Intro To GRP and Hand Laid-Up GRP Moulding-PNS JAUHAR

INTRODUCTION TO GRP AND HAND LAID-UP GRP MOULDING BY LT CDR M HASAN ADIL PN
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Introduction to GRP and Hand Laid-up GRP Moulding
AIM
To apprise the audience about various GRP materials, methods for the production of hand laid-up GRP moulding, common defects and quality control of GRP layup
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SCHEME OF LESSON
Introduction to GRP Materials Moulds and Mould Preparation
Day 1 & 2
Preparation of Material for Moulding

The Moulding Operation Curing of Mouldings Finishing Operations
Day 3
Day 4
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SCHEME OF LESSON
Sandwich Structures Handling/Transportation of finished Mouldings
Day 5
Health and Safety

Common Defects and Quality Control
Day 6
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REFERENCES
Defence Standard 02-701 (NES 701) Part 1 Defence Standard 02-701 (NES 701) Part 2 Fiberglass Boat Design and Construction by Robert J Scott Open Sources (Internet web sites)
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INTRODUCTION TO GRP
Glass Reinforced Plastic (GRP) or Fiberglass Reinforced Plastic(FRP) is a two component structural matrix consisting of:
Fiberglass or glass material Thermosetting Liquid resin
GRP is a truly synergetic material in which combination of two materials has superior characteristics than either material individually Resin with relatively poor physical properties and would not perform well as structural material The glass portion though composed of strong glass filaments, is utilized as fabric and has no structural capabilities except in tension
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INTRODUCTION TO GRP
Matrix of glass and resin is similar in principle to reinforced concrete where
Like steel reinforcing bars, glass reinforcement are main load carrying members The resin performs a function similar to concrete in supporting and positioning the reinforcement so that it can perform effectively
Glass material provides the major strength whereas resin binds the glass reinforcement together and distributes applied loads uniformly between the individual glass fibres
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INTRODUCTION TO GRP
Advantages of GRP Resistance to marine environment (Anti fouling paint however required) Light Weight (One half the weight of equivalent steel or wood structures and almost equal in weight to Aluminum) High strength to weight ratio. Long exposure to marine environment has little effects on its properties Seamless Construction Chemically inert (No threat of galvanic corrosion)
INTRODUCTION TO GRP
Advantages of GRP Ability to orient fiber strength Ability to mold complex shapes Good against impact loads (such as slamming) Competitive Cost (In case of serial production) Ability to mold in colours Easy Repair Low maintenance Durability (Prolonged Hull life)
INTRODUCTION TO GRP
Disadvantages of GRP Stiffness
Modulus of elasticity 2 x 106 PSI as compared to steel with 30 x 106 PSI and Al with 10 x 106 PSI . Modulus of elasticity can go up to 4-6 x 106 PSI in case of unidirectional laminates or high strength glass/carbon composites GRP in disadvantage in deflection critical application
Relatively lower fatigue strength. Notch toughness to be evaluated to determine stress concentration problems at hatch corners, ending of stiffeners, decks etc
INTRODUCTION TO GRP
Disadvantages of GRP Low buckling strength Creep
GRP has tendency to creep if subjected to long term loading, though this not a problem with normal boat structures
Vibration Low abrasion resistance than metals but better than wood, thus necessitates use of bumpers or chafing plates in areas where abrasive loads might occur
INTRODUCTION TO GRP
Disadvantages of GRP Vulnerability to Fire
Flame spread rate of conventional GRP and Plywood is same
Fire Retardant resins available though they give out toxic flames and properties of laminate decrease with heat
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SCHEME OF LESSON
MATERIALS
MATERIALS
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MATERIALS
GRP consists of:
Layup Resins Glass material
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LAY UP RESINS
The resins used for hand lay-up GRP fabrication are all liquids, that can be cured to form tough solids by the addition of suitable curing agents Various types of resins are:
Polyester Resins
Epoxide Resins Phenolic Resins
Gelcoat Resins
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LAY UP RESINS
POLYESTER RESINS Polyester resins are normally used as these are usually:
The most economical
Easy to handle Generally non-dermatitic
The curing of polyester resins is brought about by the addition of two materials i.e. a curing agent (catalystnormally a peroxide) and an accelerator (normally a cobalt soap)
LAY UP RESINS
POLYESTER RESINS The catalyst promotes a chemical reaction causing cross-linking of molecules in the resin The accelerator controls the rate of cure of the resin and, in particular, the usable pot life (gel-time) The amount of catalyst & accelerator used with a given resin should always be that recommended by the resin manufacturers The accelerators and curing agents for Polyester resins MUST NEVER BE MIXED TOGETHER. Each material is to be mixed separately with the resin, first the accelerator, second the catalyst. Neglect of this precaution can lead to a fire or an explosive reaction
LAY UP RESINS
EPOXIDE RESINS Epoxide resins are used on high strength structures, some specialized applications and as adhesives (polyester resins are not suitable for the latter) Epoxide resins possess
Superior abrasion resistance Less water absorption Greater bonding strength
The curing of epoxide resins is brought about by the addition of a curing agent (catalyst/hardener) only. The amount of hardener used is fixed by manufacturers and must not be varied in an effort to alter the gel-time of the system as such a variation will lead to an improperly cured resin with poor mechanical properties
LAY UP RESINS
PHENOLIC RESINS Phenolic resins have excellent inherent resistance to fire combined with very low smoke and toxic evolution The curing of phenolic resins is brought about by the addition of a catalyst. The amount and type of catalyst used is fixed by manufacturers Gel-coat phenolic resin pastes have been developed to give phenolic laminates smooth pin-hole free surface finishes Phenolic resins should not be used for GRP mouldings that are likely to come into contact with foodstuffs, directly or indirectly
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LAY UP RESINS
GEL COAT A resin applied to the surface of a mould and gelled before lay-up. The gel-coat becomes an integral part of the finished moulding, and is usually used to improve surface finish
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LAY UP RESINS
It is important to note that all the resins (polyester, epoxide, phenolic) do not develop their full mechanical properties as soon as they have hardened. All types require a period of several days at room temperature for a reasonably full cure, but the rate of cure can be accelerated by the application of heat. Again the resin manufacturers recommendations should be followed
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GLASS REINFORCEMENTS
Glass reinforcements are available in five forms
Chopped Strand Mat (CSM) Woven Rovings (WR) Woven Fibre Cloths Combination Cloths Double-bias Cloth
The composition of the glass should be that known as E-glass High strength reinforcements also exist and are discussed in later part
Chopped Strand Mat (CSM) CSM, consisting of randomly dispersed glass fibres about 50mm long held together with a suitable binder
Cheapest and most widely used reinforcement Moderate strength Homogeneous material with equal physical properties in all directions Easy to wet Builds up laminate thickness at rate of 20 piles/inch (If mat weighs 1 ounces per sq foot)
When working with mats, it is important to use the minimum amount of resin consistent with good wetting of the glass. CSM should comply with BS 3496 for use with polyester resins
CHOPPED STRAND MAT (CSM)
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Woven Roving (WR) WR consist of glass rovings (bundles of glass fibres) woven into either a plain-weave cloth, for general use, or as a predominantly unidirectional cloth for structures requiring maximum strength in one direction

