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Welding Tips and Tricks � View topic - Aluminium boat hull repair

The complex hul vessels, passenger ships aluminium boat hull repairs ships of war of the s comprise tons of steel and aluminium as well as a variety of materials that range from the most common to the very exotic. Each vessel may contain hundreds or even thousands of kilometres of pipe and wire aluminium boat hull repairs with the most sophisticated power plants and electronic aluminium boat hull repairs available.

They must be constructed and maintained to survive the aluminium boat hull repairs hostile of environments, while providing comfort and safety for the crews and passengers aboard and reliably completing their missions. Ship construction and repair rank among the most hazardous industries in the world.

While materials, construction methods, tools and equipment have changed, improved radically over time and continue to evolve, and while training and emphasis on safety and health have significantly alukinium the lot of the shipyard worker, the fact remains that throughout the world each year workers die or are seriously injured while employed in the construction, maintenance or repair of ships.

The size and shape of the components of a vessel and the complexity of the work involved in assembling and outfitting them largely preclude any kind of automated processes, although some automation has been made possible by recent technological advances.

Repair work remains largely resistant to automation. Work in the industry is very labour intensive, requiring highly specialized skills, which often must be utilized under less than ideal circumstances and in a physically aluminiu situation.

The natural environment in itself poses a significant challenge for shipyard work. While there are a few shipyards that have the capability to construct or repair vessels under cover, in most cases shipbuilding and repairing is done largely out of doors. There are shipyards located in every climatic region of the world, and while the more extreme northern yards are dealing with winter i.

Much of this work is done over, in, under or around the water. Often, swift tidal currents may be whipped by the wind, causing a pitching aluminium boat hull repairs rolling working surface on which workers must perform very exacting tasks in a variety of positions, with tools and equipment that have the potential for inflicting serious physical injury.

That same often unpredictable wind is a force to be reckoned with when moving, suspending aluminium boat hull repairs placing units often weighing in excess of 1, tons with a single or multiple crane lift. The challenges presented by the natural environment are manifold and provide for a seemingly endless combination of situations for which safety and health practitioners must design preventive measures. A well-informed and trained workforce is critical.

As the ship grows from the first alluminium plates which comprise the keel, it becomes an ever-changing, ever-more-complex environment with a constantly changing subset of potential hazards rfpairs hazardous situations requiring aluminium boat hull repairs only well-founded procedures for accomplishing the work, but mechanisms for recognizing and dealing with the thousands of unplanned situations which invariably arise during the construction process.

As the vessel grows, scaffolding or staging is added continuously repirs provide access to the hull. While the very construction of this staging is highly specialized and at times inherently hazardous work, its completion means that workers are subjected to greater and greater risk as the height of the staging over the ground or water increases.

Aluminium boat hull repairs the hull begins to take form, the interior of the ship is also taking shape as modern construction methods permit large aluminium boat hull repairs to repsirs stacked on one another, and enclosed and confined spaces are formed. It is at this point in the process that the labour-intensive nature of the work is most apparent.

Safety and health measures must be well coordinated. Worker awareness for the safety of both the individual worker and those nearby aluminium boat hull repairs fundamental to accident-free work. Each space within the confines of the hull is designed for a very specialized purpose. The hull may be a void which will contain ballast, or it may house tanks, cargo holds, sleeping compartments or a highly sophisticated combat control centre.

In every case building it will require a number of specialized workers to perform a variety of tasks within close proximity of one. A typical scenario alumihium find pipefitters brazing valves into position, electricians pulling wire cable and installing aluminium boat hull repairs boards, brush painters doing touch-up, shipfitters positioning and welding deckplates, crews of insulators or carpenters and a test crew verifying that a system is rrpairs in aluminium boat hull repairs same area at the same time.

Such situations, and others even more complex, take place all day, every day, in an ever-changing pattern dictated by schedule aluminium boat hull repairs engineering changes, personnel availability aluminium boat hull repairs even the weather. The application of coatings presents a number of hazards. Enormous progress in the area of safety and health for the shipyard worker has been made over the years through the development of improved equipment and construction methods, safer facilities and a highly-trained workforce.

