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RULES FOR CLASSIFICATION OF

DET NORSKE VERITAS AS

The content of this service document is the subject of intellectual property rights reserved by Det Norske Veritas AS (DNV). The user accepts that it is prohibited by anyone else but DNV and/or its licensees to offer and/or perform classification, certification and/or verification services, including the issuance of certificates and/or declarations of conformity, wholly or partly, on the basis of and/or pursuant to this document whether free of charge or chargeable, without DNV's prior written consent. DNV is not responsible for theconsequences arising from any use of this document by others.

The electronic pdf version of this document found through http://www.dnv.com is the officially binding version

High Speed, Light Craft andNaval Surface Craft

PART 2 CHAPTER 4

MATERIALS AND WELDING

Composite MaterialsJANUARY 2010

This chapter has been amended since the main revision (January 2010), most recently in July 2011.See “Changes” on page 3.

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FOREWORD

DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life, property and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification andconsultancy services relating to quality of ships, offshore units and installations, and onshore industries worldwide, andcarries out research in relation to these functions.

The Rules lay down technical and procedural requirements related to obtaining and retaining a Class Certificate. It is usedas a contractual document and includes both requirements and acceptance criteria.

© Det Norske Veritas AS January 2010

Any comments may be sent by e-mail to [email protected] subscription orders or information about subscription terms, please use [email protected] Typesetting (Adobe Frame Maker) by Det Norske Veritas

If any person suffers loss or damage which is proved to have been caused by any negligent act or omission of Det Norske Veritas, then Det Norske Veritas shall pay compensation tosuch person for his proved direct loss or damage. However, the compensation shall not exceed an amount equal to ten times the fee charged for the service in question, provided thatthe maximum compensation shall never exceed USD 2 million.In this provision "Det Norske Veritas" shall mean the Foundation Det Norske Veritas as well as all its subsidiaries, directors, officers, employees, agents and any other acting on behalf of Det Norske Veritas.

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Amended July 2011, see page 3 Rules for High Speed, Light Craft and Naval Surface Craft, January 2010 Pt.2 Ch.4 –


General

The present edition of the Rules includes additions and amendments approved by the Board as of December 2009, and supersedes the January 1999 edition of the same chapter.

The Rule changes come into force as described below.

This chapter is valid until superseded by a revised chapter.

Amendments July 2011

• General

— The restricted use legal clause found in Pt.1 Ch.1 Sec.4 has been added also on the front page.

Amendments January 2011

• Sec.2 Materials

— Some minor clarifications have been made in Table F2 (row “F302” and “F303”) and Table F3 (row“F401”).

Main changes coming into force 1 July 2010

• Sec.2 Materials

— Sub-section F. Adhesives: Extensive revision to define requirements for rigid and flexible adhesives andsealants and for qualification of bonding personnel.

Corrections and Clarifications

Besides the above stated rule changes, some corrections and clarifications have been made in the rule wordingin compliance with current interpretations and the updating of other chapters of the rules.

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Rules for High Speed, Light Craft and Naval Surface Craft, January 2010 Amended July 2011, see page 3Pt.2 Ch.4 Contents –


CONTENTS

Sec. 1 Type Approval and Certification Procedures ................................................................................. 5

A. General...........................................................................................................................................................................5A 100 Application............................................................................................................................................................5

B. Type Approval...............................................................................................................................................................5B 100 Approval procedure ..............................................................................................................................................5

C. Product Certification ....................................................................................................................................................5C 100 Certified materials................................................................................................................................................. 5

D. Definitions ...................................................................................................................................................................... 5D 100 Definitions ............................................................................................................................................................5

Sec. 2 Materials ............................................................................................................................................. 6

A. Glassfibre Reinforcement.............................................................................................................................................6A 100 Chemical composition .......................................................................................................................................... 6A 200 Properties ..............................................................................................................................................................6

B. Aramid Reinforcement .................................................................................................................................................6B 100 General ..................................................................................................................................................................6B 200 Impact resistance...................................................................................................................................................6B 300 Tensile and compressive strength......................................................................................................................... 6B 400 Fatigue requirements............................................................................................................................................. 7B 500 Laminate requirements.......................................................................................................................................... 7

C. Polyester and Vinylester Products...............................................................................................................................8C 100 Resin properties ....................................................................................................................................................8C 200 Fire retardant resin properties ............................................................................................................................... 8C 300 Gelcoat and topcoat properties.............................................................................................................................. 8C 400 Fire retardant gelcoat and topcoat properties........................................................................................................8

D. Sandwich Core Materials ...........................................................................................................................................10D 100 General requirements..........................................................................................................................................10D 200 Requirements to all core materials......................................................................................................................10D 300 Core material in slamming exposed areas ..........................................................................................................12D 400 Core material in fatigue areas ............................................................................................................................. 13

E. Sandwich Adhesives....................................................................................................................................................13E 100 Properties ............................................................................................................................................................13

F. Adhesives......................................................................................................................................................................14F 100 General ................................................................................................................................................................ 14F 200 Requirements to rigid adhesives.........................................................................................................................15F 300 Requirements to flexible adhesives ....................................................................................................................15F 400 Requirements to sealants ....................................................................................................................................16F 500 Qualification of Adhesive Bonding Personnel ................................................................................................... 16

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Amended July 2011, see page 3 Rules for High Speed, Light Craft and Naval Surface Craft, January 2010 Pt.2 Ch.4 Sec.1 –


SECTION 1TYPE APPROVAL AND CERTIFICATION PROCEDURES

A. General

A 100 Application101 The rules in this section apply to raw materials for FRP structures classed or intended for classificationwith the Society.