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Higher strength than mat Good drapeability and handling characteristics Builds up laminate thickness rapidly (25 piles/inch) Good resistance to impact because of continuous and untwisted strands
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Woven Roving (WR) Woven rovings for use with polyester resins are to comply with BS 3749 or NES 166
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Woven Fibre Cloth Woven fibre cloths are manufactured from spun yarns and are available in a range of weights and weaves. Because of their high cost, cloths are normally used for structures in which a high strength to weight ratio or where close control of resin to glass ratio is required The choice of weave is generally dictated by the stresses which the structure will have to withstand when in use
For maximum impact strength
Cloth having a large amount of crimp in the fibres is required; this is achieved by using a square-weave cloth woven from heavy yarns
The highest compressive, flexural and tensile strengths

Cloths of low-fibre crimp such as satin-weave and unidirectional cloths Satin-weave cloths also have the desirable property of drape which enables them to follow surfaces having compound curvature
Woven fabrics are to comply with BS 3396; Parts 13 and be made from E-glass
Combination Cloth Combination cloth is a mixture of CSM and WR and is used to improve cost efficiency. However care must be taken to ensure that the weave of the woven roving is in the correct direction for the design requirement and that the inner layers of glass are completely wetted by the resin
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Double Bias Cloth Double-bias cloth has the fibres at angles and is used to lay down reinforcement at various angles in large mouldings where it would be uneconomical or impractical to lay the normal 0/90 cloth at an angle when strength in all directions is required
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Surfacing Tissue Surfacing tissues are very thin (0.25mm0.44mm) reinforcing fabrics used to strengthen the gel-coat of a GRP structure to prevent crazing of the resin and to minimize impact damage. Very thin glass mats are sometimes used but non-woven synthetic fabrics are generally preferred. Only a single layer of surfacing tissue is use
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High Strength Reinforcements Number of high strength reinforcements available but use limited due high cost Most commonly used such reinforcement is S Glass, KEVLAR and carbon fiber, woven in bi-directional or uni-directional fabric with minimum number of fill or cross fiber Carbon fiber generally laid up with epoxy resin Besides being expensive, consideration of high strength laminate is complicated by relative performance. E.g
STORAGE OF MATERIALS
Glass Reinforcements Rolls of glass reinforcements to be stored in clean dry room with humidity less than 70% Rolls individually wrapped in moisture-proof wraping Rolls of material should not be stood on end; suitable racks or shelving should be provided NOTE: Dampness of glass reinforcements causes an irreversible loss of reinforcing strength
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CORRECT WAY
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WRONG WAY
GRP Chemicals Polyester resins and accelerators, epoxide resins, and phenolic resins should be stored in a cool dry place, at a temperature no higher than 20C
Organic peroxide catalysts present a hazard when stored in bulk
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SCHEME OF LESSON
MATERIALS
MOULDS AND MOULDS PREPARATION
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MOULDS
A variety of materials is suitable for the construction of moulds for hand-laid GRP Sheet Metal Moulds
Made from aluminum alloy or mild steel sheet
Sheet metal moulds are suitable for small mouldings and short production runs
Metal moulds for use with phenolic resins should be either stainless steel or plated to avoid acid attack
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MOULDS
Sheet Metal Moulds
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MOULDS
Timber Moulds
Moulding surface of the mould is sealed to prevent the absorption of parting agent and resin into the timber. This can be achieved, together with a good surface finish, by applying several coats of furan varnish to the mould Timber moulds are only used for short production runs (about 50 per mould) For the production of large numbers of small items densified wood is preferred to the more usual timbers Timber moulds should not be used for the production of phenolic resin mouldings
MOULDS
GRP Moulds
GRP moulds are made from a master pattern, or when available, an existing item Polyester moulds should be well cured to ensure that no free styrene is present that could result in release problems
Plaster and Concrete Moulds Wax Moulds Flexible Moulds Moulds with Undercuts
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MOULD PREPARATION PRIOR LAY-UP

Any moulds which have been stored out-of-doors should be allowed to acclimatize to the conditions within the mould shop before laminating begins Inspect and Clean/Repair Apply releasing agent
Wax, polyvinyl alcohol, sodium alginate water solutions, and polymeric resin solutions (Frekote) are preferred. No silicone containing release agents should be used when the moulding is to be painted/coated or bonded to other moulding, or when the application calls for acoustic transmission (radomes), as some of the release agent is always transferred to the moulding
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MOULD PREPARATION PRIOR LAY-UP

Apply releasing agent using spray gun, sponge or brush. Colouring of the release agent so that it contrasts with the mould surface is desirable, as the contrast helps in securing complete coverage of the mould Release agent should be allowed to dry thoroughly before any moulding is attempted As an alternative to the liquid mould-releases, regenerated cellulose sheet, eg Cellophane, may be used for the moulding of simple shapes. The grade of material recommended by the manufacturer should be used
SCHEME OF LESSON
MATERIALS
PREPARATION OF MATERIALS FOR MOULDING
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MATERIAL PREPARATION FOR MOULDING

Reinforcements Reinforcements to be cut as per mould contours A cutting and marking-out table is essential and should be reserved for this purpose to avoid accidental contamination of the glass Cut reinforcement should be laid on clean wooden sheets for transport to the mould Whilst it is desirable to carry out tailoring operations in the glass reinforcement store, tailoring may be carried out in the moulding shop provided that the cutting-out table is isolated from other operations

Resin A resin-mixing room separated from other operations is desirable but a fenced-off area in the moulding shop is a satisfactory alternative The following equipment should be provided in the mixing section:
Large balance for weighing resin Small balance for weighing curing agents, accelerators, etc Propeller agitator for mixing small quantities of resin

Resin The following equipment should be provided in the mixing section:
Planetary mixer for mixing large quantities of resin
Drum of solvent (eg styrene, MEK or acetone) for cleaning equipment

Supply of cotton rags for cleaning equipment
Containers for resin mixtures. These should be constructed from tinplate, porcelain, glass, stainless steel or polythene

Safety Precautions The accelerators and curing agents for Polyester resins MUST NEVER BE MIXED TOGETHER. Each material is to be mixed separately with the resin, first the accelerator, second the catalyst. Neglect of this precaution can lead to a fire or an explosive reaction The recommendations with regard to operator safety and fire risk apply when handling resin will be discussed at the end

