General information

Placement of Volvo Penta IPS hull mold plugs

Lamination instructions Volvo Penta IPS* Twin, Triple & Quadruple installation,

using Volvo Penta IPS hull mold plug

1 Lamination policy

2 Glass information

E-BXME-LTM

E = E-GlassL = Longitudinal direction (0°)T = Transverse direction (90°)LT = 0°/90° Biaxial BX = +45°/-45° Biaxial or Double BiasM = Chopped strand mat (CSM)

See separate poster; Installation Reference, Volvo Penta IPS Hull Plug and Engine Foundation or Installation Manual for placing of Volvo Penta IPShull mold plugs

Why use Volvo Penta hull requirements?

The purpose of this lamination poster is to guide the design and integration of the Volvo Penta IPS system into the hull structure. These requirements emphasize the stringer design and hull construction requirements established by Volvo Penta to minimize the risk of water intrusion in the event of groundings.Normal scantling rules (e.g., ISO 12215) focus on variables such as propeller thrust, steering forces, mass of machinery, etc. The Volvo Penta IPS hull requirements focus on ensuring an adequate structure to keep the hull intact in a hard grounding where the drives are designed to shear off under certain conditions. Extensive full scale testing and calculations conducted by Volvo Penta show that forces generated in an underwater collision or grounding are more than 10 times higher than protection afforded by following traditional scantling rules.

IMPORTANT!The Volvo Penta IPS is designed to function as an integrated part of the hull and laminate structure. The strength of the entire system is dependant on the integrated strength of the IPS and the hull and laminate structure. The strength of the hull structure is dependant upon a number of factors including shape, fiberglass quality and strength, type and quality of resin, lamination conditions, laminator skill, etc. The ultimate responsibility to ensure that all Volvo Penta IPS hull are produced consistently with these requirements rests exclusively with the boat builder.

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Core information

IMPORTANT! Core material must be off balsa, plywood or plastic foam material with hardness ≥ 60 kg/m3 (3.8 lb/ft3) (also known as 60H) or similar

IMPORTANT! This instruction replace prevoius lamination instructions found in drawing no. 3591073

IMPORTANT! The use of general hull core material does not yield any deviations from the instructions regarding Volvo Penta IPS reinforcements

* IPS350/400/450/500/550G/600

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NOTE! Mats should be extended at least 150 mm (6”) up on the aft bulkhead (transom)

IMPORTANT! If narrower mats are used a mat overlap of minimum 50 mm (2”) on the hull mold plug must be applied

Lamination of Volvo Penta IPS hull mold plugs

Placement of reinforcement rings

Lamination layers

Mat contour fit

Result in hull moldSectional view

Cross sections

NOTE! Pictures do not show correct scale

IMPORTANT! Alternative directed fiber mats (not CSM) of density less than 1500 g/m2

(44.3 oz/yd2) may be used from layer # 4 as long as minimum requirements for number of layers, total density and total mat thickness are met. All mats must be of both type +45°/-45° and 0°/90°. These mats should be altered in similar way as in recommended layup (see table above).

Top view

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7 8

Result in hull mold

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IMPORTANT! Putty must be high glass fiber content mix

NOTE! The reinforcement ring core can be made of several segments

IMPORTANT! If vacuum infusion is used a total thickness of minimum 21 mm (0.8”) must still be met

IMPORTANT! The mat lengths must be extended for every layer to ensure proper slope, see cross section figures. First layer must extend minimum 100 mm (4”) from the hull mold plug.

IMPORTANT! Core material must be off balsa, plywood or plastic foam material with density ≥60 kg/m3 (3.8 lb/ft3) or similar

Final measurement requirements

Sectional view

IMPORTANT! Adjust core dimensions to meet final ring measurementrequirements (see figure)

NOTE! Ensure good mat contour fit. Extend mats up to at least 35 mm (1.4”) from top off hull mold plug

IMPORTANT! Secondary bondings must be avoided for the lamination

NOTE! All pictures in this poster show a standard 2 degree toe-in installation

IMPORTANT! Putty must not be used in the v-groove before glass fiber layout is completed

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Lamination of reinforcement ringsLamination layers10

Result in hull mold

Placement of reinforcement beamsSectional view

IMPORTANT! Beams must be long enough to meet both reinforcement ring and inner transom bulkhead or compartment sides

IMPORTANT! The aft beam must be placed aft of the reinforcement ring and in line with the centerline of the hull plug

Result in hull mold

IMPORTANT! Drainage holes in any reinforcement beam must not have a diameter larger than 25 mm (1”). For the aft reinforcement beam the hole should be placed in the center of the beam

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14 15

IMPORTANT! Core material must be off balsa, plywood or plastic foam material with density ≥60 kg/m3 (3.8 lb/ft3) or similar