102 Other fibre reinforcements than glass fibre and aramid, other resins than polyester and vinylester, andother coatings than gelcoat and topcoat, may be accepted based upon testing and approval in each individualcase.

B. Type Approval

B 100 Approval procedure

101 The approval procedures for the materials covered in this section are specified in the respective type

approval programmes.

102 The following products are to be type or case by case approved by the Society:

— glass fibre reinforcements — aramid reinforcements — polyester resin, vinylester resin, gelcoat and topcoat — sandwich core materials — sandwich adhesives — adhesives.

C. Product Certification

C 100 Certified materials

101 FRP raw materials, e.g. fibre, resin, core, sandwich adhesive, and adhesives for major structural elementsare normally to be supplied with DNV Product Certificates.

102 The product certification will be based on a certification programme stating the extent of testing anddocumentation required. However, the parameters marked with a * (in Sec.2) are normally to be the minimumto be tested and documented.

D. Definitions

D 100 Definitions

101

mean = arithmetic mean of type test results

sdev = standard deviation of type test results

m – 2 sdev = mean – 2 sdev of type test results

msv = manufacturer’s specified value

msmv = manufacturer’s specified minimum value

num = number of parallels

Eimp = impact energy

t = thickness of tested laminate

N = number of cycles

σ static = manufacturer’s specified minimum value, tensile or compressive, whichever is lesser

R = R-ratio.

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Rules for High Speed, Light Craft and Naval Surface Craft, January 2010 Amended July 2011, see page 3Pt.2 Ch.4 Sec.2 –


SECTION 2MATERIALS

A. Glassfibre Reinforcement

A 100 Chemical composition101 The glass is to be of E-quality where the sum of Na2O and K 2O is to be less than 1%. A certificateshowing chemical composition is to be presented, or a chemical analysis is to be carried out showing that therequirements to E glass have been met (SiO2 52 − 56%, CaO 16 − 25%, Al2O3 12 − 16%, B2O3 6 − 12%, Na2O+ K 2O 0 − 1% and MgO 0 − 6%).

102 Fibres made of other glass qualities may be used subject to special agreement and provided that their mechanical properties and hydrolytic resistance are equally good or better.

103 Coupling agents of silane compound or complex chromium compound are to be used.

A 200 Properties

201 The glass fibres are to be produced as continuous fibres. They are tested in that product form that is to be used in the yard.

202 For roving that will be applied by spraying, a demonstration is to be made in a surveyor’s presence whichis to show that the roving is suitable for this form of application.

203 Requirements for glass fibre products are given in Table A1.

B. Aramid Reinforcement

B 100 General101 All aramid reinforcements are to comply with the requirements given in Table B1.

102 The laminate to be tested in interlaminar shear is to be according to 501 to 505. The test specimen is to be oriented in a direction parallel to the majority of the fibres when possible, or in the main direction of thereinforcement.

B 200 Impact resistance

201 Aramid reinforcements for hull applications are to have an oblique impact resistance corresponding to:

Eimp (joule) = 0.48 (joule/mm) t (mm) - 0.77 (joule).

202 The laminate to be tested is to be produced according to 501 to 504, and have a thickness between 3 and8 mm. For details regarding oblique impact testing, see type approval programme for aramid fibre

reinforcements.B 300 Tensile and compressive strength

301 The tensile and compressive capacity of the aramid reinforcement can be determined by testingaccording to Table B2.

Table A1 Glass fibre reinforcements

Property Test method 1) Required values for approval testing

Moisture content ISO 3344-1997 Maximum 0.2% on delivery. *

Loss on ignition ISO 1887-1995 The manufacturer’s nominal value. Tolerance limits for thevarious materials are subject to approval in each separate case.

*

Weight per unit length or area Roving:ISO 1889-1997Mats:

ISO 3374-1990 2)Woven fabrics:ISO 4605-1978 2)

The arithmetic mean ± 2 standard deviation is to be within themanufacturer’s value ± 10%.

*

Tensile strength ISO 527-4,5-1997 msmv *

Tensile elongation msmv *

1) Other standards may be used if agreed upon with the Society prior to testing.

2) ISO 3374 pending. The standard has status as DIS at the time of issue of these rules.

* Parameters normally required tested and documented for product certification by the Society.

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302 The laminate to be tested is to be according to 501 to 506, and the tensile tests are to be performed in themain fibre directions of a fabric/weave.

B 400 Fatigue requirements401 The fatigue capacity of the aramid reinforcement can be determined by testing according to Table B3.

402 The laminate to be tested is to be according to 501 to 506. The tests are to be run in load control in tensioncompression, with R = –1. The static strength, σ static, is the manufacturer’s specified minimum value, tensileor compressive whichever is lesser. If the requirement is not fulfilled, the static strength values have to bereduced until the fatigue condition is fulfilled.

B 500 Laminate requirements

501 The laminate is to be made with a marine grade polyester, vinylester, or epoxy. The manufacturer mayelect type of resin, but the testing will only be valid for the type of resin used, as well as resins with higher tensile strength and higher elongation at failure.

502 It is recommended that the laminate be cured at room temperature and atmospheric pressure. However,another curing cycle may be chosen by the manufacturer. It is recommended that a curing cycle that can becarried out at a yard be selected.

