Method of making syntatic modules

The method of providing a pipe member with syntatic modules as floatation devices comprising the steps of:

• a. forming a hollow preform mold having surfaces defining a cavity of desired configuration and forming a casting mold having surfaces defining a cavity of similar cross section including an arcuately convex surface for forming one surface of said modules with an arcuately concave surface thereof;
• b. forming a woven roving of predetermined size to provide a skin;
• c. forming a layer of spacing material of predetermined size and containing a plurality of voids therein;
• d. attaching the roving to the spacer material to form a laminate thereof;
• e. forming the laminate to the inside walls of the preform mold;
• f. filling the preform mold with a plurality of hollow balls;
• g. pouring a thin layer of resin into the preform mold to connect the balls and form the composite;
• h. removing the composite from the preform mold and placing end sections of spacing material thereon before placing it into the casting mold;
• i. adding a syntatic foam resin into the casting mold interior so as to fill all spaces between the balls and all voids in the spacer material;
• j. curing said syntatic foam resin and removing said mold parts so as to produce a module;
• k. repeating steps b through j to produce additional like modules;
• and
• 1. assembling said module segments around said pipe with the concave surfaces of said modules adjacent said pipe.