Iranian Classification Society Rules
< Previous | Contents | Next >
Section 2 FRP Materials
201. General
1. Application
Resins, gelcoats, fibre reinforcements, cores for sandwich construction (Hard plastic foams and End- grain balsa) and timbers and plywoods for main constructions as FRP raw materials (hereinafter referred to as "FRP materials") used for hull constructions of FRP ships are to be in accordance with requirements in this section.
2. FRP materials testing
(1) The material manufacturer is to provide the purchaser with certificates of conformity for each batch of materials supplied(hereinafter referred to as "FRP materials tests), indicating the rele- vant values specified in Table 3.1 and 3.5.
(2) The builders are to ensure that copies of all certificates of conformity are obtained for all batches of materials received, and maintain accurate records in accordance with the previous (1).
(3) The Surveyor may at any time select samples of materials for testing by an independent test or- ganization, where applicable, source and should such tests result in the material failing to meet
the specification, then that batch will be rejected.
202. Resins
1. The resin is consist of polyester resin, catalyzer, accelerant, filler, pigment and core material, etc.
2. Resin
(1) The resin is to be of approved type which are deemed appropriate by the Society.
(2) Materials testing list and the acceptance criteria for the test results are to be
Table 3.1.
in accordance with
Table 3.1 Materials testing list and Acceptance Criteria for the test results
Test item | Acceptance criteria | |
Viscosity(1) | 1.5～8(Poise) | |
Thixotropy(1) | 1.2～4 | |
Gel time(1) | Reference(3) | |
Minimum cure time(1) | Reference(3) | |
Peak exothermic temperature(1) | Not more than 190℃ | |
Acid value(1) | Reference(3) | |
Mould plate(2) | Water absorption rate | Mean value to be not more than 70 mg |
Barcol hardness | Mean value to be not less than 35 | |
Tessile elongation | Mean value to be not less than 2.0 % Test results of at least 4 test specimens are not to be less than 2.0 % | |
Tensile strength | 40 NÕmmĪ | |
Bending strength | 70 NÕmmĪ | |
Load deflection temperature | Mean value to be not less than 60℃ Test results of at least 2 test specimens are not to be less than 60℃ | |
(Note) (1) Test methods are to be in accordance with the Guidance relating to the Rules. 【See Guidance】 (2) Test methods are to be in accordance with the Guidance relating to the Rules. 【See Guidance】 (3) The value is to be assigned by the manufacturer. | ||
(3) The polyester containing wax or other materials that deteriorate bonding are to be carried out interlaminar shear strength test (KS M ISO 14130) and approved by the Society.
3. Hardeners and Accelerators
(1) The type and amount used of the hardeners and accelerators are to be carefully selected so that
they are suitable for resins for laminating and gelcoats and capable of fast and completely without heating.
(2) In case of polyester and vinylester resins, the quantity of accelerators
resins in weight ratio.
(3) The followings may be used as a mixture of catalyzer and accelerator. ing the mixtures other than followings, the details are to be submitted.
(A) Methyl-ethyl-ketone peroxide and a cobalt accelerator
(B) Cyclohexane peroxide and a cobalt accelerator
hardening the resin with is not less than 1 % of However, in case of us-
(C) Benzoyl peroxide and a tertiary amine accelerator(can not be used for gelcoats)
(4) In general, the time required for hardening the resin is not to be exceeded one hour where the temperature of moulding shop is under working ranges.
4. Color pigment
(1) Color pigment should be used after mixing with unsaturated polyester resin and styrene, and shall not be used with plasticizer.
(2) Color pigment should not disturb hardening of resin or not give to hardening time.
(3) The quantity of color pigment added in laminating resin is not to be exceeded that indicated by manufacturer.
(4) It is recommended that pigments are not to be added to the gel coat or laminating resins used in the underwater portion of the hull laminate or in laminates forming the boundaries of oil fuel
and water tanks.
5. Fillers
(1) All fillers added by builders are to be of dispersion type and the data concerning the purpose for application, kinds of filler, amount used, etc. are to be submitted to the Society.
(2) Quantities and types of fillers and/or additives are to allow sufficient wet out of reinforcement
fibers within the resin manufacturer's specified gel time.
(3) Calcium carbonate or other fillers similar to alkaline are not to be used in laminates required fire resistant.
(4) In general, the quantity of fillers is not be exceeded 20 % of resin system.
(5) The fillers should not be used in laminates which forms fuel oil tanks and fresh water tanks.
6. Fire retardant additives
(1) Where laminates are required to have fire retardant or restricting properties, details of the pro- posals are to be submitted for approval.
(2) All fire retardant resin systems are to be used strictly in accordance with the resin manu- facturer’s recommendations.