503 The laminate is to have a fibre volume fraction as specified by the reinforcement manufacturer. It isrecommended that a fibre volume fraction obtainable in a yard be selected.

504 When laminated, the fibre reinforcement is to have a moisture content at the maximum specified by themanufacturer, see 100.

505 In general, all layers of fabrics/weaves are to be oriented in the same direction in the laminate. Exceptionscan be made if symmetric laminates are needed for testing. Such cases are to be discussed with the Society.

506 Test specimens are to be wide enough to cover at least four repeats of the structure of the weave/fabric.

Table B1 Requirements for aramid reinforcements

Reference Property Test standard 1) Acceptance criteria

B100A Moisture content ISO 3344-77 Manufacturer’s specified value *

B100B Mass per unit area ISO 3374-90 2)

ISO 4605-78 2)

Mean ± 2 sdev within manufacturer’s nominal value ± 10% *

B100C Interlaminar shear strength ISO 4585-89 Mean - 2 sdev > 25 MPa *


2) ISO 3374 pending. The standard has status as DIS at the time of issue of these rules.


Table B2 Tensile and compressive testing


B300A Tensile ISO 527-4,5-1997

— strength msmv or m - 2 sdev

— modulus msv

— elongation msmv or m - 2 sdevUnidirectional: > 1.2%Stitched: > 1.1%Woven roving: > 0.9%

B300B Compressive ISO 527-4,5-1997

— with buckling prevention — strength msmv or m - 2 sdev

— modulus msv

— elongation msmv or m - 2 sdevUnidirectional: > 0.2%Stitched: > 0.2%Woven roving: > 0.2%


Table B3 Fatigue testing


B400 Fatigue ISO 527-4,5-1997 N > 105

at 0.45 σ static


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C. Polyester and Vinylester Products

C 100 Resin properties

101 The approval of polyester and vinylester are divided into the following quality grades:

— resin grade 1: quality with good water resistance — resin grade 2: quality with normal water resistance

— fire retardant resin — gelcoat and topcoat — fire retardant gelcoat and topcoat.

102 The polyester and vinylester are to be suitable for lamination by hand lay-up, spraying, resin transfer moulding, vacuum bagging method, etc. They are to have good wetting properties and are to cure satisfactoryat normal room temperature, or at other specified curing condition. Polyester and vinylester intended for other

production methods may be approved after special consideration.

103 Requirements to production of the resin and quality control are given in Table C1 or on an equivalentlevel.

104 Requirements for cured resin are given in Table C2. Comments: Unless anything else is specified by themanufacturer, the following curing procedure is to be used:

— Standard MEKP (active oxygen 9.0 - 9.2%) — Curing: 24 hours at 23°C — Post curing: 24 hours at 50°C.

Curing systems requiring high temperature may be approved after special consideration.

105 Resins containing waxes or other substances, (like DCPD resins or blends of DCPD), which might lower external adhesive capacity are to be subjected to the delamination test according to Table C3.

Preparation of test piece

1) A primary laminate consisting of five (5) layers of 450 g/m2 emulsion/powder bounded mat with excess polyester in the upper surface. Curing procedure: 48 h at 23°C. The laminate surface is not to be covered.

2) A secondary laminate consisting of five (5) layers of 450 g/m2 emulsion/powder bounded mat is built onthe first without any form of upper surface treatment.

3) Curing procedure as selected in 104. The fibre weight fraction is to be 50% ± 5%.

Preparation of reference piece

1) A laminate consisting of ten (10) layers of 450 g/m2 emulsion/powder bounded mat. Curing procedure asselected in 104.

C 200 Fire retardant resin properties

201 Polyester and vinylester can be approved as fire retardant qualities provided they are in compliance withthe following:

The hull and canopy material should be flame tested to determine its fire-retarding characteristics by placing atest specimen in a flame. After removal from the flame the burning time and burning distance should bemeasured and should be to the satisfaction of the Administration.

(IMO Res. A.689(17) Part 1, 6.2.1)

The finished resin, including all fillers, is to fulfil the requirements for liquid resin in Table C1, and cured resinin Table C2, grade 2 and the requirements to combustibility in Table C4.

A finished resin with water absorption of 100 to 150 mg per test sample may be approved after specialconsideration. (Shall be evaluated with blistering test and testing of laminate properties after aging at elevatedtemperature.)

C 300 Gelcoat and topcoat properties

301 Gelcoat and topcoat are to be produced of base polyester that fulfils the requirements in 100, grade 1 andTable C5.

C 400 Fire retardant gelcoat and topcoat properties

401 Fire retardant gelcoat and topcoat are to be produced of base resin that fulfils the requirements to fireretardant resins in 200 and are to be able to withstand long term exposure to weathering without any visible

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signs of crazing, outwash of matter or dramatic colour change.

Table C1 Manufacturer’s quality control for polyester and vinylester in liquid condition(Specify tolerances for base resin and each variant)

Control on Test method 1) Acceptance criteria

Viscosity ISO 2555 (1989) 2)

(Brookfield) or ISO 2884 (1974) (Cone/plate)msv ± 250 mPas *

Monomer content

ISO 3251(1993) msv ± 2%

Mineral content DIN 16945 (1989), item 4.10 msv ± 1% *

Gel time 3) ISO 2535 (1997) For curing time at room temperature:

— < 60 minutes: msv ± 5 minutes — 120 to 60 minutes: msv ± 10 minutes — >120 minutes: msv ± 15 minutes


2) For polyester and vinylester, the following parameters are to be used; Viscometer type A, rotational frequency 10, temperature23°C. Viscosity can be accepted with msv ± 20%.