Mat contour fitIMPORTANT! Minimum 50 mm (2”) overlap must be applied between the mats. This yields even if narrower mats are used

NOTE! Mats should be extended up on the aft bulkhead (transom) when applicable

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NOTE! In order to avoid thicker areas each layer should be rotated

IMPORTANT! Alternative directed fiber mats (not CSM) of density less than 1500 g/m2 (44.3 oz/yd2) may be used as long as minimum requirements for number of layers, mat density and total mat thickness are met

11 Sectional view

IMPORTANT! Putty must be high glass fiber content mix

IMPORTANT! The mat lengths must be extended for every layer to ensure proper slope, see cross section figure. First layer must extend minimum 100 mm (4”) from the ring core

Cross section

NOTE! Ensure good mat contour fit. Extend mats up to at least 35 mm (1.4”) from top off Volvo Penta IPS hull mold plug

IMPORTANT! Secondary bondings must be avoided for the lamination

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IMPORTANT! Dimension the core so that final ring measurement requirements are met, see

Lamination of reinforcement beamsLamination layers

Attachment of engine bed

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See Installation Manual and drawings for engine bed constructionand dimensions

Final result after laminationZones of requirements

18 IMPORTANT! Attachment of the engine bed stringers must be made to the forward part of the reinforcement ring and approximately at a 90 degree angle from the ring

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20 21

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W2 ≈ W1IMPORTANT! Maintain the width of the engine bed stringers all the way up to the reinforcement ring

IMPORTANT! Alternative directed fiber mats (not CSM) of density less than 1500 g/m2 (44.3 oz/yd2) may be used as long as minimum requirements for number of layers, mat density and total mat thickness are met

IMPORTANT! Fill transition first with putty of high fiber content mix to ease the mat layup

Final geometry

IMPORTANT! Within zone A, both Volvo Penta requirements found in "Lamination of Volvo Penta IPS hull mould plugs" ( ) and general scantling rules applies. Minimum required hull bottom thickness within this zone is given by the thickest requirement of these.

6-4IMPORTANT! Zone B refers to the lamination of the reinforcement rings and the reinforcement beams. See requirements in and13-10 19-18

Construction of engine bed

IMPORTANT! If lamination mats are divided into several segments a minimum overlap of 50 mm (2”) must be applied

IMPORTANT! Mat length must be extended for each layer. There must be is a minimum extension of 50 mm (2”) for every layer to ensure a proper slope. First layer must extend minimum 100 mm (4”) from the beam core (see figure to the right)

IMPORTANT! Secondary bondings must be avoided for the lamination

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Triple and Quadruple installationsNOTE! The lamination geometry may vary in a Triple Volvo Penta IPSinstallation depending on the tunnel design

Lamination of Volvo Penta IPS hull mold plugsSee procedure as for Twin Volvo Penta IPS installation; ⇒ 6-4

Placement of reinforcement ringsSee procedure as for Twin Volvo Penta IPS installation; ⇒ 7 9-

See procedure as for Twin Volvo Penta IPS installation; ⇒ 10 13-Lamination of reinforcement rings

Placement of Volvo Penta IPS hull mold plugsSee separate poster; Installation Reference, Volvo Penta IPS Hull Plug and Engine Foundation or Installation Manual for placing of Volvo Penta IPS hull mold plugs22

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25

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Result in hull mold - Triple

Placement of reinforcement beamsSee procedure as for Twin Volvo Penta IPS installation; ⇒ 14 15-28

Result in hull mold - Quadruple

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Result in hull mold - Triple Result in hull mold - Quadruple

Triple Quadruple

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Result in hull mold - Triple Result in hull mold - Quadruple

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Triple and Quadruple installationsLamination of reinforcement beams

See procedure as for Twin Volvo Penta IPS installation; ⇒ 16 17-

Attachment of engine bedSee procedure as for Twin Volvo Penta IPS installation; ⇒ 18

NOTE! The lamination geometry may vary in a Triple Volvo Penta IPSinstallation depending on the tunnel design

Construction of engine bedSee Installation Manual for engine bed construction and dimensions

Final resultFinal geometry Zones of requirements

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32 33

34 35Triple

Result in hull mold - Triple Result in hull mold - Quadruple

Quadruple

Triple Quadruple

IMPORTANT! Within zone A, both Volvo Penta requirements found in "Lamination of Volvo Penta IPS hull mould plugs" ( ) and general scantling rules applies. Minimum required hull bottom thickness within this zone is given by the thickest requirement of these.

IMPORTANT! Zone B refers to the lamination of the reinforcement rings and the reinforcement beams. See requirements in and

6-413-10 19-18

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