Basic Hand Lay-up Techniques

Normally the work is carried out in a female mould a GRP mould with a polished gelcoat surface on the inside. Having acquired and set up the mould at a convenient working height in the workshop, the following procedure should be adopted: 1 Wash the mould carefully with warm water and soft soap to remove any old PVC release agent, dust, grease, finger marks, etc. 2 Dry the mould thoroughly. 3 Check the mould surface for chips or blemishes. These should be repaired by filling with polyester filler and cutting back with wet/dry paper. The odd small chip can be temporarily repaired by filling with plasticine or plastic filler. 4 If the mould surface is in good condition the mould release wax is now applied, with a circular motion, using a small piece of cloth. Three coats of wax is sufficient for a mould surface which has been previously broken in but a new mould surface will require at least six applications. Each application is polished up to a high shine with a large piece of cheesecloth, after being left to harden for 15-20 minutes. Care must be taken to remove all streaks of wax. Be sure that the wax is polished and not removed by aggressive buffing. Failure to take care at this stage can result in stick up. Check application with manufacturers instructions. 5 Apply the polyvinyl alcohol (PVA blue or clear) solution carefully with a piece of sponge or foam rubber. Avoid going over the mould surface more than once with the sponge as this may lift the layer of PVA previously applied. PVA solution must be allowed to dry completely before the gelcoat is applied. At normal room temperature (approx 21C (70F) this takes about 20 minutes. A dry and dust free area is required. 6 The gelcoat is weighed out and the correct quantity of catalyst stirred in. In industry the gelcoat is usually sprayed onto the mould surface or applied by brush or large lambswool roller (50-120mm) (2.5 in). Brush is the most suitable. Care must be taken to ensure an even coverage of gelcoat, free from blobs, deep ridges, shallow furrows and air bubbles. Work from one end of the mould, spreading the gelcoat with light even strokes in one direction only. Vigorous painting strokes give too thin a gelcoat coverage and can sometimes cause the PVA to lift from the mould surface. The gelcoat

surface is applied very thickly compared to a painted surface. To avoid serious gelcoat problems, it is safer to err or the slightly heavy side, rather than apply too thin a coating. Aim for 0.5mm (0.20) thickness (600g/m). The gelcoat should have as short a pot life as possible, within reason (about 15 minutes), as lengthy geltime on the mould allows excessive evaporation of the styrene monomer and this could result in permanent undercure of the gelcoat. Also a long gellation period can allow the styrene to attack the mould surface and cause a polystyrene build-up. This will spoil the highly polished appearance of both the mould and the moulding. Ideally, the lay-up of the fibreglass reinforcement should comment as soon as the gelcoat has cured sufficiently to be hard to the touch. This stage of the cure may take from one to four hours depending on such factors as catalyst levels, working temperature, humidity and mould shape. One test is to touch the lowest point in the mould gently with the fingertips. The gelcoats should feel tacky but solid, and no pigmentation should come off on the finger. While the gelcoat should not be allowed to overcure, it is equally important that the lay-up of the polyester resin and glassfibre reinforcement should not be commenced until the gelcoat has reached the stage mentioned above, otherwise the styrene in the polyester resin will soften and wrinkle the gelcoat, causing unsightly blemishes in the finished moulding. If a mould must be left for a period of hours after gelcoat application it should be placed in an area free of dust or damp. If it is not possible to apply the laminating resin for some time, adhesion between gelcoat and laminate can be improved by giving the gelcoat surface a thorough acetone wash prior to the glassfibre lay-up. LAYING UP A GRP MOULDING After the gelcoat has cured, the moulding is reinforced by bonding some form of glassfibre reinforcement to the gelcoat with polyester laminating resin. Chopped strand mat, tissues, tapes, woven rovings and cloths may be used and each will impart specific strength and performance factors to the moulding. The glassfibre required for the lay-up should have been previously cut to the shape of the mould by means of templates, paper patterns or by approximate measurements taken directly from the mould. A steel tape measure is useful here as it can be easily flexed to follow the contours of the mould then laid out on the cutting table and used as a straight edge. The Chopped