3) Specify activator and initiator and % of each.


Table C2 Polyester and vinylester products, cured not reinforced resin(Parameters normally required tested and documented for product certification by the Society)

Property Test method 1) Requirements for approval testing / Data format

Grade 1 Grade 2

Density ISO 1675 (1985) msv (g/cm3) msv (g/cm3)

Volumetric curing shrinkage ISO 3521 (1997) msv (%) msv (%)

Ultimate tensile strength 2) ISO 527-1,2 (1993) msmv minimum 55 MPa msmv minimum 45 MPa *

Tensile modulus ISO 527-1,2 (1993) msv minimum 3000 MPa msv minimum 3000 MPa *

Fracture elongation ISO 527-1,2 (1993) msmv minimum 2.5% msmv minimum 1.5% *

Ultimate flexural strength ISO 178 (1993) msmv minimum 100 MPa msmv minimum 80 MPa

Flexural modulus ISO 178 (1993) msv minimum 2700 MPa msv minimum 2700 MPaBarcol hardness 3) EN 59 (1990)

ASTM D 2583 (1995)msv minimum 35 msv minimum 35 *

Heat deflection temperature ISO 75-2 (1993) msmv minimum 70°C msmv minimum 60°C

Water absorption 4) ISO 62 (1980) msmv maximum 80 mg msmv maximum 100 mg


2) Test samples for tensile testing ISO 527-2/1A/50; test specimen 1A and test speed 50 mm/minute.

3) Resin may deviate from these values, provided a minimum value of 30 is met and the manufacturer can demonstrateadequate cure.

4) Test sample 50 x 50 x 4 mm (± 1 x 1 x 0.2). Distilled water. Exposure time 28 days at 23°C. Resin may deviate fromthese values, provided the water ageing properties are documented.

msv = manufacturer’s specified value, verified to be within ± 10% of mean of type test results.msmv = manufacturer’s specified minimum value, verified to be below m - 2 sdev (mean - 2 standard deviation) of

type test results.

* Parameters normally required tested and documented for product certification by the Society. Barcol hardness isto be measured on each specimen and is to comply with manufacturer’s specified value.

Table C3 Interlaminar strength of LSE resins, double cantilever beam test

Property Test method 1) Requirements for approval testing

Interlaminar fracture toughness,DCB

ASTM D 5528 (1994),Mode 1 2)

Minimum 80% of mean strength in reference pieceThe fracture is not to be a typical brittle fracture with smoothsurfaces

*


2) Double cantilever beam test with high loading rate.


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D. Sandwich Core Materials

D 100 General requirements

101 Core materials are to have stable long time properties; continuous chemical processes, diffusion, etc. andare not to affect the physical properties of the material. If considered necessary, documentation may berequired.

102 On delivery the surface of the material is normally to be such that no further machining or grinding isrequired to obtain proper bonding of the material. If however surface treatment is required, this is to be stated

by the manufacturer.

103 The test methods described consider most grades of closed cell polymeric foams and end grain balsacore. For core materials of particular composition or structure, e.g. honeycombs, other/additional requirementsmay be introduced.

104 Core materials are normally to be compatible with resins based on polyester, vinylester and epoxy. Corematerials with a limited compatibility may be accepted upon special consideration. Limitations are to be stated

by the manufacturer.105 The approval will be related to a set of physical properties, which will be stated in the type approvalcertificate. The minimum properties are to be specified by the manufacturer and verified by the approvaltesting.

D 200 Requirements to all core materials

201 The requirements applicable for all core materials are stated below and in Table D1. Further detailsregarding requirements for testing/documentation are stated in the relevant type approval programme.

202 Density: The manufacturer is to specify a “Manufacturer’s Specified Minimum Value” (msmv) which isconfirmed by the test results.

203 Water absorption: The two sides of the cube that face the laminate skins are to be sealed with resin. Themanufacturer is to specify a “Manufacturer’s Specified Minimum Value” (msmv) which is confirmed by the

test results.

204 Tensile properties: The tensile tests are to be performed in the through thickness direction of the core.For very anisotropic materials, the Society may require additional tests in other directions. The core materialis to be laminated with:

— a standard ortho polyester, and/or — a resin with better adhesion properties. In such cases, the approval will be limited to the resin type used and

resins with better adhesion properties. If the selected resin is temperature sensitive, e.g. rubberised, theSociety may require testing at +50°C and –10°C.

The resin type used is to be stated in the test report, and will be printed on the type approval certificate.

The laminated core may then be glued or laminated to the test fixtures. Testing rate: Maximum speed of deformation, in mm/minute is to be 10% of the value of the measured initial thickness. The tensile properties

are to be taken as the measured value irrespective of if the failure is in the core or in the core resin interface.Elongation shall be measured with extensiometer on the core and secant modulus to be established.

The manufacturer is to specify a “Manufacturer’s Specified Minimum Value” (msmv) which is confirmed bythe test results.

Table C4 Combustibility testing of fire retardant resins

Property Test method Requirements for approval testing

Combustibility ASTM D 2863 (1995) Oxygen index minimum 23 *


Table C5 Properties of gelcoat/topcoat

Property Test method

1)

Requirements for approval testing Fracture elongation 2 ISO 527-1,2 (1993) 3) Minimum 2.0%

Covering Complete covering is to be achieved within a thickness of maximum 400 μ m of cured resin


2) Test of elongation has to be carried out only for gelcoat/topcoats containing more than 15% minerals and other filling compounds.