203.
Gelcoats
1. The gelcoat is to be approved by the Society.
2. The gelcoat may be composed of layer reinforced fiberglass or other proper material and resin for gel coat absolutely. Also the resin for gelcoats may be made of general resin for lamination with mixtire of flexible resin.
3. The resin for gelcoat should have hardening time and rapid gelation.
4. The quantities of thyrotrophic additive should be of minimum to prevent from loosening.
5. Materials testing list for gelcoat and the acceptance criteria for the test results are to be in accord- ance with Table 3.2.
Table 3.2 Materials testing list for gelcoat and Acceptance Criteria for the test results
Test item | Acceptance criteria | |
Viscosity(1) | Not less than 20 (Poise) | |
Thixotropy(1) | 1.2～4 | |
Gel time(1) | Reference(3) | |
Minimum cure time(1) | Reference(3) | |
Peak exothermic temperature(1) | Not more than 190℃ | |
Acid value(1) | Reference(3) | |
Mould plate(2) | Water absorption rate | Mean value to be not more than 60 mg |
Barcol hardness | Mean value to be not less than 35 | |
Tessile elongation | Mean value to be not less than 2.5 % Test results of at least 4 test specimens are not to be less than 2.5 % | |
Tensile strength | 40 NÕmmĪ | |
Bending strength | 60 NÕmmĪ | |
Load deflection temperature | Mean value to be not less than 60℃ Test results of at least 2 test specimens are not to be less than 60℃ | |
(Note) (1) Test methods are to be in accordance with the Guidance relating to the Rules. 【See Guidance】 (2) Test methods are to be in accordance with the Guidance relating to the Rules. 【See Guidance】 (3) The value is to be assigned by the manufacturer. | ||
204. Fibre Reinforcements
1. All fibre reinforcements are to be approved by the Society.
2. Materials testing list and the acceptance
criteria for the test results for fibre reinforcements are to
be in accordance
with Table 3.3.
Table 3.3 Materials testing list and Acceptance Criteria for Fibre Reinforcements
Test item | Acceptance criteria | |
Tensile strength of fibre of glass roving cloth(1) | Mean value : Not less than 0.35E(N) E : the stated weight(N) Test results of at least 4 test specimens in 5 test specimens of respective warp and weft directions are not to be less than 0.35E(N). | |
Deviation(1) | Chopped mat | 1 mĪ : Not greater than 10 % for each specimen 300 mm × 300 mm : Not greater than 20 % for each specimen |
Roving cloth | 1 mĪ : Not greater than 3 % for each specimen 300 mm × 300 mm : Not greater than 5 % for each specimen | |
Roving | 15 ᾛ : Not greater than 10% for each specimen | |
Ratio in weight of residual binders(1) | Chopped mat | Mean value : Not greater than 10 % Test results of at least 4 test specimens are not to be greater than 10 %. |
Roving cloth | Mean value : Not greater than 1 % Test results of at least 4 test specimens are not to be greater than 1 %. | |
Roving | Mean value : Not greater than 3 % Test results of at least 4 test specimens are not to be greater than 3 %. | |
Laminating plate(2)(3) | Bending strength(standard condition) | (1) To be in accordance with the Guidance relating to the Rules. 【See Guidance】 (2) The minimum value in the wet condition is not less than 75 % of the minimum value in the standard condition. |
Modulus of bending elasticity(standard condition) | ||
Bending strength(wet condition) | ||
Modulus of bending elasticity(wet condition) | ||
Tensile strength | ||
Modulus of tensile elasticity | ||
(Note) (1) Test methods are to be in accordance with the Guidance relating to the Rules. 【See Guidance】 (2) Test methods are to be in accordance with the Guidance relating to the Rules. 【See Guidance】 (3) The glass/regins ratio or volume ratio(except fibre reinforcements) for manufacturing of laminating plate are to be in accordance with the Guidance relating to the Rules. 【See Guidance】 | ||
3. Fibre reinforcements are to be free from incompleteness, stain, foreign substance, moisture and other defects.
4. The light weight reinforcements that are capable of absorbing large quantity of resin such as 300 g chopped strand mat should be laminated in the middle of clothes weaved thickly. The medium weight reinforcements such as 900 g chopped strand mat should be used to laminate the structures or places that resins are permeated completely.
5. All reinforcements are to be stored strictly in accordance with the manufacturer’s recommendations.
Rolls of reinforcement are to quality control documentation facturer’s batch numbers.
6. Pre-impregnated reinforcements
remain in their original packaging to minimise contamination. The is to provide traceability of all reinforcements using the manu-
are to be suitably stored in an approved area. Detailed storage re-
cords are to be maintained as part of the quality control documentation.
