We offer a complete Osmosis Repair solution and our company is committed to Success on Time.
- Our advanced boat osmosis treatment method takes under 15 days for a 10 meter boat removing the anxiety of waiting to know if the boat will dry and getting you back on the water quickly.
- Our process absolutely reduces the likelihood of osmosis re-occurrence and comes with a Ten Year Warranty.
- The heat and vacuum cycle will diagnose partial de-lamination and confirm severe hydrolysis breakdown reducing drying time to days, even with long term “hopeless cases.
- We will remove the osmosis and the causes of osmosis from your boat hull.
- We will restore structural strength to the hull improving your cruising safety and your marketing success if the boat is up for sale.
- Our process is also suitable for post-cure of new hull builds or hull repair work.
THE OSMOSIS REPAIR PROCESS
1. INITIAL DIAGNOSIS
Budget for the planned work normally needs to be determined as accurately as possible prior to work commencing. The vessel should be slipped and test peels done in several places. A professional surveyor with sound knowledge of boat osmosis problems and repair should be contracted to report. The boat owner will then have a realistic view as to the degree of osmosis repair required.
2. PEELING THE HULL
The hand-held gelcoat peeling tool will cut to 2.25mm deep by 75mm wide and is a fast, efficient means of removing affected gel-coat, chopped strand or woven roving.
3. DRYING AND POST-CURE
The object is to get the moisture content of the hull down to an acceptable level for re-laminating. Post-cure is also desirable to dry/remove any uncured resin and osmotic fluids. Our process uses a combination of heat and vacuum as an efficient method of drying and post-cure. All internal moisture must be removed from the hull as soon as the vessel is slipped. Floors are lifted and air-flow through the interior is maximized by opening hatches, use of fans etc.The Vacuum-Heating system guarantees a hull dried to acceptable moisture content, however, when moisture has permeated stringers and other foam-filled structural areas, penetrating infra-red heat will be required.
4. PREPARING THE WORK AREA
Working on a covered slipway presents problems such as lack of height and space, difficulty moving equipment etc. To improve work-space the whole area under the vessel can be floored with plywood sheets. A preparation [wetting-out etc] room is normally made under the bow or stern of the boat.
In order to remove all dried, potentially reactive material from the original lay-up the hull is grit-blasted. This process also gives an ideal ‘keying’ surface for any epoxy to be applied.
The boat hull is high pressure washed several times after grit-blasting to remove any acidic material. Ph level is tested and water washing continues until Ph is the same as the water being used for washing. The hull is then left to dry for 24-48 hours.
7. TENTING FOR ENVIRONMENT CONTROL
If local temperature and humidity are not within the accepted limits for epoxy application the hull must be tented so dehumidifiers and air conditioning may be used for environment control. A tent is initially built for sand-blasting to control emissions. To help control temperature and humidity a 2nd tent is built inside the 1st to provide double insulation. Humidity readings outside in some regions can range from 84% to 100%, temperature is normally around 32C. Ideal working conditions for applying epoxy and laminate are humidity below 70% and temperature 23-25C. With very humid conditions a partitioned room 30′ x 25′ needs four 20,000 Btu air conditioners and two dehumidifiers to maintain ideal working environment.
A wetting-out machine makes re-laminating easier and much faster. The triaxial cloth is 50″ wide and sheets up to 14′ in length can be applied when laminating the boat.
Laying up 10-14′ lengths over 2 chines takes skill and co-ordination. Peel ply is applied on top of the laminate and vacuum bagging can be used to get maximum bond. Advantages with use of peel-ply are: superior finish is attained and additional layers of cloth or resin can be applied upon removal of the peel-ply after initial cure without any further surface preparation. The hull repair normally requires 2 – 4 lay-ups of 750gm triaxial cloth to replace material removed by peeling. Each lay-up is overlapped along the hull and on alternative sides at the keel. The previous days work has the forward edges lightly sanded.
Upon completion of the above steps the boat bottom is filled and faired to client requirement and epoxy primer applied prior to anti-fouling.