3) A test sample is to be made of base resin covered with 400 μ m cured gelcoat on each side and cured according to the procedurein C104.

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205 Compression testing: The compression tests are to be performed in the through thickness direction of thecore. For very anisotropic materials the Society may require additional tests in other directions.

The cell walls at the loaded surfaces are to be stabilised with a suitable resin. Testing rate: Maximum speed of deformation, in mm/minute is to be 10% of the value of the measured initial thickness. Compression shall bemeasured with extensiometer and secant modulus to be established.

The manufacturer is to specify a “Manufacturer’s Specified Minimum Value” (msmv) which is confirmed by

the test results.206 Block shear testing: The shear strength, modulus and elongation are to be determined by block shear testing according to ISO 1922-81.

The shear strength, modulus and elongation is to be determined by the following method:

— The shear strength of each specimen, τ fail (i). is defined as the maximum shear stress measured and is to bedetermined for each specimen.

— The manufacturer’s specified minimum shear strength, τ msmv, is to be specified by the manufacturer, andis to be below the calculated value: mean - 2 standard deviations of the individual values of the τ fail (i).

— The design shear strength, τ design., is defined as 0.3 τ msmv. — The “0.3 shear elongation”, γ 0,3 τ design(i), is defined as the elongation corresponding to the τ design, and is

to be taken from the measured stress-strain curve for each specimen. — The “average 0.3 shear elongation”, γ 0.3 τ design (average), is defined as the mean of the individual γ 0.3 τ design (i),

values. — The design modulus is defined as:

207 Four point bend shear testing: In order to ensure that the tensile strength of the core and of the core/skininterface is proportionate to the shear strength, the core variant with the highest density within each grade is to

be tested in four point bend according to ASTM C393-88.

Scored core material of the highest density variant and greatest thickness delivered, is to be laminated with thefollowing lay-up:

— 200 g/m2

CSM at the core skin interface — subsequent layers of 800/100 g/m2 WR/CSM combimat or 200 g/m2CSM.

The total thickness of each skin laminate is not to exceed 10% of the core thickness. The fibre weight fraction isto be 50% + 5%.

The manufacturer may elect to use:


resins with better adhesion properties. If the selected resin is temperature sensitive, e.g. rubberised, theSociety may require testing at + 50°C and – 10°C.

The resin type used is to be stated in the test report, and will be printed on the type approval certificate.

The manufacturer may elect to fill the scores with resin, or a sandwich adhesive. In this case, this will be statedon the type approval as a condition of use.

The shear strength obtained from the four point bend test, calculated according to 206, is to confirm the datafrom the block shear testing.

If the shear strength value obtained from the four point bend test is lower than the value obtained from the block shear testing, the manufacturer may elect to:

a) retest with another resin, or

b) the obtained value will be used as the basis of approval, and the value will be printed on the type approvalcertificate. The shear modulus calculated according to 206 is to be based on the new shear strength. In suchcases, the core variant with the next lower density is to be tested in the same manner.

208 Heat resistance temperature is defined as the temperature at which either:

— shear strength, or — shear modulus

has decreased by 20%.

Gdesign

τdesign

γ 0 3 τ design (average)×,

-------------------------------------------------=

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The heat resistance temperature is to be specified by the manufacturer, and is to be greater than + 45°C. Theheat resistance temperature is to be confirmed by four point bend testing the highest density core at thespecified temperature according to 207, where the shear strength and modulus are to be > 80% of the resultsobtained in 207.

209 Water resistance is defined as the loss of shear strength and stiffness after conditioning in salt water (DIN50905) at 40°C for four weeks.

The loss of water resistance is to be confirmed by four point bend testing the highest and lowest density variantaccording to 207, where the shear strength and modulus are to be > 80% of the results obtained in 207.

D 300 Core material in slamming exposed areas

301 The requirements applicable to core material to be used in slamming exposed areas are given in 302 to307. Further details regarding requirements for testing or documentation are stated in the relevant type approval

programme. It will be stated in the certificate whether the material properties with respect to slamming have been determined or not.

302 Scored core material of the lowest and highest density variant and greatest thickness delivered is to be

tested in four point bend according to ASTM C393-88, at a high loading (i.e. slamming) rate.

303 The sandwich beam is to include a longitudinal adhesive joint between two core material planks. Theapproval is valid for the adhesive used, and for adhesives with greater shear elongation at 0°C. The adhesivetype used is to be stated in the test report.

304 The core material is to be laminated with the following lay-up:

— 200 g/m2 CSM at the core skin interface — subsequent layers of 800/100 g/m2 WR/CSM combimat or 200 g/m2 CSM.

The total thickness of each skin laminate is not to exceed 10% of the core thickness. The fibre weight fractionis to be 50% + 5%. The manufacturer may elect to use:

— standard ortho polyester, and/or

— a resin with better adhesion properties. In such cases, the approval will be limited to the resin type used andresins with better adhesion properties. If the selected resin is temperature sensitive, e.g. rubberised, theSociety may require testing at + 50°C and – 10°C.

The resin type used is to be stated in the test report.

