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Until the mid 19th century most boats were of all natural materials; primarily wood. Many boats had been built with iron or steel frames but still planked in wood. In 1855 ferro-cement boat construction was patented by yothe French. They called it Ferciment. This is a system by which a steel or iron wire framework is built in the shape of a boat's hull and covered (troweled) over with cement. Reinforced with bulkheads and other internal structure it is strong but heavy, easily repaired, and, if sealed properly, will not leak or corrode. These materials and methods were copied all over the world, and have faded in and out of popularity to the present. As the forests of Britain and Europe continued to be over-harvested to supply the keels of larger wooden boats, and the Bessemer Process (patented in 1855) cheapened the cost of steel, steel ships and boats began to be more common. By the 1930s boats built of all steel from frames to plating were seen replacing wooden boats in many industrial uses, even the fishing fleets. Private recreational boats in steel are uncommon. In the mid 20th century aluminum gained popularity. Though much more expensive than steel, there are now aluminum alloys available that will not corrode in salt water, and an aluminum boat built to similar load carrying standards could be built lighter than steel. Nonetheless, boats are generally built in such a manner as to keep water from invading the hull, which would cause the boats to sink.

Around the mid 1960s, boats made out of glass-reinforced plastic, more commonly known as fiberglass, became popular, especially for recreational boats. The coast guard refers to such boats as 'FRP' (for Fiberglass Reinforced Plastic) boats. Fiberglass boats are extremely strong, and do not rust (iron oxide), corrode, or rot. They are, however susceptible to structural degradation from sunlight and extremes in temperature over their lifespan. Fiberglass provides structural strength, especially when long woven strands are laid, sometimes from bow to stern, and then soaked in epoxy or polyester resin to form the hull of the boat. Whether hand laid or built in a mold, FRP boats usually have an outer coating of gelcoat which is a thin solid colored layer of polyester resin that adds no structural strength, but does create a smooth surface which can be buffed to a high shine and also acts as a protective layer against sunlight. FRP structures can be made stiffer with sandwich panels, where the FRP encloses a lightweight core such as balsa or foam. Cored FRP is most often found in decking which helps keep down weight that will be carried above the waterline. The addition of wood makes the cored structure of the boat susceptible to rotting which puts a greater emphasis on not allowing damaged sandwich structures to go unrepaired. Plastic based foam cores are less vulnerable. The phrase 'advanced composites' in FRP construction may indicate the addition of carbon fiber, kevlar(tm) or other similar materials, but it may also indicate other methods designed to introduce less expensive and, by at least one yacht surveyor's eyewitness accounts, less structurally sound materials.


       

Cold molding is similar to FRP in as much as it involves the use of epoxy or polyester resins, but the structural component is wood instead of fiberglass. In cold molding very thin strips of wood are laid over a form or mold in layers. This layer is then coated with resin and another directionally alternating layer is laid on top. In some processes the subsequent layers are stapled or otherwise mechanically fastened to the previous layers, but in other processes the layers are weighted or even vacuum bagged to hold layers together while the resin sets. Layers are built up thus to create the required thickness of hull.

People have even made their own boats or watercraft out of commonly available materials such as styrofoam or plastic, but most homebuilts today are built of plywood and either painted or covered in a layer of fiberglass and resin.

Glass-reinforced plastic (GRP), is a composite material or fiber-reinforced plastic made of a plastic reinforced by fine fibers made of glass. Like graphite-reinforced plastic, the composite material is commonly referred to by the name of its reinforcing fibers (fiberglass). The plastic is thermosetting, most often polyester or vinylester, but other plastics, like epoxy (GRE), are also used. The glass is mostly in the form of chopped strand mat (CSM), but woven fabrics are also used.

The fiberglass mold process begins with an object known as the plug or buck. This is an exact representation of the object to be made, and can be made from a variety of different materials. Certain types of foam are commonly used.

After the plug has been formed, it is sprayed with a mold release agent. The release agent will allow the mold to be separated from the plug once it is finished. The mold release agent is a special wax, and/or PVA (Polyvinyl alcohol). Polyvinyl Alcohol, however, is said to have negative effects on the final mold's surface finish.

Once the plug has its release agent applied, gelcoat is applied with a roller, brush or specially-designed spray gun. The gelcoat is pigmented resin, and gives the mold surface a harder, more durable finish.

Once the release agent and gelcoat are applied, layers of fiberglass and resin are laid-up onto the surface. The fiberglass used will typically be identical to that which will be used in the final product.

In the laying-up process, a layer of fiberglass mat is applied, and resin is applied over it. A special roller is then used to remove air bubbles, which will significantly reduce the strengh of the finished mold.

Once the final layers of fiberglass are applied to the mould, the resin is allowed to set-up and cure. Wedges are then driven between the plug and the mold in order to separate the two.

Advanced techniques such as Resin Transfer Molding are also used.

    
 

The component-making process involves building up a component on the fiberglass mold. The mold is a negative image of the component to be made, so the fiberglass will be applied inside the mold, rather than around it.

As in the mold-making process, release agent is first applied to the mold. Colored gelcoat is then applied. Layers of fiberglass are then applied, using the same procedure as before. Once completed and cured, the component is separated from the mold using wedges.


 

       
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