repair procedure of fiber boat

8/3/2019 Repair Procedure of Fiber Boat

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Guide to simple repairs ofFRP boats in a tropical climate

Guide to simple repairs ofFRP boats in a tropical climate

BOBP/MAG/27


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Guide to simple repairs of

FRP boats in a tropical climate

Thomas AnmarkrudFAO Consultant

Per DanielssonGlobal Project Coordinator

Safety at sea for small-scale fisheries in developing countries

&

Ari Gudmundsson


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DisclaimerThis guide was prepared during the course of the FAO project GCP/GLO/200/MUL. The designaemployed and the presentation of material in this information product do not imply the expression oopinion whatsoever on the part of the Food and Agriculture Organization of the United Nations (concerning the legal or development status of any country, territory, city or area or of its authoritieconcerning the delimitation of its frontiers or boundaries. The mention of specific companies or proof manufacturers, whether or not these have been patented, does not imply that these have been endorsedor recommended by FAO in preference to others of a similar nature that are not mentioned.

The views expressed in this publication are those of the authors and do not necessarily reflect the vieof FAO.

Copyright

All rights reserved. Reproduction and dissemination of material in this information product for educaor other non-commercial purposes are authorized without any prior written permission from the copyholders provided the source is fully acknowledged. Reproduction of material in this information prfor resale or other commercial purposes is prohibited without written permission of the copyright holApplications for such permission should be addressed to:Chief, Electronic Publishing Policy and Support Branch Communication Division, FAO, Viale delle di Caracalla, 00153 Rome, Italy or by e-mail to: [email protected]


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Foreword

This booklet was prepared under the FAO Project on Safety at sea for smscale fisheries in developing countries (GCP/GLO/200/MUL) implemin South Asia and West Africa during 2007 2009. It results from FAOsexperience in FRP work in many developing countries, particularly in Asia. Thisbooklet would be useful for fishers and small workshops in the fishing villagesto undertake minor repairs on the FRP boats. It may also serve as a guide forofficials of the department of fisheries and other concerned agencies with trainingin matters of simple repairs of FRP boats. It is recommended to translate andadapt the contents of this booklet for each target audience, in order toconsistent with the local weather conditions, topography, types of vessels, etc.


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AcknowledgementsThis guide to simple repairs of FRP boats in a tropical climate has been prepared with the suppof a number of people working with FRP boatbuilding. It was developed under the FAO pSafety at sea for small-scale fisheries in developing countries , GCP/GLO/200by the Swedish International Development Cooperation Agency (Sida) and the InternatMaritime Organization (IMO).

Most of the pictures and illustrations in the guide were provided by Thomas Anmarkrud durinprevious work in India, Sri Lanka and the Maldives. Other pictures have been providPer Danielsson, Global Project Coordinator for the Safety at sea for small-scale fisheries proand R Ravikumar, Regional Coordinator of the South Asia component of the project andBOBP-IGO.

The authors would like to thank John Mcveagh, FAO Consultant, who conducted an FRP traicourse for boatbuilders under the project in Kakinada, India as well as R Ravikumar for his invaluadvice. Special thanks go to the BOBP-IGO and its Director, Dr Yugraj Singh Yadava, foexcellent support in producing the guide.


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IntroductionThis guide to simple repairs of FRP boats was developed to address simple repairs that can be fishing boat owners or others who do not have the necessary expertise. A great deal of repair wboat owners, including work that should have been carried out by FRP experts, because thehave difficulties in finding a skilled FRP boatbuilder or taking the boat to a boatyard for prThis booklet gives simple guidance to owners or laminators on how to carry out good simplthe beach, the pitfalls and the dos and donts. It also advises when a skilled FRP expert shoulbecause of the complexity of the repair work.

Common bad practices in relation to FRP repairs

Substandard workshop conditions.

Incorrect FRP handling. Inadequate lamination methods. Lack of personal safety and protection. Careless handling of dangerous and highly inflammable materials. Insufficient waste disposal.


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Figure 1

Abrasion of gelcoat and shallow dafibreglass.

This is an example of damage that cthe beach by the boat owner.

What can be repaired on the beach?

Figure 2

Small damages on the gunwale.

Another example of damage


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Figure 3

This is a typical example of major damage that needsrepair work.

Damages that penetrate the laminate should only be rFRP boatbuilder.

What is FRP?Fiberglass reinforced plastic, or FRP, is a composite o(mainly fibreglass fibres and resin) laid down in alterhardened to form a solid laminate.

If put together correctly,the laminate can beboth strong and stiffwith good resistance tofatigue and theinfluence of water.If constructed badly,

Figure 4


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Handling of FRP materialsFigure 5

FRP materials should be protected from su

Here are some guidelines to follow when cFRP repair work.

Always check that you actually get whfrom the supplier.

Keep the fibreglass dry and clean. All polyester-related materials should

and cool places as possible, and the hastored separately.