Moulding Inserts Timber and metal inserts are used in GRP mouldings to provide anchoring points for bolts and screws and as reinforcing or stiffening members
Timber inserts should be clean. Any contamination should be removed with glass paper. Some timber preservatives may inhibit the cure of the resin. Zinc naphthenate is acceptable as a timber preservative
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Moulding Inserts Metal inserts are to have their surfaces roughened, preferably by grit-blasting, and then be thoroughly degreased Uncoated copper-based metals are not to be used as inserts as copper tends to prohibit the cure of laminates, however they may be used if coated with an epoxy resin Metal inserts for use with phenolic resins should be coated with a material compatible with the acid base of the phenolic resin
SCHEME OF LESSON
MATERIALS
MOULDING OPERATION
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MOULDING OPERATION
Moulding Shop The shop used for the actual moulding operation should preferably be used for this purpose alone. No other form of operation should be allowed in the moulding area (except for cloth cutting, resin mixing if extremely essential) The shop is to be heated such that the room temperature never falls below 15C during lamination and 10C during curing Condensation should be kept to minimum. Draught free ventilation to remove vapours
MOULDING OPERATION
Moulding Shop Air flow velocity over the face of uncured laminates must not exceed 1metre/sec; greater air-flow velocity would remove styrene too rapidly and prohibit satisfactory cure
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MOULDING OPERATION
Moulding Tools Tools are required to ensure thorough impregnation of the glass and that all air bubbles are worked out The usual tools are paint brushes, metal, polythene, nylon and lambswool rollers, flat squeegees
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MOULDING OPERATION
Moulding Tools Paint brushes used for hand lay-up should have unvarnished handles and bristles (hair, coat). The varnishes used in brush manufacture and rubber compounds used for setting some brush bristles are resin solvent and inhibit resin cure
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MOULDING OPERATION
Laminating Temperatures Polyester Resin
Laminating should not to be undertaken when the ambient temperature is below 15C or above 30C
Epoxide Resins
Manufacturers advice should be sought regarding laminating temperatures for epoxide systems
Phenolic Resins
Laminating should be carried out at a minimum temperature of 15C
MOULDING OPERATION
Application of Gel Coat The first step in fabricating a GRP moulding by hand lay-up is to apply a gel-coat. The gel-coat may be applied either by hand or by spray gun
Hand application of gel-coat resins should be:

