Rules for Classification and Construction

II Materials and Welding

2 Non-metallic Materials

1 Fibre Reinforced Plastics and Bonding

Edition 2006
 The following Rules come into force on November 15th , 2006.

Alterations to the preceding Edition are marked by beams at the text margin.

Germanischer Lloyd Aktiengesellschaft

Head Office
Vorsetzen 35, 20459 Hamburg, Germany
Phone: +49 40 36149-0
Fax: +49 40 36149-200
headoffice@gl-group.com

www.gl-group.com

"General Terms and Conditions" of the respective latest edition will be applicable
(see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys).

Reproduction by printing or photostatic means is only permissible with the consent of

Germanischer Lloyd Aktiengesellschaft.

Published by: Germanischer Lloyd Aktiengesellschaft, Hamburg

Printed by: Gebrüder Braasch GmbH, Hamburg
II - Part 2 Table of Contents Chapter 1
GL 2006 Page 3

Table of Contents

Section 1 Requirements for Materials and Production

A. Definitions .................................................................................................................................. 1- 1
B. Materials .................................................................................................................................... 1- 1
C. Approval of Materials ................................................................................................................ 1- 3
D. Requirements for Manufacturers ................................................................................................ 1- 3
E. Guidelines for Processing ........................................................................................................... 1- 4
F. Manufacturing Surveillance ....................................................................................................... 1- 6

Section 2 Inspection and Testing of Fibre Composite Materials

A. Requirements .............................................................................................................................. 2- 1

Section 3 Repair of Components

A. General ....................................................................................................................................... 3- 1
B. Procedure ................................................................................................................................... 3- 1
C. Documentation ........................................................................................................................... 3- 3
D. Enclosures .................................................................................................................................. 3- 3
II - Part 2 Section 1 B Requirements for Materials and Production Chapter 1
GL 2006 Page 1–1

Section 1

Requirements for Materials and Production

A. Definitions 1.1 Gelcoat and topcoat resin

Gelcoat and topcoat resins shall protect the surface of
1. Fibre-reinforced plastics (FRP) the laminate from mechanical damage and environ-
mental influences. Therefore, in a cured stage, the
Heterogeneous materials, consisting of a thermoset-
resin is to have a high resistance to existing media
ting resin as the matrix and an embedded reinforcing
(e.g. fuel, river and sea water), to maritime and indus-
material.
trial environments), and to abrasion, in addition to low
water absorption capabilities. Thixotropic agents and
2. Thermosetting resin colouring pigments are the only permitted additives
for gelcoat resins. In topcoat resins, additives for low
Two-component mixture consisting of resin and hard- styrene evaporation are also permitted.
ener as well as possible additives.
1.2 Laminating resin
3. Reinforcing materials
Laminating resins shall have good impregnation char-
Materials generally in the form of fibre products acteristics when being processed. In a cured stage,
which are embedded in a matrix in order to improve they shall be resistant to fuels, river and sea water, and
certain properties. In doing so, fibres of different ma- shall exhibit a high resistance to ageing. Furthermore,
terials displaying isotropic or anisotropic properties adequate resistance to hydrolysis shall be ensured
are processed in the form of semi-finished textile when used with permissible additives and filling mate-
products (mats, rovings, fabrics, non-wovens). For rials. When using unsaturated polyesters (UP) as the
special requirements, mixtures of different fibre mate- resin, the resistance to hydrolysis shall be significantly
rials are also used (hybrids). higher than that of standard UP resin (for example
through the use of a resin with an isophtalic acid ba-
sis).
4. Prepreg
Reinforcing material which is pre-impregnated with a 1.3 Additives
thermosetting resin which can be processed without
any further addition of resin or hardener. 1.3.1 All additives (catalysts, accelerators, filling
materials, colouring pigments etc.) shall be suitable
for the thermosetting resin and shall be compatible
5. Laminate with it as well as the other additives, such that a com-
A moulded part which is manufactured by placing plete curing of the resin can be ensured. The additives
layers of reinforcing material on top of each other shall be dispersed carefully throughout the resin, in
together with the thermosetting resin. accordance with the guidelines of the manufacturer.