However, the greatest gains have been made and continue to be made as we turn our attention toward the individual worker and focus on eliminating behaviour which contributes so significantly to accidents. While this could be said of almost any industry, the labour-intensive character of shipyard work makes it especially important. It is with this ownership that true success in safety and health can be realized.

The construction hukl a ship is a highly technical and complicated voat. It involves the blending of many skilled trades and contract employees working under the control of a primary contractor.

Shipbuilding is performed for both military and commercial purposes. It is an international business, with major shipyards around the globe competing for a fairly limited amount of work.

Shipbuilding has changed radically since the s. Formerly, most construction took re;airs in a building or graving dock, with the ship constructed almost piece by piece from the ground up.

However, advances in technology and more detailed planning have made it possible to construct the vessel in subunits or modules that have utilities and systems integrated. Thus, the modules may be relatively easily connected. This process is faster, less expensive and provides better quality control.

Further, this type of construction lends itself towards automation and robotics, not only saving money, but reducing exposures to chemical and physical hazards.

Figure The initial step is design. The design considerations for various types of ships vary widely. Ships may transport materials or people, may be surface ships or subsurface, may be military or commercial and may be aluminiu or non-nuclear powered. In the design phase, not only should normal construction parameters be considered, but the safety and health hazards associated with the construction or repair process must be considered.

In addition, environmental issues must be addressed. Newport News Shipbuilding. The basic component of ship building is steel plate. The plates are cut, shaped, bent or otherwise manufactured to the desired configuration specified by the design see figure Typically the plates are cut by an automatic flame cutting process to various shapes.

These shapes may be then welded together to form I and T beams and other structural members see figure Eileen Mirsch. The plates are then sent to fabrication shops, where they are joined into various units and aluminium boat hull repairs see figure At this juncture, piping, electrical and other utility systems are assembled and integrated into the units.

The units are assembled using automatic or manual welding or a combination of the two. Several types of welding processes are employed. The most common is stick welding, in which a consumable electrode is used to join the steel. Other welding aluminium boat hull repairs use inert gas repaigs arcs and even non-consumable electrodes. The units or subassemblies are usually then transferred to an open-air platen or lay down area where erection, or joining of assemblies, occurs to form even larger units or blocks see figure Here, additional welding and fitting occurs.

Further, the alumnium and welds must undergo quality-control inspections and testing such as radiography, ultrasonic and other destructive aluminium boat hull repairs non-destructive tests. Those welds found defective must be removed by grinding, arc-air grouping or chiseling and then replaced. At this stage the units are abrasive blasted to ensure proper profiling, and painted aluminium boat hull repairs figure Paint may be applied by brush, roller or spray gun.

Spraying is most commonly utilized. The paints aluminium boat hull repairs be flammable or toxic or pose an environmental threat. Control of abrasive blasting and painting operations must be performed at this time. Judi Baldwin. The completed larger units are then hulk to the graving dock, shipway or final assembly area. Here, the larger units are joined together to form the vessel see figure Again, much welding and fitting occur.

Once the hull is structurally complete and watertight, the vessel is launched. This may involve sliding it into the water from the shipway on which it was constructed, flooding of the dock in which it was constructed or lowering the vessel aluminium boat hull Aluminium Hull Boat 60 repairs the water. Launchings are almost always accompanied by great celebration and fanfare. After the ship is launched, it enters the outfitting phase.

A large amount of time and equipment are required. The work includes the fitting of cabling and piping, the furnishing of galleys and accommodations, insulation work, installation of electronic equipment and navigation aids and installation of propulsion and ancillary machinery. This work is performed by a wide variety of skilled trades. Finally, after all testing and associated repair work is performed, the ship is delivered to the customer.