Table D1 General requirements for all core materials

Reference Property Test method 1) Acceptance criteria

D202 Density for materials withsdev/mean < 5%

ISO 845-88 msmv in kg/m3 *

Density for materials withsdev/mean > 5%

D203 Water absorption ISO 2896-87Duration: 1 week in salt water (DIN 50905) at 40°C

1.5 kg/m2

D204 Tensile - strength ASTM C-297 - 94 m - 2 sdev > 1.6 msmv shear strength in

MPaTensile - modulus mean > 1.7 msv shear modulus in MPa

D205 Compressive - strength ISO 844-78 m - 2 sdev > 1.0 msmv shear strength inMPa

Compressive - modulus mean > 2.5 msv shear modulus in MPa

D206 Block shear - strength ISO 1922-81 msmv > 0.4 MPa *

Block shear - modulus msv > 9 MPa *

Block shear - elongation msv of γ 0.3 t design (average) *

D207 Four point bend shear -strength

ASTM C393-88 ± 10% of msmv shear strength

D208 Heat resistance - strength Conditioned to heat resistancetemperature, then ASTM C393-88

all values > 80% of msmv shear strength

Heat resistance - modulus mean > 80% of msv shear modulus

D209 Water resistance - strength Conditioning: 4 weeks in saltwater (DIN 50905) at 40°C,then ASTM C393-88

all values > 80% of msmv shear strength

Water resistance - modulus mean > 80% of msv shear modulus



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305 The manufacturer may elect to fill the scores with resin, or a sandwich adhesive. In this case this is to bestated.

306 The beam is to be loaded at a rate of dτ /dt = 65 MPa s -1.

307 The shear strength obtained from the four point bend test at slamming rate, is to confirm the data fromthe block shear testing determined in 206.

D 400 Core material in fatigue areas401 The requirements applicable to core material to be used in slamming fatigue exposed areas, are given in402 to 407. Further details regarding testing or documentation are stated in the relevant type approval

programme. It will be stated in the certificate whether the material properties with respect to fatigue have beendetermined or not.

402 Scored core material of the lowest and highest density variant and greatest thickness delivered is to befatigue tested in four point bend according to ASTM C393-88.

403 The sandwich beam is to include a longitudinal adhesive joint between two core material planks. Theapproval is valid for the adhesive use, and for adhesives with greater shear elongation at 0°C. The adhesive typeused is to be stated in the test report.

404 The core material is to be laminated with the following lay-up:

— 200 g/m2 CSM at the core skin interface — subsequent layers of 800/100 g/m2 WR/CSM combimat or 200 g/m2CSM.

The total thickness of each skin laminate is not to exceed 10% of the core thickness. The fibre weight fractionis to be 50% + 5%. The manufacturer may elect to:


resins with better adhesion properties. If the selected resin is temperature sensitive, e.g. rubberised, theSociety may require testing at + 50°C and - 10°C.

The resin type used is to be stated in the test report.

405 The manufacturer may elect to fill the scores with resin, or a sandwich adhesive. In this case this is to bestated.

406 The beam is to be load cycled between 5% and 50% of the manufacturer’s specified minimum shear strength for each density variant, τ msmv, for 105 cycles. The test machine is to be run in load control. Theloading/de-loading rate is to be dτ /dt = 65 MPa s -1, but a cooling period between loadings, up to a period of 0.1 s, will be allowed.

407 After fatigue testing, the residual strength of the beams are to be determine by testing according to 207.The shear strength and modulus is to be > 80% of the results obtained in 207.

E. Sandwich Adhesives

E 100 Properties

101 The approval of sandwich adhesives are separated into two different quality grades:Grade 1: Required quality of sandwich adhesives for hull constructions.

Grade 2: Required quality of sandwich adhesives for less critical applications.

102 The approval will be related to a set of physical properties which will be specified in the type approvalcertificate. The minimum properties are to be specified by the manufacturer and verified by the approvaltesting. The properties to be specified on the certificate are given in Table E1 and E2.

103 Requirements for production of the adhesive and quality control are given in Table E1.

104 Requirements for cured material in the joint are given in Table E2.

105 Curing conditions are to be according to the manufacturer’s specifications, preferably at temperaturesobtainable in a yard. Detailed description of surface treatment and application procedure is required.

106 Heat resistance temperature is defined as the temperature at which flatwise tensile strength has decreasedto 80% of room temperature strength.

The heat resistance temperature is to be specified by the manufacturer, and is to be greater than + 45°C.

The heat resistance temperature is to be confirmed by testing according to flatwise tensile testing at the

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specified temperature, where the flatwise tensile strength is to be > 80% of the results obtained at roomtemperature.

For testing of shear and flatwise tension, the test samples are to be made of two pieces of high density corematerial (preferably PVC foam) with the sandwich adhesive located in the midplane parallel to the steelsupports. The adhesive layer is to be > 1 mm thick.

F. Adhesives

F 100 General

101 Stress patterns in adhesive joints are highly sensitive to joint geometry, and the performance of anadhesive is thus highly dependent on the type of joint. General requirements for the adhesive, valid for all jointgeometry’s can therefore not be given.

102 The requirements in subsection F define:

— tests to preselect adhesives suitable for use in a marine environment — mechanical performance data for basic joint design — requirements for qualification of adhesive bonding personnel.

