Cost of Boat Hull Osmosis Repair

An example of a costing for an 11M power catamaran.

Vessel: 11m x 5.9m Fountaine Pajot

Work location: Coastal Boats Co Ltd factory, KM 5, Highway 332, Sattahip, Chonburi, Thailand.

Scope of work

Remove Gelcoat, tissue and chopped strand mat using a Gelplane. This quotation allows for two complete peels of each hull with the Gelplane. If any further peels are required these will be charged at the rate of 35,000 Thai baht/peel.

Dry the hulls using the HotVac method. We estimate drying time to be 3 – 4 weeks. During this time the boat interior will need to be open with all floor hatches to bilge removed or open.

Grit blast the peeled surface to remove any traces of dried osmotic material and provide a good key for the new laminate.

Wash down the hulls with high pressure fresh water.

Repair any deeper blistered areas by planing/sanding until clear and then applying a normal repair using biaxial E-glass and epoxy resin. This quotation allows for the repair of 20 blisters, any further repairs required will be charged using our applicable labor rate which is currently 525 Thai baht/hour [USD 15/hour].

Fair repaired areas with epoxy resin and micro-balloons and prepare hulls for laminating.

Laminate the required thickness of E-glass to the hulls using epoxy laminating resin and biaxial cloth 300 – 450 gms/m2. Peel ply is applied after each lamination to minimize preparation and enhance secondary bonding.

Fair the finished laminate using minimal amount of fairing compound [microfiber/epoxy resin].

Apply epoxy primer and standard anti-fouling to hull bottoms, repaint waterline area.

Materials to be used

Saint Gobain Vetrotex multi-axial yarn, Epoxy Resin from Aditya Birla Chemicals Thailand , Microfiber and micro-balloons – local supply.


650,000 Thai Baht [USD 18,112 approx. 17-09-2015] with boat delivered to and removed from our factory site by Owner. Terms of payment – 50% down payment, 30% upon completion of peeling and repairs, 20% final payment before boat is removed from Coastal Boats factory.