Figure 6


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Dry storageFigure 7In a tropical climate, FRP materiaconditions as dark and cold as posmaximum shelf-life.

Figure 8

It is very important to protect the work area from sun, windand rain.

Work area


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Figure 9

Brushes are best for applying gelcoat but can also be uspolyester resin into tight corners and on to small details.

Resin rollers of different sizes can be used. They shoulmaterials that will not be damaged by solvents.

A variety of compacting rollers are used for different should be applied firmly but not too hard. Compacting mas the resin starts to gel, otherwise the continued used of create air bubbles rather than remove them.

Tools

Figure 10

Electric disused for sanFRP. They cbacking dis


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Repairing of damage to the laminate

Marking of the damaged area to be grindedFigure 11

This damagelaminate.

The scarf sh

Figure 12

Mark the area on the surface of the lamin

Hull Shell

10 mm 3 mm

7 mm

1:20 = 140 mm

Laminate

140 mm


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Prepairing for the repair work

Figure 13Prior to grinding, all surface contaminatiosilicone, should be washed off and removeappropriate solvent.

Figure 14

For grinding, 40 gritpaper, or coarser, is a

SoapWater

De-Grease Choosing the right paper


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Grinding

Figure 15The area should be grinded with grit paby power tools, such as disc grinders.

All damaged fibreglass must be remove

Remember that the scarf should be at le

FibreglassFigure 16

For simple repair work, choose choppewhich should be tailored for the repair.

The first piece should fit in the deepestpieces should increase gradually in size


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Figure 17

A handy tool for measuring hardener can be made byattaching a piece of steel wire to a bottle cap.

A typical cap from a soda bottle will hold 5 ml (0.18 oz)of hardener, which is sufficient for 500 ml(17.6 oz) of resin.

The resin and the hardener should be mixedthoroughly.

Figure 18


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Figure 20

The correct amount ofhardener to resin is 1 percent,however 0.8 percent willnormally also work in the

Mixing the resin and hardener

Figure 19A cut-off plastic bottle may be used to measure the exactly 500 ml (17.6 oz).

The resin is poured into a bucket.


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Applying the resin

Figure 22

A coat of resin should always be appliedfibreglass mat.

33.3% 66.6%

1 kgFibreglass

1 kg polyester

3 kg Laminate

Figure 21

This is the correct amount ofibreglass.

For example, the amount of450g/m 2 CSM is 1000 g (o


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Compacting the resin and ftogether

Figure 24

The metal roller should be used to eliminateany air bubbles and to compact the resin

Figure 23

Another coat of resin should be apfibreglass mat.


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Topcoating

Figure 26The topcoat is applied on the top of the rep

The purpose of the wax is to ensure proper topcoat.

If the topcoat does not have wax included, with a layer of thin plastic or a coat of poly

Preparation of the topcoat

Figure 25The topcoat can be prepared by mixing gelchardener in the percentages shown in the fig

A colour pigment can be added to the topconoted, however, that it is virtually impossibcolour match with the surrounding area.

GELCOAT + 4% WAX + 2% MEK = TOPCOATPEROXIDE


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Gelcoat or topcoat repair work

1

2

Gelcoat

Laminate

Figure 27

When there are small cracks or abratiotopcoat, but no damages in the fibreglafixed by repairing only the gelcoat or to

Preparing for the repair workFigure 28

All surface contamination, such as oil awashed off and removed with an appro


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Topcoating

Figure 30

Finally, the fibreglass should be sealed with

Figure 29

The damaged area should then be grinded bpaper or coarser.


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Figure 31A typical repaigunwale.Damaged area

Cut back to solidlaminate

Bevel ground out

Repaired laminateBacking piece

Examples


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Occupational safety and health

Always use eye protection when working with FRP, thereare hazards both from chemicals, which can be anythingfrom an eye irritant to a severely corrosive liquid, to airborneparticulate matter.

Always use respirator and/or dust mask when working with

FRP to protect from hazardous fumes and FRP grindingdust.

Always use proper gloves when working with FRP repairwork to protect skin from hazardous liquids and solvents.

Always use ear protection when working with noisy

machinery during FRP repair work.


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Environment

Always get rid of waste in a safe and environmentally friendly way.Check with your local authorities on how to handle hazardous waste .Always reuse as much as possible to save money and the environment.

Further readingAnmarkrud, T. 2009. Fishing Boat Construction: 4. Building an undecked fibreglass reinforceFisheries and Aquaculture Technical Paper. No.507. Rome. FAO.Coackley, N. 1991. Fishing Boat Construction: 2. Building a fibreglass fishing boat. FAO Paper. No.321. Rome. FAO. 84p.McVeagh, J. et al. 2010. Training manual on the construction of FRP beach landing boats. C

Note:

These publications can be downloaded from the Safety for Fishermen Web site at: www.safety-for-fishermen.org


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Do not pull your boat up on to a rocky shorewithout protection!

5 0


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BOBP/MAG/27

repair procedure of fiber boat

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