By means of a camel-hair brush or a lambswool roller. The rate of application should be approximately 450600g/m2 which gives a gel-coat 0.40.5mm thick
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MOULDING OPERATION
Application of Gel Coat If applied by spray gun
The resin will have to be diluted with styrene (if a polyester) to allow for styrene loss by evaporation The dilution rate recommended by the resin manufacturer is not to be exceeded
To achieve even coverage, it may be necessary to use a thixotropic additive or a formulated gel-coat resin. The gel-coat should be lightly pigmented, to the colour scheme of the finished moulding, to assist complete coverage of the mould
MOULDING OPERATION
Application of Gel Coat The gel-coat should be inspected as per Part 2 of NES 701 prior layup After the gel-coat has been applied to the mould, the surfacing tissue should be laid in the mould and be gently rolled into the gel-coat The gel-coat should then be allowed to gel (gel time as specified by manufacturer), before proceeding with the build up of the laminate. Lay-up of the laminate should then follow within 12 hours of the gel-coat setting
MOULDING OPERATION
Lay-up of Laminates The tailored section of reinforcement should be weighed and to ensure complete wetting out of the reinforcement, a slightly greater weight of mixed resin than is required to give the specified resin glass ratio should be taken Apply resin using paint brush on first layer of laminate Using a roller or squeegee, the resin should be worked through the reinforcement until the latter is thoroughly wetted and visible air bubbles minimized
MOULDING OPERATION
Lay-up of Laminates A second application of resin should now be made followed by a second layer of reinforcement and so on until the finished thickness of the laminate has been reached Less and less resin may be required for successive layers of reinforcement Over-rolling must be avoided. This is particularly important when using glass mats as the binder dissolves in the resin and if the laminate is over-rolled the glass fibres are distributed by the roller so that glass-rich and resin-rich areas are formed in the laminate
MOULDING OPERATION
Lay-up of Laminates It is essential that the quantities of resin and reinforcement are continuously monitored and recorded throughout fabrication since The resin glass ratio and uniformity of impregnation will influence the physical properties of the finished laminate
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MOULDING OPERATION
Lay-up of Laminates Edges of adjacent pieces should be butted or overlapped depending on the application and thickness tolerance Overlaps should be 5075mm in the case of CSM For WR the weft selvedge tails should overlap the outer warp roving of the adjacent cloth by their own length (20mm) Overlaps should when possible be staggered to aid production of a smooth surface
MOULDING OPERATION
Lay-up of Laminates Butts in the reinforcement should be staggered 150mm relative to butts in the underlying ply and superimposed butts must be separated by at least six passing plies Corners and re-entrant angles in a moulding should be thoroughly wetted
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MOULDING OPERATION
Lay-up of Laminates Mouldings over 9mm in thickness must be laid up in several stages to avoid excessive exothermic heat during the initial cure of the resin Practical maximum layup limit, at compartment temperatures of 20C, is approximately four plies of 600g/m2 CSM or ten plies of 830g/m2 WR; if this limit is reached, a period of 12 hours is to elapse before any further plies are laid When the compartment temperature is higher, the number of plies laid must be reduced
MOULDING OPERATION
Lay-up of Laminates When unbalanced weave-materials are being used, eg unidirectional cloths, care must be taken to ensure that the cloth warp is laid in the direction of maximum stress Inspection is essential during each stage of fabrication For large mouldings, pre-impregnated cloth should be used. The glass cloth is passed to a resin dispenser into which resin and catalyst are fed at a controlled rate to give the required resin:glass ratio. The dispensing equipment is mounted on a gantry and traversed across the mould laying down the impregnated cloth which is then consolidated using rollers or squeeges
MOULDING OPERATION
Lay-up of Laminates If completion of a lamination is delayed for an extended period a peel-ply, usually of terylene, should be lightly rolled into the surface. This can be peeled-off when laminating recommences. If a peel-ply cannot be laid down then, if the elapse period extends for more than seven days, the surface of the laminate should be wiped with styrene and left 15 minutes or abraded (care being taken to avoid cutting plies of reinforcement) before additional plies are laid. Lay-up delays of up to seven days are acceptable without surface preparation of use of peel-ply
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MOULDING OPERATION
Lay-up of Laminates Phenolic-based adhesives are widely used in woodworking, consequently no woodworking operations using phenolic-based adhesive should be allowed in the moulding shop
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SCHEME OF LESSON
MATERIALS
CURE OF MOULDS
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CURE OF MOULDS
Cure Time in Moulds After completion of the lay-up, the assembly must be left until the resin has hardened sufficiently The cure period varies with the resin used and the design specification and/or the resin manufacturers recommendations In cases of difficulty in the removal of mouldings, the application of compressed air between the moulding and the mould is usually an effective aid Phenolic resin mouldings may be heated to 4070C whilst still in the mould.
CURE OF MOULDS
Post cure Although amoulding is usually strong enough to be handled some twelve hours after the completion of the lay-up, the resin will not have hardened sufficiently for the maximum mechanical properties of the laminate to have developed; therefore, a postcure must be applied to the moulding before finishing operations can be carried out Post cure may include leaving mould at room temp for specified time or in a heated room for specified time
CURE OF MOULDS
Post cure
Temperature 20C 30 C 40 C Post-cure time 30 days 14 days 3 days 80 C 120 C 7 hours 2 hours
A period of at least 24 hours at room temperature must be allowed to elapse before any post-cure is applied The lower the post-curing temperature, the less chance of distortion in the moulding
CURE OF MOULDS
Post cure With epoxide resin systems the post-cure manufacturers curing schedules must be followed For phenolic laminates the amount of post-cure given is governed by the use to which the moulding is to be put, i.e by the performance specification, and the resin manufacturers advice should be sought. Typical post-cure times are in the range 48 hours at 5060C.
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SCHEME OF LESSON
MATERIALS
FINISHING OPERATIONS
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A Guide to Methods for Production of Hand Laid-Up GRP Mouldings
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The finishing operations carried out on GRP mouldings, are much the same as those used for other materials, e.g sawing, drilling of holes, riveting, painting, etc
In all cases, deviations from normal wood or metal working practice are necessary if the best product is to be made
Mouldings are to be fully cured before finishing operations are begun
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Introduction to GRP and Hand Laidup GRP Moulding
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Sawing and Trimming Because of the very abrasive nature of glass the best saws are those with an electrometallic bonded diamond cutting edge
Tungsten carbide and high speed steel tipped saws can be used but have a much shorter life than the diamond tools Band-saws with a tooth pitch in the range 8 to 18 teeth per 25mm should be used with cutting speeds up to 300m/min
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Sawing and Trimming The direction of cut must always be such as to start at the gel-coat and then proceed into the body of the moulding. This prevents chipping and crazing of the gel-coat Saw blades must always be sharp and correctly set After sawing, the cut edge of the moulding should be smoothed with fine emery cloth applied along the length of the cut edge and never at right angles to it as this latter action causes local delamination and chipping of the gel-coat
Sawing and Trimming After smoothing, the cut edge of the laminate should be sealed with a room-temperature curing epoxide resin or in the case of polyester laminates with polyester resin Ensure health safety
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Drilling All holes drilled in GRP should be drilled from the gel-coat side Holes more than 6mm diameter require the use of rigidly supported back-up pieces of hardwood or plastic to prevent chipping of the back face Holes in excess of 40mm diameter and non-circular holes should be cut either by sawing or using an electrometallic diamond edge routing tool
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Drilling If a hand held jig saw of the pattern which cuts as the saw is drawn into the body of the tool is used, sawing must be carried out from the back of the laminate to avoid gel-coat damage The cut edges of all holes should be sealed with a coat of room temperature curing epoxide resin or polyester resin Safety precautions in drilling of GRP are the same as for sawing (will be discussed in health and safety)
Water-Jet Cutting Water-jet cutting is relatively new and offers fast, low temperature, distortion-free, accurate and clean cutting Abrasive water-jet cutting, in which abrasives are introduced into the water jet, is especially suited to nonhomogeneous materials, such as GRP, that are abrasive in nature and damaging to more conventional cutting tools The equipment can have simple XY movement or have intricate shape cutting capabilities by the use of computer controlled articulated robots with multiple axes cutting ability
Water-Jet Cutting A hydraulically driven intensifier unit pumps filtered and conditioned water, at pressures up to 410 MPa and rates of 4 to 8 L/min The high pressure fluid is expelled through an orifice to form a jet of water, propelled at speeds up to 850m/s For abrasive water-jet cutting an abrasive material, eg garnet grit, is introduced into the water stream after the primary jet is formed. A fine grit may be used to produce a smooth surface finish
Water-Jet Cutting Because composite materials may delaminate in the area surrounding the initial penetration, the water-jet is usually activated away from the work piece and then guided into the desired edge The technique produces very low dust-level, so reducing the risk to health and fire hazard. However, because of the air coupling into a large high-velocity volume of air/water, noise levels are high and appropriate ear protection is required
Laser Cutting Focused CO2 laser beams are now being used to cut a wide range of composites and complex cutting can be achieved by manipulating the beam by a five-axes robot In order to cut, a laser must be integrated with the means to deliver the beam, handle the workpiece and be in an enclosure that ensures the safety of personnel from the beam and any irritating and/or toxic gases released by the thermal degradation of the resin
Laser Cutting When cutting GRP thermal damage to the matrix may result due to heat conduction along the fibres. Also when cutting laminates over 10mm thick charring may be a problem Charring is a chemical process of incomplete combustion of certain solids when subjected to high heat. The resulting residue matter is called Char.
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Bolting of Laminates Fasteners must never be pulled up directly on to the laminate surfaces but should have large diameter washers or a drilled clamping plate of the fastening material under both the bolt head and the nut Where the use of nuts and bolts is not possible and recourse has to be made to the use of bolts screwed into tapped holes, a metal insert should be included in the moulding. The fastening holes can then be drilled and tapped in the insert A wire thread insert (Helicoil or Crosswire) in a hole tapped in the GRP is only suitable for lightly loaded structures
Bolting of Laminates Bolt hole spacing should be:
not less than 3 bolt diameters from the edge of the laminate;
from 3.5 to 4.5 bolt diameters apart for structural and watertight joints;
from 5 to 8 bolt diameters apart for non-structural applications.
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Riveting of Laminates Riveting of laminates should be avoided whenever possible. However, when used, rivets should be of soft aluminium and be driven with a washer of the same material under both head and point. Rivets greater than 5mmshould be avoided whenever possible Spacing of rivets should be:
not less than 3 rivet diameters from the edge of the laminate from 3.5 to 4.5 rivet diameters apart
During all riveting operations, GRP mouldings must be very soundly supported
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Riveting of Laminates Explosives and similar riveting systems must not be used. The proprietary Advel fastener is recommended as an alternative to riveting for sizes above 5mm
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SCHEME OF LESSON
MATERIALS
SANDWICH STRUCTURES
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SANDWICH STRUCTURES
Sandwich structures consist of lightweight core material with a skin of GRP on either side The purpose of sandwich construction is to increase rigidity of panel by increasing its thickness with relatively little increase in weight The core materials commonly used are:
Wood Foamed Plastics
Honeycomb
Microballons Buoyancy Foam
SANDWICH STRUCTURES
Alternative core materials, i.e polyetherimide (PEI) and phenolic foams, possessing superior fire characteristics to those listed above are being evaluated and may eventually be considered
The basic lay-up technique is used when making sandwich structures, with some detail modifications in both mould design and lay-up procedure. NES 752 may be considered as guideline
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CORE MATERIALS
WOOD Plywood, Soft Woods and Balsa are typically used woods as core material Plywood
Good strength, rigidity and ability to withstand local loads
Commonly used for bulkheads and deep girders Relatively heavy and should be of exterior grade only
Hard woods are not used since they have tendency to swell and crack the covering laminate and do not bond well with GRP
CORE MATERIALS
WOOD Soft Woods
Soft woods such as pine used for framing and similar application Can cause swelling problems, however, bond well with GRP
Balsa
Balsa wood, weighing b/w 6 to 9 pounds per cubic foot, is commonly used as light weight core material for small boat construction
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CORE MATERIALS
WOOD Balsa
In end grain configuration, with the grain perpendicular to laminate, the bond strength is relatively high, upto 1000 PSI due the resin wicking into elongated cells of balsa Bond strength can further be increased by use of vacuum injection, which provides added benefit of filling the gaps between individual balsa blocks to prevent water migration through core
CORE MATERIALS
WOOD Due possible rotting, swelling and degradation, the use of wood cores in areas below the waterline, or adjacent to tanks is not recommended unless special precautions are taken In case of balsa, there has been a controversy over its use below waterline. Some research however shows penetration of the end grain balsa of less than 1/8 inch after 1000 hours exposure to sea water
CORE MATERIALS
FOAMED PLASTIC Foamed plastics such as polystyrene, polyurethane and ployvinyl chloride (PVC) offer advantages of light weight and resistance to water, fungi and decay
Low shear and compressive strength, especially of very light foams, make them susceptible to delamination and damage from local loads To avoid excessive core thickness on highly loaded panels, FRP shear webs between faces of sandwich panels may be used
CORE MATERIALS
FOAMED PLASTIC Polystyrene
Not generally recommended since it is attacked by polyester resin
Polyurethane
A rigid material which will generally not conform to surface curvature, however, used in boat building
Polyvinyl Chloride (PVC)