To the extent permitted by law and subject to any implied warranties under the Trade Practices Act 1974, we make no warranties and representations, express or implied, as to the

description,merchantable quality or fitness for purpose of the goods described or the care and skill of any services provided.If any implied statutory provisions apply, to the extent that is permitted by law, our liability will be limited at our option to: (a) in the case of supply of goods: (i) the replacement of the goods or supply of equivalent goods; (ii) the payment of the cost of replacing the goods or acquiring equivalent

goods; or (iii) the payment of having the goods repaired or the repair of the goods; 1 (b) in the case of services: (i) the supply of the services again; or (ii) the payment of the cost of having the services performed again.To the extent permitted by law, we will not be liable for Basic Hand Lay-up Techniques (cont.) Strand Mat (or other reinforcement) should be cut so that, when placed in the mould, it should not extend beyond the edge of the mould by more than about 25mm (1in). Otherwise the excess material may sag when wet and pull the mould material away from the surface, leaving an air cavity between mat and gelcoat. The lay-up takes place in the following stages: 1 The laminating resin is weighed out, and then catalysed. 2 A brush or roller is used to apply a liberal coating of resin to the gelcoat surface. 0 3. A shaped layer of Chopped Strand Mat is placed carefully in the mould and the previously applied resin worked through it. Additional resin is applied to the CSM surface at this stage and all fibres are stippled or rolled until thoroughly and evenly wetted out with resin. 1 The first layer is very important as it reinforces the gelcoat and prevents air pockets from forming behind it. For this reason a thin layer of CSM is often laid up first. This ensures that the CSM will not pull out of tight corners or uneven spots in the gelcoat. 3 A second layer of CSM is applied as soon as the first is thoroughly wetted out and as much resin as possible is stippled through the mat from the previous layer. Additional resin is added sparingly by brush, the object being to achieve a thorough wet out of the CSM with the minimum quantity of resin. 4 Immediately after the second layer of CSM has been applied a compression roller (is used) to compress the mat and squeeze air bubbles and excess resin from the laminate. This technique appreciably improves the strength of the moulding by increasing its density and reducing its porosity on the inside surface, so it is important that the roller are used firmly and evenly across the entire surface. 5 Successive layers of laminate are now applied to the mould until the lay-up is complete. Each layer is compression rolled as described above. The number of layers required will depend on the type of moulding and the structural stresses it will need to withstand in use. 7. When the resin in the lay-up has gelled sufficiently to allow the laminate to be trimmed with a stanley knife or plain blade the cure has

any loss, damage, expense, injury or death sustained or incurred by a customer or any other party resulting directly or indirectly out of: 2 (i) the supply, performance or use of any goods or services; (ii) the breach of any agreement between us and a customer; or (iii) our negligence.

reached what is known as the green stage. This is the ideal time to trim all the edges and usually lasts for a few minutes. If trimming is delayed until the initial cure is complete a coping saw and surform will be required. This is hard work and often takes more time than that involved in the actual lay-up. Trimming at the green stage, on the other hand, is the work of only a few minutes and if done carefully gives a clean, precise cut along the edge of the mould. NOTES ON LAY-UP TECHNIQUES The glassfibre laminate used in any FRP moulding can be made up from different types of glassfibre material depending on the specific function of the end product. Refer to the Reinforcement Selector and Guide to the use of high Performance Reinforcements data sheets, or contact FGI for further details. Any FRP laminate will generate heat during the polymerisation of the resin so it is important to limit the thickness of the lay-up (average1800gm/m 2). Otherwise, there will be a risk of over heating the moulding which could result in warping and weakening of the finished product. In addition to the reinforcing used in normal laminating, a FRP moulding can be further reinforced at specific points simply by increasing the thickness of the reinforcement material during the lay-up procedure. Overlapping two sheets of CSM on a corner, for example, offers twice the thickness and thus greatly increased strength at that point. Additional reinforcement can be added by using a wide range of materials which are moulded into the job after the initial lay-up has been cured. Some of these materials are: STRIP STRENGTHENING MATERIALS These can be in the form of timber, polyurethane foam strips, cardboard or plastic tubes. These materials when bonded onto the inside surface of the cured laminate act as corrugations and as such give the moulding rigidity with minimum weight gain. To the extent permitted by law and subject to any implied warranties under the Trade Practices Act 1974, we make no warranties and representations, express or implied, as to the description,merchantable quality or fitness for purpose of the goods described or the care and skill of any services provided.If any implied statutory provisions apply, to the extent that is permitted by law, our liability

will be limited at our option to:

(a) in the case of supply of goods: (i) the replacement of the goods or supply of equivalent goods; (ii) the payment of the cost of replacing the goods or acquiring equivalent goods; or (iii) the payment of having the goods repaired or the repair of the goods;

1 (b) in the case of services: (i) the supply of the services again; or (ii) the payment of the cost of having the services performed again.To the extent permitted by law, we will not be liable for any loss, damage, expense, injury or death sustained or incurred by a customer or any other party resulting directly or indirectly out of: 2 (i) the supply, performance or use of any goods or services; (ii) the breach of any agreement between us and a customer; or (iii) our negligence. Basic Hand Lay-up Techniques (cont.)

AREA STRENGTHENING MATERIALS These usually consist of termanto foam or end grain balso used as sandwich reinforcement. They give strength, in the form of rigidity, to large areas of a moulding with a minimum of weight gain. They also help to keep GRP costs down. Available in sheet form on a flexible backing so that they can be made to follow the contours of the mould. They are sandwiched within the laminate with glass fibre skins each side. PULLING THE MOULDING FROM THE MOULD In industry, compressed air or water is sometimes used between mould and moulding to help release mouldings with deep draw from the mould. Split moulds are also used where difficult shaped mouldings are made. The mould is in two halves which can be unbolted and easily levered apart, thus cracking the moulding clear of the mould. In the home workshop, however, these methods are usually neither practical nor necessary. Shallow moulds, with reasonable draw, and which are slightly flexible should be used and the moulding released by flexing gently. Slight twist may also be applied to the mould to help break the bond and as a rule this is the only effort required to crack out a shallow moulding, provided it has been correctly trimmed to the edge of the mould and the release agents have been properly applied. Flexing the mould will start the mould at one or two points and strips of soft plywood or masonite can then be wedged between mould and moulding. The wedges are then carefully pulled along the top edge of the moulding until it is released from the mould all round. If need be, the strips can then be pressed further down round the contours of the mould until the total release is obtained. Under no circumstances should chisels,

screwdrivers or plane blades be used to wedge or lever the moulding from the mould. This will result in scratching or even chipping of the mould and would ruin it for future mouldings. FLOW COATING After all reinforcements (if any) have been bonded into the moulding the inside surface is usually rubbed down with 80 grit garnet paper to removed any sharp fibres, the dust is removed and a flow coat applied to the laminate. The flow coat is used: 1 To seal the laminate surface from attack by moisture, grit, grease, chemicals etc. 2 To remove th tacky feel from the laminating resin used in the lay-up. 3 To give the moulding a clean internal finish with colour uniformity, if desired. Wax floats to the surface of the flow coat and prevents air inhibition of the resin cure which would leave the surface tacky. The result is a hard, shiny surface free from porosity and sharp fibres. To the extent permitted by law and subject to any implied warranties under the Trade Practices Act 1974, we make no warranties and representations, express or implied, as to the description, merchantable quality or fitness for purpose of the goods described or the care and skill of any services provided If any implied statutory provisions apply, to the extent that is permitted by law, our liability will be limited at our option to: (a) in the case of supply of goods: (i) the replacement of the goods or supply of equivalent goods; (ii) the payment of the cost of replacing the goods or acquiring equivalent goods; or (iii) the payment of having the goods repaired or the repair of the goods; (b) in the case of services: (i) the supply of the services again; or (ii) the payment of the cost of having the services performed again. To the extent permitted by law, we will not be liable for any loss, damage, expense, injury or death sustained or incurred by a customer or any other party resulting directly or indirectly out of: (i) the supply, performance or use of any goods or services; (ii) the breach of any agreement between us and a customer; or (iii) our negligence. Repair Techniques