1.3.2 Catalysts, which initiate the hardening pro-

6. Sandwich laminate cess, and accelerators, which control the working time
Two laminate layers connected together by means of (pot life, gel-time) and the cure time, shall be used in
an intermediate core of a lighter material. accordance with the processing guidelines provided by
the manufacturer. For cold-setting systems, catalysts
shall be proportioned in such a way that complete
curing is ensured between temperatures of 16 °C and
25 °C. Cold-setting systems that are to cure at
B. Materials temperatures outside of this range, as well as warm-
curing systems, may be used after consultation with
1. Thermosetting resin GL Head Office (GL-HO).

Depending on the purpose, and consequently the re- 1.3.3 Filling materials shall not significantly impair
quirement, a distinction is made between laminating the properties of the cured resin. The type and quantity
resin and coating resin. Compatibility shall be demon- of the filling materials shall be approved by GL-HO
strated for the combination of gelcoat and laminating and shall not lead to non-compliance with the mini-
resin if the basic formulation of the resins are not the mum properties of the resin (cf. Section 2, A.2.5). In
same. general, the proportion of filling materials in the lami-
Chapter 1 Section 1 B Requirements for Materials and Production II - Part 2
Page 1–2 GL 2006

nating resin compound shall not exceed 12 % by 3.2 The joining surfaces of local reinforcements
weight (including a maximum of 1,5 % by weight of made of metallic materials (e.g. inlets, connections)
the thixotropic agent). If a smaller value is specified shall be cleaned in the same manner as for a gluing
by the manufacturer, this value shall apply. The pro- process, in order to ensure optimal bonding (cf. DIN
portion of thixotropic agent in the gelcoat resin com- 53281, Part 1).
pound shall not exceed 3 % by weight. Laminates
used for fuel and water tanks shall not contain filling 3.3 Core materials other than those listed below
materials. may be used, provided that they are suitable for the
intended purpose and that this is accepted by GL-HO
1.3.4 Colouring pigments shall be climate-proof beforehand.
and consist of inorganic or non-fading organic dyes.
The maximum permissible proportion shall not exceed
3.4 Rigid foam materials
the value specified by the manufacturer; if no value is
specified, then it shall not exceed 5 % by weight. Rigid foam materials which are used as core material
for sandwich laminates, or as shear webs, shall be of a
2. Reinforcing materials closed-cell type and have high resistance against the
laminating resin or the adhesive, as well as against
ageing, fuels, river and sea water. A low water absorp-
2.1 Various types of reinforcing materials with tion capability is required, together with a minimum
filaments of glass or carbon are available: apparent density of 60 kg/m³.
Roving: A large number of parallel fila- It shall be ensured that the allowable temperature of
ments placed together with or foam material is not exceeded during the curing reac-
without twisting. tion (exothermic reaction).
Mat: Irregular layering of continuous
filaments (fleeces), or chopped 3.5 End-grained balsa wood
rovings (minimum 50 mm long)
which are joined together by End-grained balsa wood used as core material for
means of a binder. sandwich laminates shall fulfil the following require-
ments. It shall
Fabric: Rovings woven together by means
of the weaving techniques used in – have immediately been treated after felling
the textile industry, such as bind- against attack by fungi and insects,
ing cloth, satin, body, atlas etc. – be sterilized and homogenized,
Different materials and/or filament
thicknesses are possible for warp – be kiln-dried within 10 days after felling, and
and weft.
– have an average moisture content of maximum
Non-woven fabric: Unidirectional layers of fibres 12 %.
which are laid on each other in an
arbitrary manner. The layers are
fixed by thin fibre strands, either 4. Prepregs
together or on mats. Different ma- Fibre reinforcements pre-impregnated with laminating
terials and/or filament thicknesses resin shall satisfy the requirements placed on their
are possible in the individual lay- components. In addition, a minimum resin content of
ers. 35 % by volume shall be ensured, as well as adequate
tack at the processing temperature.
2.2 Fibre surface treatment with sizing, coupling
agents or finish shall be matched to the thermosetting
resin, in order to ensure adequate material properties, 5. Adhesives
also under the influence of media.
5.1 When bonding fibre-reinforced plastics to-
2.3 Only low-alkaline aluminium boron silicate gether, or with other materials, only solvent-free adhe-
glass may be used for glass fibres (alkali oxide content sives shall be used. Preference shall be given to two-
component reaction adhesives, if possible with the
≤ 1%), e.g. E-glass in accordance with VDE 0334/Part
same basis as the laminating resin.
1, 9.72, Section 4.
5.2 Laminates shall only be bonded in the cured
3. Core materials for sandwich constructions state. Hot-setting adhesives generally attain a higher
strength; however, the maximum allowable tempera-
3.1 It shall be demonstrated that the core materi- ture of the materials to be bonded shall not be ex-
als used are suitable for the intended purpose. They ceeded. This applies especially when using single-
shall not impair the curing of the laminating resin. component hot-melt adhesive.
II - Part 2 Section 1 D Requirements for Materials and Production Chapter 1
GL 2006 Page 1–3