PVC available in thermoplastic form, when heated to 200 deg F, softens sufficiently to be draped over curved surface. It regains its hardness when returns to room temp
CORE MATERIALS
FOAMED PLASTIC Polyvinyl Chloride (PVC)
Tendency to soften when heated can however cause problems if ambient temp is too high. Hence use of PVC on surfaces exposed directly to intense sunlight like deck or in engine room compartment is not recommended A cross linked foam containing both PVC and polyurethane is available which reduces above mentioned problem, but has somewhat reduced properties PVC core material is also softened by polyester resin and must be either treated with a sealant or used in conjunction with resin having a styrene content below 30% and gel time of less than 30 min for the first layer of re-inforcement
CORE MATERIALS
FOAMED PLASTIC Structural grade foams usually have 96 to 128 Kg per cubic meter density. Lighter foams may be used, however physical properties diminish rapidly with decreasing density
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CORE MATERIALS
HONEYCOMB Honeycomb cores of aluminium, fibergalss laminate, phenolic, waterproof paper and nylon are available in various sizes and weights
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100
CORE MATERIALS
HONEYCOMB They have light weight, good rigidity and poor resistance to concentrated loads Highly developed fabrication techniques required to produce good bonding b/w core and facing. Imperfect bonding will result in water travel throughout core in case of a leak In marine construction, honeycomb cores limited to interior decks, flats and bulkheads where light weight is essential
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CORE MATERIALS
HONEYCOMB Honeycomb cores configurations available in various
Hexagon and square recommended for use on flat panels and applications as radomes For conforming to shaped surfaces, knifed and flex- core honeycombs are available
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CORE MATERIALS
MICROBALLONS Light weight hollow glass or gas-filled phenolic spheres and polystyrene beads embedded in resin are example of high density, trowelled-in-place core material presently being used in some boat hulls and deep-submergence vehicles Use is limited due high cost, used only where high core strength is required Alternate may be a core insert of vermiculite and resin (80% resin by weight)
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CORE MATERIALS
BUOYANCY FOAM Polyurethane or polystyrene foams of about 32 Kg per cubic meter used for flotation in small boats Foams may be installed as pre-cured blocks or in case of polyurethane foamed in place
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SCHEME OF LESSON
MATERIALS
HANDLING/TRANSPORTATION OF FINISHED MOULDINGS
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105

PREPARATION All traces of release agents, fibers, dust etc should be cleaned/removed Openings should be blanked in order to prevent ingress of foreign agents likely to be met during transportation or storage. Care should be taken to ensure that enclosed mouldings are ventilated at all times When necessary to prevent overstressing during handling and transportation, temporary stiffening/support devices may be used Where lifting positions have been provided in design, drawing showing lifting position, handling technique, equipment required and any other important information for safety like restriction on angle of lift, should be provided

LIFTING When lifting lugs are not provided, moulding should only be lifted using webbing or rope slings passed around the mould
Chain or wire rope is permitted if adequate arrangement to prevent local loads and abrasion is made When lifting, care should be taken not to apply shock loads to the lugs or moulding
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TRANSPORTATION Loads imposed by transportation should be considered and temporary supports provided if necessary
Moulding should be secured to avoid its movement during transportation
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108

STORAGE If stored temporarily, should be stored on a level surface free from sharp protrusions Storage locations should be selected to minimize risk of impact damage Possible movement due wind be considered and temporary anchors be provided if necessary
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SCHEME OF LESSON
MATERIALS
HEALTH AND SAFETY
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110
HEALTH AND SAFETY

HANDLING RESINS All resins and solutions should be handled and used in well-ventilated flameproof areas The warning against the mixing together of undiluted curing agents and accelerators needs no further emphasize because of the fire and explosion risks involved Catalysts, being organic peroxides, present a hazard when stored in bulk and should be stored separately, preferably outside the main building in a metal lockable-bin sited in a cool, shady position
HEALTH AND SAFETY

HANDLING RESINS All the resins used in hand lay-up work, together with cleaning solvents, constitute a fire hazard. Smoking and the carrying of matches, etc must be forbidden in any area in which uncured resins are handled. Cleaning rags used during a days work should be taken to an open space and burnt at the end of the day because such rags may ignite spontaneously
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112
HEALTH AND SAFETY

HANDLING RESINS Operators handling resins should use a suitable barrier cream. Any resin contamination of the skin should be cleaned off with a cream formulated for this purpose, followed by soap and water. Solvents must never be used to remove resins from the skin as they remove the natural oils from the skin and increase the risk of dermatitic troubles. It is also possible for rubber or PVC protective gloves to absorb resin and so lead to skin irritation
HEALTH AND SAFETY

