Epiglass® Multipurpose Epoxy Resin ABOUT THE AUTHORS ROGER MARSHALL For eight years award winning author Roger Marshall has been the technical editor for Soundings magazine where his articles are read by about 250,000 people each month. Marshall’s experience as a writer spans for many years. His work has appeared worldwide as well as the New York Times, Daily Telegraph (UK), Sports illustrated, Sail, Cruising World, Motor Boating and sailing, Yachting and many other newspapers and magazines. Marshall is also the author of twelve marine related books, two of which were translated into Italian and Spanish. His last book All about Powerboats was published by International Marine in the spring of 2002. He has another book Rough Weather Seamanship due in the fall of 2003 and is currently working on a new book, Elements of Powerboat Design for International Marine. But writing is only a small part of Marshall’s talents. He is also a designer of boats, both power and sail. After completing a program in small craft design at Southampton College in England, Marshall, who still holds a British passport, moved to the United States in 1973 to take a position at Sparkman & Stephens, Inc. in New York. He worked there as a designer for nearly 5 years and then left to establish his own yacht design studio in Jamestown, Rhode Island. As an independent designer he has designed a wide range of boats and was project engineer for the Courageous Challenge for the 1987 America’s Cup campaign in Australia. In 1999 one of his cruising yacht designs was selected for inclusion in Ocean Cruising magazine’s American Yacht Review. Marshall has extensive sailing and boating experience. He has sailed at all levels including 12 metres and Admiral’s cup boats (once with the British team on Qualio III, another time for the British team aboard Prime Minister Heath’s Morning Cloud, and once with the Japanese team). He has also sailed in many world and national championships, in the half-ton worlds as the lone British entrant, 10 Bermuda races (twice with the British Orion Patch team), and 5 Fastnet races (twice with the British Admiral’s Cup team(, and the 1997 Atlantic Challenge from New York, to Falmouth, England, placing third. He has cruised on both power and sailboats in many parts of the world, especially the European, Mediterranean, and North American coastlines. He has also built his own boat and is currently rebuilding an eighteen-foot Seacraft centre console, using Epiglass ® and other International Paint Products. KEITH RYMAN Keith Ryman is International Paint’s Technical Manager for Australasia and has been involved with the marine industry for over 25 years. Keith left university after gaining a degree in chemistry and computing and sailed from New Zealand to Hawaii on a plywood yacht and decided this was the industry he wanted to be in. Since starting work in the New Zealand laboratory to Hawaii on a plywood yacht and decided this was the industry he wanted to be in. Since starting work in the New Zealand laboratory he has been involved with formulating many unique products fir the yacht industry and the industrial sector, involving constructional products as well as surface coatings and antifoulings based on a wide range of chemistries including polyurethane, epoxy, polyester and vinylester. 2 EUROPE.QT04.EPGG04 Keith has also been involved in numerous epoxy composite constructions over the years dating back to New Zealand’s first Americas Cup campaign, the so called Plastic Fantastic boat which was constructed from the HT9000 (Epiglass Epoxy). He has also formulated specifically for the Asia Pacific market a high tech wet layup post curable epoxy resin laminating system. Keith has built two small sailing craft and is currently involved with putting Epiglass ® Epoxy into the air by way of building and flying a variety of large performance light weight radio controlled model aircraft using carbon fibre, glass cloth and Kevlar® construction. KEN HICKLING After training in Yacht Manufacturing and Boatyard Management at Southampton UK, Ken Hickling spent four years working for epoxy experts SP Systems working with Marine and Automotive systems. Prior to this he has worked in boatyards and marinas in Cape Cod, USA and Emsworth, UK. After starting in 1994 with International as a Product Manager he was responsible for the introduction into Europe of the highly successful New Zealand epoxy system; Epiglass. After spending three years in North America working on Superyachts and as International Marketing VP he returned to Europe to manage Southern Europe which include the prolific superyacht building nations of Italy and Turkey. In the latter, Epiglass has been used for new buildings of wooden superyachts up to 32m in length. 3 EUROPE.QT04.EPGG04 INTRODUCTION This application guide is designed to give information on how to get the best results using Epiglass® Epoxy. It is also designed with the professional user in mind. Epiglass has always been at the forefront in the supply of epoxy resin products to the marine industry. As far back as the 1950’s, Epiglass resin technology was amongst the first to be developed in New Zealand specifically for marine use. Since this time, International has developed new, easier-to-use products with an even higher performance. These products have been relied upon in the most demanding environments, including the America’s Cup and Volvo Round the World races. International has consistently set new standards of performance in Epiglass epoxy resins through a total commitment to research and manufacturing quality. For those just starting to use epoxies, Section 1 is a must. The underlying principles of epoxies, coupled with an introduction to the various uses and components of the system are covered along with a glossary of common terms. The more advanced user familiar with this type of product will find Section 2 most valuable. Discussion of use of the system for various projects and some special application notes will give insight into how Epiglass can be an important part of boatyard activity. The section includes the ways that Epiglass Epoxy combines with the rest of the range to give total project approach. For semi-production and custom boatbuilders, Section 3 is probably the most useful. Here the use of Epiglass in both composite and wooden building is covered along with a glossary of terms, and some discussion on choice of laminate reinforcement fibres and wood construction types. Osmosis continues to be a challenge for boats made with polyester resin, and Epiglass Epoxy can be the best solution; turn to Section 4. In Section 5 you will find all the facts and figures as well as safety information and frequently asked questions, including where you can use Epiglass away from the boatyard. We hope you will find this guide useful and if you need further assistance, please contact International technical service. ROGER MARSHALL 4 EUROPE.QT04.EPGG04 ABOUT THE AUTHORS.............................................................................................................2 INTRODUCTION ........................................................................................................................4 1. Epoxy Basics................................................................................................. 6 THE EPIGLASS EPOXY RESIN SYSTEM.................................................................................6 HOW TO MIX & USE THE EPIGLASS EPOXY RESIN ...........................................................12 2. Advanced Techniques & Projects ............................................................. 18 BEFORE YOU START..............................................................................................................18 SMALLER PROJECTS.............................................................................................................20 MAJOR PROJECTS .................................................................................................................27 THE ULTIMATE FINISH ...........................................................................................................40 3. Boatbuilding................................................................................................ 43 COMPOSITE CONSTRUCTION ..............................................................................................43 WOOD CONSTRUCTION ........................................................................................................48 4. Osmosis/Gelcoat Blistering ....................................................................... 51 EPIGLASS AND OSMOSIS......................................................................................................51 APPLYING ANTIFOULING PAINT ...........................................................................................55 5. Further Information..................................................................................... 57 EPOXY TERMINOLOGIES: AN EXPLANATION .....................................................................57 TECHNICAL DATA ...................................................................................................................59 HEALTH & SAFETY .................................................................................................................62 FREQUENTLY ASKED QUESTIONS ......................................................................................64 EPIGLASS FOR NON-MARINE USE.......................................................................................67