5.3 The adhesives shall be used in accordance available, the minimum requirement shall consist of
with the processing guidelines issued by the manufac- training completed for a technical profession, in con-
turer. They shall not affect the materials to be bonded junction with internal training and several months of
and shall exhibit a high resistance to humidity and experience.
ageing. The influence of the operating temperature on
the adhesive strength shall be small. 1.3 The shop approval is granted by GL Head
Office (GL-HO) on the basis of the information to be
5.4 Adhesives shall be usable within a minimum submitted with Form F 506 and the report submitted
temperature range of – 20 ° to + 60 °C. by the GL surveyor F 525. The form deals with the
following points:
– general information on the shop

C. Approval of Materials – personnel

– internal quality management
1. All materials to be used during production of
– incoming inspection
components from FRP shall first be assessed and ap-
proved by GL. Approval by other organizations can be – storage of the materials in the shop and during
recognized following agreement by GL, provided that field work
the tests required for approval are in accordance with
GL requirements. – mechanical processing capabilities
– production equipment
2. The manufacturer and/or supplier of the ma-
terial shall apply to GL-HO for approval. 1.4 All manufacturing facilities, store-rooms and
their operational equipment shall fulfil the require-
ments of the responsible safety authorities and profes-
3. Approval is granted if the material fulfils the sional employers liability insurance associations. The
requirements of GL. For this purpose, specific tests manufacturer is exclusively responsible for compli-
are necessary, and they shall either be carried out ance with these requirements.
under supervision of GL or the results shall be docu-
mented in the report of a recognized testing institute. 1.5 The danger of contamination of laminating
The respective test criteria are given in Section 2, materials shall be minimized through separation of
A.2.4.3. production facilities from store-rooms.

4. Before production starts, the required mate- 1.6 During laminating and bonding in the lami-
rial approvals shall be submitted to GL-HO and/or the nating shop, no dust-generating machinery shall be
responsible GL inspection office. If no approvals, or operated nor any painting or spraying operations car-
not all required approvals have been obtained, then as ried out. As a matter of principle, such work shall take
an exception and following agreement with GL-HO, place in separate rooms.
proof of the properties of the basic material can be
demonstrated as part of material testing of the compo- 2. Laminating workshops
nent laminate.
2.1 Laminating workshops shall be closed spaces
5. The packaging or wrapping material shall capable of being heated and having supply and ex-
bear a reference to the approval. haust ventilation. During laminating and curing, a
room temperature of between 16 °C and 25 °C and a
maximum relative humidity of 70 % shall be main-
tained, provided that the manufacturer of the laminat-
D. Requirements for Manufacturers ing resin compound does not specify otherwise.