HANDLING RESINS When handling curing agents and accelerators, operators should wear suitable protective clothing, goggles and gloves. Any accidental splashes in the eye should be immediately thoroughly washed out with water and then be attended by a doctor Some people are sensitive to amine curing agents associated with epoxide resins and readily develop dermatitis and should avoid all contact with such materials
HEALTH AND SAFETY

WASTE DISPOSAL Large spillages of resin or resin solutions must be dealt with promptly and operators should wear appropriate protective equipment Liquid resins should be absorbed on to dry sand or similar inert materials for controlled incineration. Rags or paper used as absorbents constitute a fire risk and should be disposed of in the same way, as promptly as possible
In the event of a serious spillage which enters public drains or waterways, the Local Water Authority must be informed immediately (CANT SAY ABOUT PAKISTAN)
HEALTH AND SAFETY

WASTE DISPOSAL Waste peroxides must be disposed off after consulting safe procedures from OEM Empty drums etc contain vapours of the monomer present in the original resin solution and therefore entail fire, explosion and noxious vapour risks. They should only be disposed of by methods that follow recognized safe procedures Disposal of contaminated solvents should only be undertaken after consultation with the relevant Authorities
SCHEME OF LESSON
MATERIALS
COMMON DEFCTS AND QUALITY CONTROL
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117
INSPECTION METHODS CURED LAMINATES

Different methods for inspection of cured laminates are:
Visual Inspection Ultrasonic Inspection
Tap Tests
Radiographic Inspection
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VISUAL INSPECTION Visual inspection to be carried out after removing parting agent and adequately cleaning laminate Visual inspection to be carried out using light. Where access is possible, inspect from both sides Inspection is to be carried out in subdued light, using an inspection lamp of sufficient intensity to penetrate the laminate
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VISUAL INSPECTION When inspecting visually, following points should be specially scrutinized:
surface imperfections and general appearance
freedom from air voids entrapped in the laminate. (The use of unpigmented resin makes visual inspection much easier) dimensions
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120

ULTRASONIC INSPECTION Ultrasonic inspection may be used to measure:
Laminate thickness, Lack of adhesion
0 compression waves should be used with frequencies in the range 0.5 to 5MHz. Guidance on the selection and use of ultrasonic equipment is given in NES 729 Part 5
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121

TAP TESTS The coin tap method is a simple test and is based upon the principle that a laminate will resonate differently when lightly tapped with a coin should there be any variations in the laminate underneath the point of testing Method requires training and practice to obtain reliable result Mechanical device as a Tapometer (manufactured by Rolls Royce MatEval Ltd) may be used. It produces more consistent results, however, training and experience is required

RADIOGRAPHIC INSPECTION Radiographic inspection may be used to detect some types of cracking and gross damage to reinforcement
Radiography generally unsuitable for the detection of lack of bonding or delamination
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GEL-COAT DEFECTS
Surface Fibre Pattern Star Cracking Crazing Pin Holes on Gel-Coat Cratering and Blistering Wrinkling of Surface Poor Adhesion Fish Eyes Internal Dry Patches Leaching Distortion or Warping
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GEL-COAT DEFECTS
SURFACE FIBRE PATTERN If the gelcoat is thin or the reinforcement is applied before the gelcoat is sufficiently cured the roving pattern may print through and be visible in the gelcoat when the hull is released
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125
GEL-COAT DEFECTS
Fault Cause Gel-coat not cured sufficiently before commencing lay-up Gel-coat too thin Remedy Ensure adequate cure of gel-coat
Surface Fibre Pattern
Ensure gel-coat minimum thickness of 0.3mm
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GEL-COAT DEFECTS
STAR CRACKING Due to an over thick gelcoat but this time it must have received an impact from the inside
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127
GEL-COAT DEFECTS
Fault Star Cracking Cause Remedy no
Result of an over thick Ensure gel-coat gel-coatoccurs when thicker laminate has received a than 0.5mm reverse impact
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128
GEL-COAT DEFECTS
CRAZING Crazing usually indicates a gelcoat which is too thick and has crazed during flexing of the hull
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GEL-COAT DEFECTS
Fault Cause Gel-coat too thick Use a brittle resin or resin containing excess monomer Excessive accelerator in formulation or curing temperature too high. (Sometimes gives orange peel effect) Remedy Use even thickness gelcoat Use properly formulated gel-coat resin Check resin formulation Use experimentally verified mix Avoid high temperatures
Crazing
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GEL-COAT DEFECTS
PIN HOLES IN GEL-COAT Small air bubbles trapped during the cure show up on release
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131
GEL-COAT DEFECTS
GEL-COAT
Fault Cause Remedy
Use non-silicone wax on Gel-coat not wetting mould surface followed by release agent on mould a PVA release agent Minute air bubbles in the surface of the laminate. Caused by poor mixing of filler into thixotropic gelcoat and/or overbrushing of gel-coat when applied to mould Occluded air in the filler used in resin formulation Mix resin by mechanical means. Apply resin carefully using minimum brushwork consistent with uniform resin coverage Use only fillers which have been treated for use with polyester or epoxy resin as appropriate
Pinholes in Gel-coat
Dust particles in the parting agent or the gel-coat