Table E1 Quality control for sandwich adhesives

Property Test method Acceptance criteria

Density ISO 3521-1990ISO 1675 (1985)

msv ± 10%

Viscosity ASTM D 1084-1988, method B (for free-flowing adhesives) msv ± 20%

Table E2 Sandwich adhesives

Property Test standard 1) Acceptance Criteria

Grade 1 Grade 2

Overall volumeshrinkage

SO 3521-1990 2) msv msv

Flatwise tensile strength ASTM C 297-1994,

(Specimen: 5 x 5 cm, speed:1 mm/minute) 3)

At 23°C:At heat resistancetemperature

msmv minimum 1.0 (MPa)

All values > 80% of msmvat 23°C

msmv minimum 1.0 (MPa)

All values > 80% of msmvat 23°C

Heat resistance Conditioned to heatresistance temperature, thenflatwise tensile testingaccording to ASTM C 297-1994

minimum 45°CAll values > 80% of msmvat 23°C

minimum 45°CAll values > 80% of msmvat 23°C

Tensile strength ISO 527-1997 (Specimenthickness 4 mm)At –10°C, 23°C and at heatresistance temperature

msmv (MPa) msmv (MPa) *

Fracture elongation msmvat 23°C: minimum 3.5%at –10°C: minimum 2.0%

msmvat 23°C: minimum 2.0%at –10°C: minimum 1.0%

*

Shear strength ISO 1922-1981 (23°C) 3) msmv minimum 0.4 (MPa) msmv minimum 0.4 (MPa)Water resistance 4 weeks immersion in salt

water (DIN 50905) at 40°C.Flatwise tensile testingaccording to ASTM C 297-1994 (Specimen: 5 x 5 cm,speed: 1 mm/minute,minimum 23°C).

minimum 80% retainedstrength after immersion

minimum 80% retainedstrength after immersion

Approval may be refused for materials considered having a too low fracture elongation.


2) Curing shrinkage is relevant only for gap filling fillers.

3) The test samples are to be made of two pieces of high density core material (preferably PVC foam) with the sandwich adhesivelocated in the mid plane parallel to the steel supports. The adhesive layer is to be > 1 mm thick.


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103 Requirements have been defined for the following classes of adhesives:

— Rigid adhesives: high strength adhesives with high stiffness, one typical example are high performanceepoxy adhesives.

— Flexible adhesives: have low strength, low stiffness and high strain to failure, one typical example are polyurethane adhesives.

— Sealants: are very similar to flexible adhesives with the only exception that they are not meant to transfer

loads or moments.104 The design of each joint is to be evaluated during approval of classed objects.

105 If one of the adherents is glass subject to sunlight, a ceramic coating is to be applied to effectively block the UV radiation. If a joint is loaded in fatigue, impact, etc. further testing may be required.

106 Information regarding incompatibility of the adhesive’s curing system with other curing systems or chemicals, and possible lack of chemical resistance of the cured adhesive, to oils, detergents, etc. is to besubmitted by the adhesive manufacturer.

107 The following procedures are to be followed when testing and applying adhesives to classed objects:

— procedure for preparation of each adherent — procedure for application including:

— mixing ratio — pot life/open time — range of:

— temperature — humidity — temperature over dew point — maximum and minimum thickness of adhesive joint.

— procedure for curing.

108 The adhesive is to be tested according to the test methods stated in Table F1, F2 and F3 with eachadherent it is to join. Aluminium of different series are to be tested if applicable.

F 200 Requirements to rigid adhesives

201 Lap-shear strength – control : Test specimens according to ASTM D 1002 – 94 or ASTM D 3163 – 92,ISO 4587 – 03 and record: the lap-shear strength, the elongation at break, as well as the width, and the overlapof the test specimens and the thickness of the bond line.

202 Lap-Shear – aged : Lap-shear tests are carried out after having been weathered according to ASTM D1183 – 92 (procedure D, 4 times). The test specimens shall be loaded to destruction after weathering.

203 Measurement of pH : Measurement of pH to avoid corrosion problems later on in the joint.

204 Young’s Modulus (E): Measure the Young’s Modulus (E) according to ISO 527-1 and 2.

205 Poisson’s ratio: Measure the Poisson’s ratio ( μ ) according to ISO 527-1 and 2.

206 Shear Modulus (G): Shear modulus (G) is calculated from Young’s Modulus and Poisson’s ratioaccording to:

207 Glass transition temperature, T g : The glass transition temperature (Tg) of the adhesive shall bedetermined according to ISO 6721-2 – 08 (torsion pendulum method).

F 300 Requirements to flexible adhesives

301 Lap-shear strength – control : Test specimens according to ASTM D 1002 – 94 or ASTM D 3163 – 92and record: the lap-shear strength, the elongation at break, as well as the width, and the overlap of the testspecimens and the thickness of the bond line.

302 Lap-Shear – constant elongation: Test specimens shall be tested in accordance with EN ISO 8340 with10% and 30% extension, while weathered according to ASTM D 1183 – 92 (procedure D, 4 times).

The test specimens shall be loaded to destruction after weathering.


304 Young’s Modulus (E): Measure the Young’s Modulus (E) according to ISO 527-1 and 2.

( ) μ +=

12

E G

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305 Poisson’s ratio: Measure the Poisson’s ratio ( μ ) according to ISO 527-1 and 2.

306 Shear Modulus (G): Shear modulus (G) is calculated from Young’s Modulus and Poisson’s ratioaccording to:

307 Glass transition temperature, T g : The glass transition temperature (Tg) of the adhesive shall bedetermined according to ASTM E 1356 – 08 (Differential Scanning Calorimetry).