Fibreglass Repair Techniques INTRODUCTION Fibreglass Reinforced Plastic (FRP) parts are tough, but like any other products they can be damaged. Fortunately repairs are easily accomplished if proper procedures are followed. The repair procedures recommended here are based on accepted industry practices and when followed should achieve satisfactory results. Quality of the finished part is largely dependent on surface preparation, cleanliness, sufficient laminate overlap and thicknesses. It is equally important to follow the manufacturers or material suppliers instructions for the mixing and application of materials needed for repairs. Should you experience any other problems with FRP that are not discussed in this booklet or require further information, please call the Fibreglass Sales Office in your state. (Refer to back cover). Contents Safety Is The First Step Important Things To Remember Inspection What You Will Need for FRP Repair Work Page 1 1 23

To the extent permitted by law and subject to any implied warranties under the Trade Practices Act 1974, we make no warranties and representations, express or implied, as to the description,merchantable quality or fitness for purpose of the goods described or the care and skill of any services provided.If any implied statutory provisions apply, to the extent that is permitted by law, our liability will be limited at our option to: (a) in the case of supply of goods: (i) the replacement of the goods or supply of equivalent goods; (ii) the payment of the cost of replacing the goods or acquiring equivalent goods; or (iii) the payment of having the goods repaired or the repair of the goods; 1 (b) in the case of services: (i) the supply of the services again; or (ii) the payment of the cost of having the services performed again.To the extent permitted by law, we will not be liable for any loss, damage, expense, injury or death sustained or incurred by a customer or any other party resulting directly or indirectly out of: 2 (i) the supply, performance or use of any goods or services; (ii) the breach of any agreement between us and a customer; or (iii) our negligence.

Repair Procedures Procedure A Surface or cosmetic damage Procedure B

Structural damage accessible from both sides 5 Procedure C Structural damage inaccessible from the rear 7 SAFETY IS THE FIRST STEP Before you undertake any of the repair techniques discussed in this booklet, carefully read these safety hints. 1 Most resins, solvents and catalysts are highly flammable. Store in closed, original containers and in cool dark area. 2 Do not smoke when using the above and avoid all naked flames and excessive heat. 1 To avoid any contamination, properly dispose of unused materials. 2 Do not return unused material to storage container. 3 Never mix catalysts and promoters. 4 Catalysts and solvents can damage skin and eyes. Wear close-fitting eye protection, PVC gloves and protective clothing as recommended by suppliers.

5 Do not use oral suction methods for measuring, such as a pipette. 6 Ask for manufacturers safety and emergency instructions if you are in any doubt as to the correct handling procedures. IMPORTANT THINGS TO REMEMBER When making any of the FRP repairs that are outlined in this booklet, take care to adhere to the following points. 1 Carefully follow the instructions given for gelcoats and thickening agents, to calculate current working and curing times. 2 The catalyst must be thoroughly mixed with the gelcoat/resin in the range of 1%-2% of catalyst by volume. To prevent deterioration it must be within shelf life (approx. 3-6 months). 3 Acetone, used for surface preparation and cleaning of equipment, is highly flammable. Read and follow the suppliers handling instructions carefully. 4 Avoid working in direct sunlight the repair materials are heat sensitive and cure at around 15-25 degrees Celsius. 5 Avoid working in damp, humid or draughty conditions. 6 Ensure your work area is well ventilated; open doors and windows, where possible. 7 All pigments will change colour after a

period of exposure to sunlight. Exact colour matching is difficult, particularly with old parts. Excessive catalyst or cure temperature will cause discolouration of gelcoat, which is more noticeable in pale colours. To the extent permitted by law and subject to any implied warranties under the Trade Practices Act 1974, we make no warranties and representations, express or implied, as to the description,merchantable quality or fitness for purpose of the goods described or the care and skill of any services provided.If any implied statutory provisions apply, to the extent that is permitted by law, our liability will be limited at our option to: (a) in the case of supply of goods: (i) the replacement of the goods or supply of equivalent goods; (ii) the payment of the cost of replacing the goods or acquiring equivalent goods; or (iii) the payment of having the goods repaired or the repair of the goods; 1 (b) in the case of services: (i) the supply of the services again; or (ii) the payment of the cost of having the services performed again.To the extent permitted by law, we will not be liable for any loss, damage, expense, injury or death sustained or incurred by a customer or any other party resulting directly or indirectly out of: 2 (i) the supply, performance or use of any goods or services; (ii) the breach of any agreement between us and a customer; or (iii) our negligence.