205. Surfacing materials
1. Lightweight surfacing materials for reinforcing resin rich surfaces are to be compatible with the res- in being used. Details of the materials and the fibre contents, by weight, are to be included on the Materials Data Sheet.
2. Where peel ply materials are to be used, the finish is to be such that, after removal, it does not interfere with any subsequent bonding processes.
206. Core Materials for Sandwich Construction
1. All core materials for sandwich construction are to be a type approved by the Society.
2. End-grain balsa
(1) Balsa wood for sandwich construction is to be end grained.
(2) Materials testing list and acceptance criteria for end-grain balsa are to be in accordance
Table 3.4.
with
Table 3.4 Materials testing list and Acceptance Criteria for end-grain balsa
Apparent density (kgÕm Į) | Strength (NÕmmĪ) | Compressive modulus of elasticity (NÕmmĪ) | Shear modulus of elasticity (NÕmmĪ) | |||||
compressive | Tensile | Shear | ||||||
Direction of stress | Direction of stress | |||||||
Parallel to grain | Perpendicular to grain | Parallel to grain | Perpendicular to grain | Parallel to grain | Perpendicular to grain | |||
96 | 5.00 | 0.35 | 9.00 | 0.44 | 1.10 | 2300 | 35.20 | 105 |
144 | 10.60 | 0.57 | 14.60 | 0.70 | 1.64 | 3900 | 67.80 | 129 |
176 | 12.80 | 0.68 | 20.50 | 0.80 | 2.00 | 5300 | 89.60 | 145 |
(Note) (1) Test methods are to be in accordance with the Guidance relating to the Rules. 【See Guidance】 | ||||||||
(3) Balsa wood is to be chemically treated against fungal and insect attack and kiln dried shortly after felling;
(4) Balsa wood is to be an average moisture content of 12 per cent;
3. Hard plastic foams
(1) Materials testing list and acceptance criteria for hard plastic foams for sandwich construction are to be in accordance with Table 3.5.
Table 3.5 Materials testing list and Acceptance Criteria for Hard plastic foams
Material | Apparent density (kgÕmĮ ) | Strength (NÕmmĪ ) | Modulus of elasticity (NÕmm Ī) | |||
Tensile | Compressive | Shear | Compressive | Shear | ||
Polyurethane | 96 | 0.85 | 0.60 | 0.50 | 17.20 | 8.50 |
Polyvinylchloride | 60 | |||||
(Note) (1) Test methods are to be in accordance with the Guidance relating to the Rules. 【See Guidance】 | ||||||
(2) Hard plasic foams are to be of closed-cell types and be compatible with the resin system.
(3) Hard plasic foams are to be impervious to water, fuel and oils and have good ageing stability.
(4) Hard plasic foams are to have good strength retention at 60 °C.
4. Timbers and plywoods are to be tested and inspected on the items in the following :
(1) Compressive strength and modules of compressive elasticity
(2) Tensile strength and modulus of tensile elasticity (only in case where timbers of plywoods reckoned in tensile strength)
(3) Bending strength and modules of bending elasticity (only in case where timbers or plywoods reckoned in bending strength)
(4) Shearing strength obtained from specimens of sandwich construction.
are
are
207. Sub Materials
1. Core bonding materials
(1) Details concerning the handling, mixing and application of adhesives are to be submitted to Society.
(2) Details of the proposed core bonding paste to be used with the core material are to be
dicated on the Materials Data Sheet and the appropriate construction plans.
the in-
(3) The builder is to demonstrate that a uniform thickness of bonding paste is obtained by use of notched trowels or comb gauges.
2. Adhesives
(1) Details concerning the handling, mixing and application of adhesives are to be submitted to the Society.
(2) Particular attention is to be given to the surface preparation and cleanliness of the surfaces to
be bonded.
(3) Where excessive unevenness of the faying surfaces exists a suitable gap filling adhesive is to be used or local undulations removed by the application of additional reinforcements.
3. Sealant material
Details concerning the handling, mixing and application of adhesives are to be submitted to the Society.
4. Repair compounds
(1) For acceptance purposes, the manufacturer is to submit full product details, and user instructions, listing the types of repair for which the system is to be used together with details of any in- staller accreditation schemes.
(2) Dependent on the proposed uses, the Society may require testing in accordance with a specified test programme.
(3) Materials should not be accepted for the following uses unless specific evidences of their suit- ability are provided:
(A) Any component in rubbing contact.
(B) Any component subject to dynamic cyclic loading.
(C) Any pressure part in contact with gas or vapour.
(D) Any pressure part in contact with liquid above 3,5 bar.