308 Additional requirements to flexible adhesives used for direct glazing : Adhesives that will be used for direct glazing need to meet as well the requirements defined in Pt.3 Ch.6 Sec.1.

F 400 Requirements to sealants

401 Lap-Shear – constant elongation: Test specimens shall be tested in accordance with EN ISO 8340 with10% and 30% extension, while weathered according to ASTM D 1183 – 92 (procedure D, 4 times).

The test specimens shall be loaded to destruction after weathering.

402 Glass Transition Temperature, T g : The glass transition temperature (Tg) of the adhesive shall bedetermined according to ASTM E 1356 – 08 (Differential Scanning Calorimetry).

403 UV-Resistance: Test specimens shall be aged in QUV for a minimum of 500 hours. Both aged and un-aged specimens are to be tested according to DIN 53504 to determine the elongation at break.


F 500 Qualification of Adhesive Bonding Personnel

501 Application: These requirements shall apply to the Society’s acceptance of bonding personnel for adhesive bonding of steel, non-ferrous metals and polymer materials and composites.

502 Adhesive Bonding Personnel shall be qualified according to the European Federation for Welding,Joining and Cutting (EWF) scheme or equivalent to at least European Adhesive Bonder.

503 Recognition of other standards is subject to acceptance by the Society.

Table F1 Requirements to rigid adhesives Property Test method 1) Number of

parallels Acceptance criteria, data format, and unit

F201 Lap-Shear -control

ASTM D 1002 – 94, or ASTM D 3163 – 92, or ISO 4587 – 03

10 Cohesive failureMPa (mean)

F202 Lap shear test – aged Test sample in accordancewith ASTM D 1002 – 94 or ASTM D 3163 – 92, or ISO4587:2003

Weathering according toASTM 1183 – 92, Test cycle Dnew 28 days, tested to

destruction after ageing

10 Acceptance criterion: more than95% cohesive failure of

bondline.MPa (mean)

F203 Measurement of pH Prepare test specimen as inF204Insert test specimen into testtube, fill with de-ionized water and close test tube.Store the test tube in atemperature chamber for 30days at 40ºC.Measure pH value using litmus

paper

2 Document pH. If pH value isoutside the allowed range, theadhesive joint must be protectedagainst the impact water.Acceptable levels of pH:

— aluminium: pH 6 to pH 8 — polycarbonate: pH 4 to pH

10 — steel: always to be

protected against theimpact of water

F204 Young’s Modulus, E 527-2, specimen 1A, and527-1

5 MPa

( ) μ +=

12

E G

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F205 Poisson’s ratio 527-2, specimen 1A, and527-1

5 –

F206 Shear Modulus, G Calculate - MPa

F207 Glass Transition temperature(Tg) ISO 6721-2 – 08 (torsion pendulum method) - ºC

1) Other standards may be agreed upon with the Society prior to testing

Table F2 Requirements to flexible adhesives

Property Test method 1) Number of parallels

Acceptance criteria, data format, and unit

F301 Lap-Shear - Control ASTM D 1002 – 94or ASTM D 3163 – 92

10 Cohesive failureMPa (mean)

F302 Lap shear - constant elongation Test sample in accordancewith EN ISO 8340 with 10%and 30% extension.Weathering according toASTM 1183 – 92, Test cycle Dnew 28 days, tested todestruction after ageing

10 Acceptance criterion: adhesivefailure occurs in less than 5% of the bonding area. MPa (mean)

F303 Measurement of pH Prepare test specimen as inF304Insert test specimen into testtube, fill with de-ionized water and close test tube.Store the test tube in atemperature chamber for 30days at 40ºC.Measure pH value using litmus

paper

2 Document pH. If pH value isoutside the allowed range, theadhesive joint must be protectedagainst the impact of water.Acceptable levels of pH:


10

— steel: always to be protected against theimpact of water

F304 Young’s Modulus, E S2 according to DIN 53504Test according to ISO 527-2and 527-1

5 MPa

F305 Poisson’s ratio S2 according to DIN 53504Test according to ISO 527-2and 527-1

5 –

F306 Shear Modulus, G Calculate - MPa

F307 Glass Transition temperature(Tg)

ASTM E 1356 – 08(Differential ScanningCalorimetry)

- ºC


Table F1 Requirements to rigid adhesives (Continued)



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Table F3 Requirements to Sealants



F401 Lap shear test – constantelongation

Test sample in accordancewith EN ISO 8340 with 10%and 30% extension.Weathering according to

ASTM 1183 – 92, Test cycle Dnew 28 days, tested todestruction after ageing

10 Acceptance criterion: adhesivefailure occurs in less than 5% of the bonding area.MPa (mean)

F402 Glass Transition temperature(Tg)

ASTM E 1356 - 08 - ºC

F403 UV Resistance DIN 53504, S-2or ASTM D 412min. 500hrs QUV2)

3, un-aged3, aged

Reduction in elongation at break <30%

F404 Measurement of pH Prepare test specimen as inF403Insert test specimen into testtube, fill with de-ionized water and close test tube.

Store the test tube in atemperature chamber for 30days at 40ºC.Measure pH value using litmus

paper

2 Document pH. If pH value isoutside the allowed range, theadhesive joint must be protectedagainst the impact water.Acceptable levels of pH:


10 — steel: always to be

protected against theimpact of water


2) 2 mm thick sheet, die cut dumbbell-shaped specimen (ASTM D 412 or DIN 53 504), aged in QUV

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