Repair Techniques (Cont.) INSPECTION Damage to FRP laminates can be described as either cosmetic and/or structural. The technique needed for the repair of damage to FRP laminates will vary according to the extent and type of damage. Discussed in the booklet are various types of damage with corresponding repair procedures. Surface or Cosmetic Damage: Scratches, shallow and deep, cracks or crazing as a result of impact and/or stress and small holes that do not affect the strength of the product fall into the category of surface defects. USE REPAIR PROCEDURE A eg Scratches and grazes to boat hulls and canoes. Structural Damage Accessible from Both Sides: Structural damage includes cracks, punctures, breaks and holes that penetrate the laminate affecting the soundness of the damage product. USE REPAIR PROCEDURE B eg Damage to boat hulls and canoes. Structural Damage Inaccessible from the Rear: This damage is identical to procedure 2 except that the damage area is accessible from one side only. USE REPAIR PROCEDURE C eg Rear deck spoiler of cars. WHAT YOU WILL NEED FOR FRP REPAIR WORK Tools: Personal safety equipment eg glasses, gloves, overalls, face-masks. Angle grinder or power drill with sanding disc. Sandpaper and sanding discs. Jig Saw/Hacksaw blade Power drill and bits Inexpensive paint brushes. Laminate consolidating rollers Glass, polyethylene, or non-waxed paper containers, for mixing chemicals Mixing sticks Kitchen scales (up to 5kg) Catalyst dispensing bottle (graduated) Bonding tags Pop rivets Pop rivet pliers Optional: Spray Gun Compressor (portable) Air lines

Materials: Fibreglass Chopped Strand Mat (CSM) Fibreglass Woven Rovings (WR) Gelcoat (suitably coloured) Thickening agent Resin Polyurethane paint Acetone Wax in styrene Masking tape Buffing compound Body filler Catalyst

To the extent permitted by law and subject to any implied warranties under the Trade Practices Act 1974, we make no warranties and representations, express or implied, as to the description,merchantable quality or fitness for purpose of the goods described or the care and skill of any services provided.If any implied statutory provisions apply, to the extent that is permitted by law, our liability will be limited at our option to: (a) in the case of supply of goods: (i) the replacement of the goods or supply of equivalent goods; (ii) the payment of the cost of replacing the goods or acquiring equivalent goods; or

(iii) the payment of having the goods repaired or the repair of the goods; 1 (b) in the case of services: (i) the supply of the services again; or (ii) the payment of the cost of having the services performed again.To the extent permitted by law, we will not be liable for any loss, damage, expense, injury or death sustained or incurred by a customer or any other party resulting directly or indirectly out of: 2 (i) the supply, performance or use of any goods or services; (ii) the breach of any agreement between us and a customer; or (iii) our negligence.

Repair Techniques (Cont.) To the extent permitted by law and subject to any implied warranties under the Trade Practices Act 1974, we make no warranties and representations, express or implied, as to the description,merchantable quality or fitness for purpose of the goods described or the care and skill of any services provided.If any implied statutory provisions apply, to the extent that is permitted by law, our liability will be limited at our option to: (a) in the case of supply of goods: (i) the replacement of the goods or supply of equivalent goods; (ii) the payment of the cost of replacing the goods or acquiring equivalent goods; or (iii) the payment of having the goods repaired or the repair of the goods; 1 (b) in the case of services: (i) the supply of the services again; or (ii) the payment of the cost of having the services performed again.To the extent permitted by law, we will not be liable for any loss, damage, expense, injury or death sustained or incurred by a customer or any other party resulting directly or indirectly out of: 2 (i) the supply, performance or use of any goods or services; (ii) the breach of any agreement between us and a customer; or (iii) our negligence.

Repair Techniques (Cont.)

 Grind away damaged laminate and tape the repair area surrounding the hole. It should be approximately 30cm larger than the damaged area. Cut a backing plate slightly larger than the

hold from a sheet of FRP and sand the surface of the backing plate. (Figure 4a). Drill two holes in the backing plate, feed a length of wire in this hole and double back the protruding section of the wire so that the backing plate hangs from the wire.