A detailed discussion of the steel fabrication process follows. It is discussed in the context of cutting, welding and painting. Here, large steel plates of various strengths, sizes, and thicknesses are stored and readied for fabrication. The steel is then blasted with abrasive and primed with a construction primer that preserves the steel during the various phases of construction.

The steel plate then is transported to a fabrication facility. Here the steel plate is cut by automatic burners to the desired size see figure The resulting strips are then welded together to form the structural components of the vessel figure The structural framework of most ships is constructed of various grades of mild and high-strength steel.

Steel provides the formability, machinability and weldability required, combined with the strength needed for ocean-going vessels. Various grades of steel predominate in the construction of most ships, although aluminium and other nonferrous materials are used for some superstructures e.

Other materials found on ships, like stainless steel, galvanized steel and copper-nickel alloy, are used for a variety of corrosion-resistance purposes and to alumijium structural integrity.

However, nonferrous materials are used in far less quantity than steel. Shipboard systems e. These materials are required to perform a wide variety of functions, including the ship propulsion systems, back-up power, kitchens, pump stations for fuel transfer and combat systems.

Steel used for construction can be subdivided into three types: mild, high-strength and high-alloy steel. Mild steels have valuable properties and are easy to alminium, purchase, form and weld.

On the other hand, high-strength steels are mildly alloyed to provide mechanical properties that are superior to the mild steels.

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Getting the right kit is probably the hardest part of the job. From there, it's just a matter of following directions and taking your time. As with most things, preparation of the damaged area is key. You'll need to thoroughly clean it and remove all of the damaged material. In most cases, this only means sanding, but if the accident caused structural damage to the fiberglass fabric or the damage goes all the way through the hull or deck, you often need to cut away the damaged strands.

This can be a bit traumatic � "What, you want me to make a bigger hole? Once the damaged material has been removed, clean away the dust and debris. In our case, the damage was superficial and didn't go all the way through the hull. If the damage does go all the way through, simply tape a piece of cardboard on the inside of the hull.

Make sure you cover the cardboard with cellophane or some type of release paper so the patch won't stick to the cardboard when you remove it. Mix the patching materials. Most repair kits come with separate containers of resin or epoxy and a hardening agent that you mix together to form a paste.

In our case, the epoxy resin and the hardening agent came in two tubes. We squeezed equal parts of each onto a small plastic plate a plastic cup works, too , estimating about how much material we'd need to fill in the damaged area, and then mixed them thoroughly until the green dye in the epoxy disappeared.

Most kits use a similar system. Once the resin and the hardening agent are mixed, you have about 15 to 20 minutes to apply the goop before it starts curing or setting up.

Larger repairs often require two or three applications. Apply the paste to the damaged area, filling the hole or gouge to the original level. Most modern epoxys and resins are designed not to shrink, so you don't want to overfill the hole.

If the area is large or in a place that undergoes a lot of stress or absorbs impacts, you should use a fiberglass screen to strengthen the patch. To do that, cut the screen to fit the hole and force the epoxy or resin into the screen with a squeegee so that all the holes are filled.

Then lay the the screen in the damaged area. If the hole is deep enough, you may want to lay several layers of screen on top of one another.

Add the finishing touches. To get a high-gloss finish like you find on your deck, use release paper on top of the patch. Most kits will supply a couple of sheets, but cellophane will also work. Tape the release paper in place and smooth the surface with your finger.

Once you are done, let the epoxy set for 30 minutes and then remove the paper. If your patch is in a painted area, you can usually apply the paint after 30 minutes, although you should check with the directions in your kit to make sure. Back Explore View All. Back Types View All.

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Liked it? Share it! Facebook Twitter. Chris Caswell. Boating Guides. Boat Buyer's Guide. Boat Seller's Guide. Spring Commissioning for Your Boat. Extensive storm damage required repairs to bow rail, rub rail, fiberglass, structural fiberglass, and swim deck.

Collision damage structural fiberglass repair with perfect gelcoat color match in white and forest green. Storm damage caused major structural damage to yacht transom. LandCraft provided structural fiberglass repairs and a perfect gelcoat color match to all areas of damage.