2.2 In order to control the climatic conditions,

1. General thermographs and hydrographs shall be provided. The
equipment shall be set up following agreement with
1.1 Manufacture of FRP-components shall only GL, their number and arrangement depending on op-
be performed by workshops which are approved by erational conditions. The equipment shall be calibrated
GL for the manufacture of components made from in accordance with statutory regulations. The re-
fibre-reinforced thermosetting resins. cordings shall be kept for at least 10 years and submit-
ted to GL on request.
1.2 The manufacture of FRP-components shall
only be carried out by persons with sufficient profes- 2.3 Ventilation facilities shall be arranged in such
sional knowledge. This professional knowledge shall a manner that no inadmissible amounts of solvents are
in general be verified by certificates of the corre- removed from the laminate, and also that no inadmis-
sponding training courses. If such certificates are not sible workplace concentrations (MAK values) occur.
Chapter 1 Section 1 E Requirements for Materials and Production II - Part 2
Page 1–4 GL 2006

2.4 The workplaces shall be illuminated ade- 1.2 For the preparation and processing of the
quately and suitably, but at the same time precaution- resin compounds and reinforcing material, these
ary measures shall be taken to ensure that the con- Rules, the instructions issued by the material manufac-
trolled curing of the laminating resin compound is turers and the regulations of the local authorities shall
neither impaired through sunlight nor lighting equip- also be observed.
ment.
1.3 Resin, hardener and resin additives shall be
3. Storage-rooms mixed in such a way as to ensure a uniform distribu-
tion and to minimize the amount of air introduced into
the mixture as far as possible. A degassing of the resin
3.1 Laminating resins shall be stored in accor- compound may be necessary in individual cases.
dance with the manufacturer's instructions. If no such
instructions are provided, then they shall be stored in
dark, dry rooms at a temperature between 10 °C and 1.4 During lamination, the processing time of the
18 °C. The temperature of the storage-rooms shall be prepared resin compound specified by the manufac-
recorded continuously by means of thermographs. turer shall not be exceeded. If such a time is not speci-
fied, the pot-life shall be determined by means of a
preliminary test and the processing time then estab-
3.2 Prepregs shall be stored in special cold- lished in consultation with GL.
storage rooms in accordance with the manufacturer's
instructions.
1.5 It is not possible to cover all types of moulds
and processing methods in detail. Deviations are
3.3 Hardeners, catalysts and accelerators shall be therefore possible for special cases with the consent of
stored separately in well-ventilated rooms in accor- GL.
dance with the manufacturer's instructions. If no in-
structions are provided, they shall be stored in dark,
dry rooms at temperatures between 10 °C and 18 °C. 2. Requirements for moulds

3.4 Reinforcing materials, fillers and additives 2.1 The moulds shall be made of a suitable mate-
shall be stored in closed containers, in dry and dust- rial that, on the one hand, has adequate stiffness to
free conditions. prevent inadmissible deformations while laminating or
curing, and on the other hand has no influence on the
curing of the laminate. Moulds made of FRP may be
3.5 Storage shall be arranged in such a way that
used only after complete curing and subsequent tem-
the identification of the materials, their storage condi-
pering.
tions and maximum period of storage (expiry date) as
prescribed by the manufacturer are clearly visible.
Materials whose duration of storage exceeds the ex- 2.2 In the case of moulds for products which are
piry date shall be removed immediately from the made using vacuum bags, absolute air tightness of the
stores. mould shall additionally be ensured.

2.3 The surface of the moulds shall be as smooth

3.6 Quantities of materials due to be processed
as possible and shall have no sharp edges. The mould
shall be brought to the production shops as early as
shall be designed in such a way as to permit flawless
possible to ensure complete adjustment to the process-
removal of the product from the mould.
ing temperature (ΔT ≤ 2° C), with the containers re-
maining closed.
2.4 Before commencing with the laminating, the
surface of the components shall be treated with a suf-
3.7 Materials taken from the stores and partially ficient quantity of a suitable release agent and brought
used shall only be replaced in the stores in special up to the temperature required for lamination. The
cases (e.g. hot-curing prepregs) and with the consent surfaces shall be dry and free of dust. It is not permis-
of GL. sible to use release agents with a silicon base.