 Slip the backing plate into the hole to be repaired and using the wire, pull the backing plate, reshape and replace it until there is a good fit between the plate and the interior surface. (Figure 4b). Holding the backing plate tight against the internal surface, drill just inside the edge of the tapered area Then insert sheet metal screws through the tapered laminate and into the back plate. (Figure 4c). Remove the wire. Applying the Patch: Prepare a series of fibreglass chopped strand mat patches. The smaller patch should just fit the hole and the rest should be increasingly large. ie. the same as the tapered area. Following the manufacturers instructions for the various materials, place several layers of To the extent permitted by law and subject to any implied warranties under the Trade Practices Act 1974, we make no warranties and representations, express or implied, as to the description,merchantable quality or fitness for purpose of the goods described or the care and skill of any services provided.If any implied statutory provisions apply, to the extent that is permitted by law, our liability will be limited at our option to: (a) in the case of supply of goods: (i) the replacement of the goods or supply of equivalent goods; (ii) the payment of the cost of replacing the goods or acquiring equivalent goods; or

catalysed resin-soaked Chopped Strand Mat and Woven Rovings patches over the damaged area, taking care to overlap the second and subsequent patches in order of size. Roll out the wet laminate with the consolidating roller to remove entrapped air and allow to cure (12 to 24 hours at room temperature). Remove the screws supporting the backing plate. Slightly sand the repair laminate before applying the next layers. Build up the patch with layers of catalysed, resinimpregnated Chopped Stand Mat and Woven Rovings, taking care to squeeze out entrapped air by rolling the area with the consolidating roller. If more than 4mm thickness is required, complete the patch in phases, letting the first layers cure to a leather-like condition before applying the remainder. In hot weather if left to cure for more than a few hours, light sanding may be required before applying the next layers. (iii) the payment of having the goods repaired or the repair of the goods; 1 (b) in the case of services: (i) the supply of the services again; or (ii) the payment of the cost of having the services performed again.To the extent permitted by law, we will not be liable for any loss, damage, expense, injury or death sustained or incurred by a customer or any other party resulting directly or indirectly out of: 2 (i) the supply, performance or use of any goods or services; (ii) the breach of any agreement between us and a customer; or (iii) our negligence.

Repair Techniques (Cont.) Filling: Filler can be purchased as stock items at FRP suppliers. Avoid talc filled compounds if repair is subjected to constant immersion in water (FRP supplier will advise). Apply the filler material to refine the patch shape to the surface contour, then allow the filler to cure. Using sandpaper (80 grit to 180 grit), sand the patch until it blends into the original surface shape. Mask off the surrounding area (approx. 200mm) around the repair. Sand the area with 180 grit. Clean the surface dust with a clean rag dampened with acetone. Applying the Gelcoat: Prepare sufficient catalysed gelcoat to cover the patch. Thin with acetone or styrene monomer for spraying. Gelcoat by brushing or spraying until the desired film thickness is achieved. Apply PVA release agent over the gelcoat (if wax in styrene has not been added) and allow it to cure properly (overnight). Remove the PVA release agent by washing the surface thoroughly with water. Finishing Off: Remove masking materials. Sand the work area until the join line around the patch is gone. Begin with a coarse dry rubbing paper (180 or 320 grit, free cut) and finish with wet and dry sandpaper (400 to 1200 grit). Dry and clean the surface. Finish the repair by rubbing or buffing with a cutting compound to the desired level of gloss. Be careful not to cut through the gelcoat, corners and edges are particularly vulnerable.

Figure 4
To the extent permitted by law and subject to any implied warranties under the Trade Practices Act 1974, we make no warranties and representations, express or implied, as to the description,merchantable quality or fitness for purpose of the goods described or the care and skill of any services provided.If any implied statutory provisions apply, to the extent that is permitted by law, our liability will be limited at our option to: (a) in the case of supply of goods: (i) the replacement of the goods or supply of equivalent goods; (ii) the payment of the cost of replacing the goods or acquiring equivalent goods; or (iii) the payment of having the goods repaired or the repair of the goods; 1 (b) in the case of services: (i) the supply of the services again; or (ii) the payment of the cost of having the services performed again.To the extent permitted by law, we will not be

liable for any loss, damage, expense, injury or death sustained or incurred by a customer or any other party resulting directly or indirectly out of: 2 (i) the supply, performance or use of any goods or services; (ii) the breach of any agreement between us and a customer; or (iii) our negligence.