Semi-Truck impact damaged this boat while it was on its trailer�boat was repaired to original shape and strength. Repaired scratches and impact damage in multiple colors of metal flake finish. Metalflake Gel Coat Repair. Removed improper automotive materials used by different repair shops, then both re-repaired old damage and repaired new damage on the Legend boat with proper materials and methods.

Custom color matched multi-color fade metalflake. Removed improper materials used by a Wisconsin boat shop, then prepped and re-repaired the boat with proper materials and methods. Repaired scratches and impact damage in multiple colors of metal flake on Ranger bass boat.

First 7 pictures show damage and improper work by another repair shop that includes: overspray, substandard gelcoat application, substandard materials and material mixtures. Gelcoat Refurbishing restoring existing gelcoat on boat.

Removed dead layers of gelcoat and polished to gloss�the original gelcoat color is fully restored! Removed dead layers of gelcoat and polished to gloss�the original gelcoat colors are fully restored! This service is also considered an economy or budget exterior restoration.

The busy, chipped and aged striping was removed, dead layers of gelcoat were removed and then then the finish was polished to gloss. Simple striping was added and the boat looks years younger!

Maxum boat restored to like-new condition with a beautiful finish. Emergency repair to bottom hull gelcoat damage. Important to repair properly based on high speed hydro velocity. Gelcoat Restoration and Other Misc. Repairs to Update Boat Appearance. Removed dead layers of gelcoat, polished to gloss with original color fully restored. New decal striping was added to update the boat appearance. Hatch Installation. Repaired grounding damage including repair to original sandwich core construction, keel and strake, and perfect color match of gelcoat finish.

Restored to blueprint condition. High Performance Boat Gelcoat Repair. Repaired miscellaneous gelcoat areas in checkered-stripe gelcoat graphics. Repaired severe side-impact collision damage, requiring reconstruction of the port mid-gunnel and port mid-hull side.

Restored to perfect factory strength and shape, with perfect gelcoat color match. Installed aftermarket wake tower and marine sound system. Collision damage repair�removed destroyed fiberglass bow deck and rebuilt new fiberglass deck with a perfect gelcoat color match finish. Repaired hull side collision damage with original construction composite materials, refinished with a perfect color match.

Removed destroyed fiberglass, rebuilt with original construction composite materials and refinished with a perfect color match gelcoat. Heavily used personal watercrafts required numerous top deck repairs and complete paint refinishing with application of new decals.

Completed hull repairs and custom painted graphics to match existing racing helmet graphics for professional high performance PWC racer. Custom paintwork to client specs. Changed graphics and custom painted hull sides and top gunnel, giving the boat a cleaner and updated look.

Sail Boat Complete Exterior Refinishing. Complete hull side paint refinishing in flag blue with white boot stripe and bottom performance anti-fouling finish. Sailboat Structural Repair. We never panic when we see damage like this, and neither should you! Major structural repairs were completed to the mid-upper hull side top gunnel and refinished in two-toned gelcoat white and gray with a non-skid pattern finish.

Perfect in-house color match. Repair guaranteed lifetime. Repaired cracked hull damage with materials custom for Sea Doo Bombardier personal watercraft, refinished in a perfect color match and replaced factory parts as needed. Swim Deck Reconstruction and Repair.

Severely damaged and distorted Sea Ray swim platform, removed by the customer and repaired in our shop, was restored to proper shape and structural strength. The swim platform fit back on the boat perfectly when installed by customer. Transom Repair. Total re-core and re-fiberglass of the transom on a classic fiberglass boat.

Custom gelcoat work, perfect in-house color match. Re-cored transom and stringers, then fiberglass and finish with in-house color matched gelcoat. Yamaha waverunner hull repair and refinishing. Repaired delaminated hull damage with materials custom for Yamaha personal watercraft, refinished in factory finish, and replaced factory parts and decals as needed. More pictures coming soon! Send us a message Contact Us Name:.

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