15-Feb-14 GRP Moulding
Mould under clean conditions. Ensure that dust cannot fall on mould before Introduction to GRP and Hand Laid-up application of gel-coat
132
GEL-COAT DEFECTS
CRATERING AND BLISTERING An indication of delamnation between layers on older vessels. It is potentially the most serious of problems
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GEL-COAT DEFECTS
Fault Cause Usually caused by air or solvent trapped between gel-coat and laminate proper. If reinforcement is carefully rolled down this defect should not occur Remedy
Cratering and Blistering
Check resin:glass ratio; a deficiency of resin often causes air ubbles. Check the grade of any glass mat used. If the binder is insoluble in the resin the fibre will not If parting agent not bed down. Ensure that agent is thoroughly dry, volatiles parting will cause lifting of gel- thoroughly dry before applying gel-coat coat
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GEL-COAT DEFECTS
WRINKLING OF SURFACE This is caused by the heat released by the following laminate immediately attacking an under cured thin gelcoat
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135
GEL-COAT DEFECTS
Fault Cause Remedy
Wrinkling of Surface
Prevent drainage of gelToo thin a gel-coat coat by ensuring which is under cured. adequate amount of Often on vertical thixotropic agent in surfaces formulation Under cure as a result of Ensure that there are no styrene (or other draughts in vicinity of monomer) evaporation the moulding
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GEL-COAT DEFECTS
POOR ADHESION It occurs when a gelcoat is left unreinforced for too long. A weekend is long enough
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137
GEL-COAT DEFECTS
FISH EYES Fish Eyes are caused by the gelcoat de-wetting from the polished mould surface in spots. Occurs mainly when silicone based waxes are used. These, in particular car waxes, should be avoided
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GEL-COAT DEFECTS
INTERNAL DRY PATCHES Areas where resin has not penetrated
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GEL-COAT DEFECTS
LEACHING Leaching a serious fault. Severe weathering can remove a poor resin from surface of a laminate
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GEL-COAT DEFECTS
DISTORTION OR WARPING Causes
Differential shrinkage between unreinforced gel-coat and reinforced laminate
Remedy
Use a reinforced gel-coat Use thin gel-coat Use a specially formulated gel-coat resin
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141
ACCEPTANCE CRITERIA
GEL-COAT Small areas up to 1200mm2 exhibiting defects shown on previous slides are acceptable except in case of radomes and sonar domes
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142
LAMINATE DEFECTS
Bubbles in Body of Laminate Resin-rich and Glass-rich Areas Delaminated Areas within Body of Laminate Crazed Areas Tacky Laminate Surface Internal Dry Patches
Undercure
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LAMINATE DEFECTS
BUBBLES IN BODY OF LAMINATE Air trapped in a laminate is undesirable because its presence lowers the strength of the part, reduces radar and acoustic transparency, and in extreme cases, results in a porous laminate
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144
LAMINATE DEFECTS
Fault Cause Remedy
Check resin glass:ratio Insufficient resin and/or being worked. Ensure mat incorrect binder on glass binder is soluble in resin in mat use. Check operator is fully trained Bubbles in Body of Laminate
Damp reinforcement
Check reinforcement storage conditions. If recently delivered, reinforcement may require drying in a warm room
Excessively short gel-time Check resin formulation. Do or too thick a lay-up leading not lay-up more than 8mm to excessive heating or of laminate at one time resin on gelation
LAMINATE DEFECTS
RESIN-RICH AND GLASS-RICH AREAS (WASHING)
This defect is almost entirely confined to chopped strand mat reinforced laminates and is caused by excessive working of the material during fabrication leading to displacement of the glass and consequently to glass-rich and resin-rich areas. Resin-rich areas in a laminate are points of weakness and, if excessive, call for rejection of the moulding
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146
LAMINATE DEFECTS
Fault Resin-rich and Glass-rich Areas Cause Generally with mat laminates, caused by over-rolling of the reinforcement after binder has dissolved Remedy Check operator is fully trained. No more rolling than is necessary to remove air should be carried out
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147
LAMINATE DEFECTS
DELAMINATED AREAS WITHIN BODY OF LAMINATE Internal delaminations are caused by the application of excessive local force, usually when the moulding is being removed from the mould, or by local contamination of the reinforcement. An internal delamination may also be detected by tapping the surface of the laminate with a coin. A delaminated area gives a dead sound whilst a perfect area gives a clear ringing sound
LAMINATE DEFECTS
DELAMINATED AREAS WITHIN BODY OF LAMINATE
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LAMINATE DEFECTS
LAMINATE FAULTS AND CAUSES
Fault Cause Remedy
Check storage and handling of reinforcement. Cleanliness is essential. Localized contamination Occasionally chrome of reinforcement finishes are misapplied. This is shown by green patches on Delaminated Areas Reinforcement. Reject within Body of Laminate Inadequate wetting of glass. Brushes or rollers Caused by operator contaminated with water carelessness or solvent Use of excessive force Minor form of crazed in removing mould tool areas (below) Introduction to GRP and Hand Laid-up
15-Feb-14 GRP Moulding 150
LAMINATE DEFECTS
LAMINATE FAULTS AND CAUSES
Resin-rich patches
Fault
Cause
Remedy
See Resin-rich Glass-rich Areas and
Crazed Areas
Treat mouldings with respect particularly Local impact damage. before post-cure. Use Excessive localized absolute minimum of force used in removing force when stripping moulding from mould mouldings. Check release agent application methods Loss of monomer by evaporation Gel-time too long
Tacky Laminate Surface

15-Feb-14
Check resin formulation. Air-inhibited resin Use resin not prone to system used Introduction to GRP and Hand Laid-up air inhibition GRP Moulding 151
LAMINATE DEFECTS
CRAZED AREA
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152
LAMINATE DEFECTS
INTERNAL DRY PATCHES (WHITE LAMINATES) White laminates are found when the resin fails to wet the surface of the reinforcement. As a result the pattern of the reinforcement may be clearly seen
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153
LAMINATE DEFECTS
INTERNAL DRY PATCHES (WHITE LAMINATES) This condition is caused by gross contamination of the reinforcement, by the use of a finish which is not compatible with the resin system, or by local exotherm. The result is an unacceptably weak and possibly porous laminate. Small areas may be considered for repair but large areas should always be rejected (Read NES for more details)
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154
LAMINATE DEFECTS
Fault Cause Remedy and
Attempting to impregnate more than See Resin-rich one layer of glass at a Glass-rich Areas time
Internal Dry Patches Use of insufficient resin. Inadequate consolidation Incorrect finish on glass
Check resin:glass ratio

Ensure that glass wetsout satisfactorily with resin in use
15-Feb-14
155
LAMINATE DEFECTS
Fault Cause Workshop temperature too low Loss of styrene caused by draughts Remedy
No laminating to be undertaken at temperatures below 15C

Ensure no draughts or excessive air flow over laminate
Undercure
Presence of inhibitors Check materials e.g unsuitable pigments Incorrect resin formulation, e.g too Check resin formulation little catalyst or accelerator Introduction to GRP and Hand Laid-up
15-Feb-14 GRP Moulding 156
THANK YOU
THANKS FOR YOUR PATIENCE
15-Feb-14
157
EXTRA SLIDES
LINKS
15-Feb-14
158
SPUN YARN
A yarn made by taking a group of short staple fibers, which have been cut from the longer continuous filament fibers, and then twisting these short staple fibers together to form a single yarn, which is then used for weaving or knitting fabrics
15-Feb-14
Introduction to GRP and Hand Laid-up GRP Moulding By Lt Cdr M Hasan Adil PN
159
CRIMP
When warp and weft (fill) yarns interlace in fabric they follow a wavy or corrugated path. Crimp percentage is a measure of this waviness in yarns. Percentage crimp is defined as the mean difference between the straightened thread length and the distance between the ends of the thread while in the cloth, expressed as a percentage. C=(l-p)/p*100% where, c = crimp, l = uncrimped length and p = crimped length Warp is the lengthwise or longitudinal thread in a roll, while weft is the transverse thread
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160
SATIN WEAVE
A weave in which each weft thread floats over as many as 12 warps and then under a single warp. The next weft passes over the same number of warps, but is woven in by different warps
15-Feb-14
161
NOTCH TOUGHNESS
Notch toughness is the ability that a material possesses to absorb energy in the presence of a flaw A tough material will resist the initiation of a crack at points of stress concentration. Although, under certain abnormal conditions, the stress may rise locally to such levels that a crack is initiated, a tough material will better resist the propagation of the crack. The consideration of fracture mechanics principles may be necessary in some instances. Some examples of when notch toughness should be specified include:
dynamic or impact loading fatigue loading service temperatures below 25 degrees F.
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162
CREEP & ABRASION

