity. The hull joint of the opening shall be subjected to an externally applied jet of water at a pressure of not less than 207 kPa, for not less than 1 minute, during which time no internal seepage shall occur.

3215. Where hull openings referred to in section 3214 are fitted with closings, the closings are to be additionally subjected to a similar test when in the closed position.

3216. Bilge Pumping System.

All pipes, branches and components of permanently installed bilge pumping systems shall be subjected to an internal pressure test during the course of which an initial pressure of not less than 1.5 times the pressure which the pipe or component may experience in service shall not fall by more than 10% in 30 minutes.

3217. Systems Containing or Carrying Pressurized or Flammable Fluids.

Piping systems designed to carry fluids under pressure or flammable shall be subject to a pressure test to ensure integrity of all pipes, couplings and fittings. Test standards and procedures for each system shall be approved, generally requiring a pressure of not less than 1.5 times the pressure to which the system will be subjected in normal service. For special application system, e.g. fixed fire extinguishing, test standards required by an applicable system approval authority shall be observed.

3218. All metal pipes carrying flowing fluids which may generate static electricity shall be subjected to an electrical continuity test to ensure an adequate conducting discharge path to ground.

3219. Electrical Systems.

All switchboards and distribution panels shall be subjected to an insulation resistance test. With all circuit breakers and switches open and all fuse links removed, the insulation resistance shall be not less than 1 megohm measured between each bus-bar and ground and between each insulated bus-bar and the other pole(s).

3220. Paying due regard to normally applied voltages in service, all lighting and power circuits may be required to be subjected to an insulation resistance test between all insulated poles and ground, and where practical between poles.

3221. All circuits or systems provided for electrical bonding shall be tested to ensure that a continuous electrical path is provided.

Chapter 3 - Inspection during Construction. ^

3300. The manufacturer shall be responsible for ensuring that adequate inspection procedures are established and instituted in order to ensure that safety of operation of the vehicle, it's machinery and systems is not impaired during construction.

3301. The inspection function shall exercise adequate control to ensure quality of:-

1. Materials, components and equipment used in the vehicle manufacture;
   
   
2. Fabrication and treatment processes used in the vehicle manufacture;
   
   
3. Tools, equipment and machinery used in vehicle manufacture or in fabrication or treatment processes;
   
   
4.  Workmanship during fabrication or treatment processes and vehicle manufacture;
   
   
5. Standards and practices employed during vehicle manufacture, and during installation and assembly of equipment and components.

3302. The inspection function shall also be responsible for maintaining adequate standards of calibration or testing of tools, equipment or machinery used in the fabrication, manufacture and testing of the vehicle and it's machinery and systems.

3303. The inspection function shall conduct, or arrange for the conduct of, progressive inspections of the vehicle, it's sub-assemblies, components and installations during the course of manufacture or assembly to ensure compliance with drawings or design data and with established standards and practices.

3304. The inspection function shall also conduct, or arrange for the conduct of, such tests during construction as required by these Standards and by the vehicle designer.

3305. Permanent records of all inspections and tests required, and of their results, shall be maintained and made available where required for the purposes of approval.

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