(E) Any component where operating temperature exceeds 90°C.
5. Release agents
Release agents are to have no inhibiting effect on the gelcoat resin and are to be those recom- mended by the resin manufacturer.
208. Timbers and Plywoods for Primary Structures
1. Wood
(1) The
woods are to be of good quality and dried properly and free from defects that might im-
pair the strength or durability such as blueing, brittleness, rot, cracks, knots and sapwood etc.
(2) The moisture content of the wood is to be within the limits required by the method of joining
the
parts (glueing, laminating, sheathing) and consideration of the dimensional stability of the
structure. Timber for structural purposes where encapsulated or over-laminated should have an
average moisture content not greater than 15 %.
2. Plywoods
(1) The plywoods are to be of prime quality for ships and glued by approved glues. The glues are to be of resorcinol system, phenolic system or others approved and to be used in accordance with manufacturer's guidance under the conditions which are deemed appropriate by the Society.
(2) In general, the plywood is to be manufactured to a high standard of finish in accordance with
ISO(KS) or other recognised standards and is to meet, or be equivalent to, the following general requirements:
(A) Have good quality face and core veneers of a durable hardwood species.
(B) The number of veneers due to plywoods' thickness is to be in accordance with Table 3.6.
Table 3.6 Number of veneers
Board thickness, (mm) | Minimum number of plies(plies) |
≤ 9 | 3 |
10 ≤ t ≤ 19 | 5 |
20 ≤ t | 7 |
(C) The veneers are to be bonded with a WBP (water and boil proof) type adhesive.
(D) Having a moisture content is not to exceed 15 per cent.
(3) Plywood intended to be used for external structural members (e.g. hull, weather deck not
sheathed by FRP laminate or similar, superstructures and deckhouses) should be marine-grade plywood. Where a ship is intended to be only temporarily used in the water and the hull is protected by a wood-penetrating medium(e.g. epoxy resin) other waterproof and boilproof ex- ternal-grade plywood may be used.
(4) Other members inside the hull may be made of waterproof and boilproof plywood which does not fully comply with marine-grade plywood. It should be durable.
209. Cores for Moulding 【See Guidance】
1. Cores used for moulding in frames, longitudinals, etc., are to be of oil resistance, styren resistance and water resistance, and to have good adhesion to polyester resins.
2. Where the cores for moulding are reckoned in strength, tests are to be carried out on tensile strength and modulus of tensile elasticity or bending strength and modulus of bending elasticity. However, where sufficient data are submitted to and approved by the Society, the above-mentioned tests may be dispensed.
210. Receipt and Storage for FRP Materials
1. Receipt
The following tests are to be carried out, where applicable, on receipt of any material:
(1) The consignment is to be divided into its respective batches and each batch is to be labelled accordingly.
(2) Each batch is to be visually examined for conformity with the batch number, visual quality and
date of expiry.
(3) Each batch is to be separately labelled and stored separately.
(4) Each unit, within the batch, is to be labelled with the batch number.
(5) Records are to be maintained of the above and these are to be cross-referenced with the certifi- cate of conformity for the material and/or the Builder’s own test results.
2. Storage
(1) Storage premises are to be so equipped and arranged that the material supplier's directions for storage and handling of the raw materials can be followed.
(2) Resins are to be stored under controlled condition in accordance with manufacture's
recommendations. Where resins contain ingredients of solidifications, it is to be ensured that it is are in accordance with resins manufacture's recommendations concerning blending and con- ditioning before use.
(3) Polyester, gelcoat and the like should not be stored by temperatures that will affect the qualities of the material. Raw materials which are stored at temperatures lower than 18 ℃ should be
heated up before use to the temperature of the moulding shop. Tanks for polyester are to be equipped and arranged so that the contents can be stirred every day.
(4) The storage temperature and the storage periods for resins and coating are to be within the lim- its specified by the material supplier.
(5) Storage premises for glassfibre are to be kept clean and as free from dust as possible, so that the raw material is not contaminated. Glassfibre parcels are also to be protected against rain and moisture.
(6) The glassfibre material is, whenever possible, to be stored for at least two days in storage premises, with air of a lower relative humidity than in the manufacturing premises, and at an
air temperature at least 2 ℃ higher than in the manufacturing premises. If such storage of the
glassfibre material before transfer to the manufacturing is not possible, the material is to be
stored for at least two days in premises with air of the same condition as in the moulding
premises.
(7) Catalyzers and accelerants are to be stored in accordance with manufacture's recommendations.
(8) Fillers and additives used for moulding procedures are to be stored in the closed container to be protected from dust and moisture.
(9) Core materials are to be stored dry according to and protected against mechanical damages.