Creep In materials science, creep is the tendency of a solid material to move slowly or deform permanently under the influence of stresses.
Abrasion
The process of wearing down or rubbing away by means of friction
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163
BUCKLING
In practice, buckling is characterized by a sudden failure of a structural member subjected to high compressive stress, where the actual compressive stress at the point of failure is less than the ultimate compressive stresses that the material is capable of withstanding.
15-Feb-14
164
TOOTH PITCH
The distance between one tooth tip and the next
15-Feb-14
165
MOULDING OPERATION - PICS
Application of Honey Wax

Application of GelCoat
15-Feb-14
167
Application of Surfacing Tissue
15-Feb-14
168
Application of CSM
15-Feb-14
169
Application of Woven Roving
15-Feb-14
170
Application of Woven Roving

Application of CSM and Dislaminating Cloth
15-Feb-14
172
Sheet Release
MOULDING TOOLS
15-Feb-14
174
GEL-COAT DEFECTS
SURFACE FIBRE PATTERN Causes
Gel-coat not cured sufficiently before commencing lay-up
Gel-coat too thin
Remedy
Ensure adequate cure of gel-coat Ensure gel-coat minimum thickness of 0.3mm
15-Feb-14
175
GEL-COAT DEFECTS
STAR CRACKING Causes
Result of an over thick gel-coatoccurs when laminate has received a reverse impact
Remedy
Ensure gel-coat no thicker than 0.5mm
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176
GEL-COAT DEFECTS
CRAZING Causes
Gel-coat too thick Use a brittle resin or resin containing excess monomer
Excessive accelerator in formulation or curing temperature too high (Sometimes gives orange peel effect)
Remedy
Use even thickness gel-coat
Use properly formulated gel-coat resin

Avoid high temperatures
15-Feb-14
177
GEL-COAT DEFECTS
PIN HOLES IN GEL-COAT
Causes
Gel-coat not wetting release agent on mould Minute air bubbles in the surface of the laminate. Caused by poor mixing of filler into thixotropic gel-coat and/or overbrushing of gel-coat when applied to mould Occluded air in the filler used in resin formulation
Dust particles in the parting agent or the gel-coat
Remedy
Use non-silicone wax on mould surface followed by a PVA release agent Mix resin by mechanical means. Apply resin carefully using minimum brushwork consistent with uniform resin coverage
Use only fillers which have been treated for use with polyester or epoxy resin as appropriate
Mould under clean conditions. Ensure that dust cannot fall on mould before application of gel-coat
15-Feb-14
178
GEL-COAT DEFECTS
CRATERING AND BLISTERING Causes
Usually caused by air or solvent trapped between gel-coat and laminate proper. If reinforcement is carefully rolled down this defect should not occur
If parting agent not thoroughly dry, volatiles will cause lifting of gel-coat
Remedy
Check resin:glass ratio; a deficiency of resin often causes air bubbles. Check the grade of any glass mat used. If the binder is insoluble in the resin the fibre will not bed down. Ensure that parting agent is thoroughly dry before applying gel-coat
15-Feb-14
179
GEL-COAT DEFECTS
WRINKLING OF SURFACE Causes
Too thin a gel-coat which is under cured. Often on vertical surfaces
Under cure as a result of styrene (or other monomer) evaporation
Remedy
Prevent drainage of gel-coat by ensuring adequate amount of thixotropic agent in formulation Ensure that there are no draughts in vicinity of the moulding
GENERAL DEFECTS AND ACCEPTANCE CRITERIA

GEL-COAT
Fault Cause Remedy Ensure adequate cure of gel-coat Ensure gel-coat minimum thickness of 0.3mm
Surface Fibre Pattern
Gel-coat not cured sufficiently before commencing lay-up

Gel-coat too thin
Distortion or Warping
Differential shrinkage between unreinforced gel-coat and reinforced laminate

Result of an over thick gel-coatoccurs when laminate has received a reverse impact
Use a reinforced gel-coat Use thin gel-coat Use a specially formulated gel-coat resin Ensure gel-coat no thicker than 0.5mm
Star Cracking
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181
MOULDING OPERATION
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182
STEEL PATTERN
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183
GRP MOULD FABRICATION
15-Feb-14
184
GRP MOULD
15-Feb-14
185
GRP LAYUP OF BOAT
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186
GRP HULL RELEASE
15-Feb-14
187

Intro To GRP and Hand Laid-Up GRP Moulding-PNS JAUHAR

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INTRODUCTION TO GRP AND HAND LAID-UP GRP MOULDING BY LT CDR M HASAN ADIL PN

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Preparation of Material for Moulding

Health and Safety

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Easy to handle Generally non-dermatitic

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

CHOPPED STRAND MAT (CSM)

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

The highest compressive, flexural and tensile strengths

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Organic peroxide catalysts present a hazard when stored in bulk

Introduction to GRP and Hand Laid-up GRP Moulding

MOULDS AND MOULDS PREPARATION

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

MOULD PREPARATION PRIOR LAY-UP

MOULD PREPARATION PRIOR LAY-UP

PREPARATION OF MATERIALS FOR MOULDING

Introduction to GRP and Hand Laid-up GRP Moulding

MATERIAL PREPARATION FOR MOULDING

MATERIAL PREPARATION FOR MOULDING

MATERIAL PREPARATION FOR MOULDING

Drum of solvent (eg styrene, MEK or acetone) for cleaning equipment

MATERIAL PREPARATION FOR MOULDING

MATERIAL PREPARATION FOR MOULDING

Introduction to GRP and Hand Laid-up GRP Moulding

MATERIAL PREPARATION FOR MOULDING

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Hand application of gel-coat resins should be:

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding

A Guide to Methods for Production of Hand Laid-Up GRP Mouldings

Introduction to GRP and Hand Laidup GRP Moulding

Introduction to GRP and Hand Laidup GRP Moulding

Introduction to GRP and Hand Laidup GRP Moulding

Introduction to GRP and Hand Laidup GRP Moulding

Introduction to GRP and Hand Laidup GRP Moulding

A Guide to Methods for Production of Hand Laid-Up GRP Mouldings

Introduction to GRP and Hand Laidup GRP Moulding

Polyvinyl Chloride (PVC)

Introduction to GRP and Hand Laid-up GRP Moulding

Introduction to GRP and Hand Laid-up GRP Moulding