3. Building up the laminate

E. Guidelines for Processing
3.1 If the surface protection is to be achieved by
providing a gelcoat, then the gelcoat resin compound
1. General shall be applied with a uniform thickness of between
0,4 and 0,6 mm, using a suitable process.
1.1 As a matter of principle, only materials ap-
proved by GL shall be used. In addition to the choice 3.2 The first laminate layer shall be applied as
of suitable and approved materials, special care shall soon as possible after application of the gelcoat. A
be taken when working with them because of the great fibre mat or fabric with low weight per unit area and a
influence on the properties of the product. high resin content shall be used (e.g. for glass fibres: a
II - Part 2 Section 1 E Requirements for Materials and Production Chapter 1
GL 2006 Page 1–5

maximum of 450 g/m² and a maximum of 30 % glass 3.10 Parallel or insert linings shall be free of all
by weight). moisture and pollution (dirt). Their bonding surfaces
with the laminate shall be prepared in a suitable man-
3.3 The laminate shall be built up in accordance ner (roughening, coupling agent or similar).
with the approved technical documentation, whereby
GL shall be consulted about the method. Air shall be 4. Glass-fibre resin spraying
adequately removed from the reinforcing layers and
these layers shall be compacted in such a manner to Glass-fibre resin spraying, a partly mechanical method
ensure that the required proportion of resin is of lamination by hand, requires fulfilment of the fol-
achieved. Resin enrichment shall be avoided. lowing specific requirements:

3.4 The maximum thickness of the material that 4.1 The equipment to be used shall be demon-
can be cured at one time is determined by the maxi- strated before use and its suitability proven.
mum permissible heat development. In the case of
vacuum bagging, as a rule, the decisive factor is the 4.2 The qualification of the fibre-resin sprayer,
maximum number of layers from which air can still be and where appropriate his assistant, shall be demon-
totally removed. strated to GL by means of procedure test.

3.5 If a laminating process is interrupted for a 4.3 The equipment shall be calibrated in accor-
period causing the base laminate resin to exceed the dance with the guidelines of the manufacturer. Cali-
point of gelation, a test is to be performed to verify bration shall be checked regularly before fibre-resin
adhesion between the base laminate and the top lami- spraying, but the very least at the beginning of every
nate. For each resin system, under the given process- production day.
ing conditions, the permissible period of interruption
of the laminating process is to be determined. In the 4.4 The length of a roving cut shall be between
event of this period being exceeded, the laminate shall 25 mm and 50 mm.
be thoroughly ground in order to provide a surface
exhibiting adequate adhesion properties after removal 4.5 A powder-bound textile glass mat of maxi-
of the dust. For UP resins on an orthophthalic acid and mum 450 g/m² shall be used for the first laminate
standard glycol basis not containing any skin-forming layer. The glass part of this layer (to be applied manu-
agents a 48 h interruption on the laminating process ally) shall be less than 30 % by weight.
may, without any further proof being furnished, be
considered uncritical with respect to lamination. 4.6 The glass weight per unit area of the spray
laminate layer of a combined laminate shall not ex-
3.6 When grinding laminates containing resins ceed 1150 g/m².
with low styrene evaporation as the matrix system, the
surface shall be removed down to the mat layer. In 4.7 After a maximum of 1150 g/m² of fibres have
order to ensure that no skin-forming agent elements been sprayed, air shall be removed and the composite
(e.g. paraffins) will be left on the surface, the surface shall be compacted.
shall finally be polished using new abrasive paper.
The same procedure shall also be applied when 4.8 Tests shall be performed on a regular basis to
treating the surfaces of materials to be bonded (see check whether a uniform laying up of the reinforced
6.2.3). layers as well as a uniform distribution of percentage
glass weight has been achieved. GL reserves the right
3.7 Transitions between different thicknesses of to demand test pieces to check the resulting mechani-
laminate shall be made gradually. A minimum value cal properties.
(for glass fabric in the fibre direction) of 25 mm per
600 g/m² reinforcing material can be used. In the tran- 5. Curing and tempering
sition region from a sandwich construction to a solid
laminate, the core material shall be tapered with a 5.1 Completed components may only be taken
gradient of not more than 1 : 3. from the moulds after adequate curing of the thermo-
setting resin compounds. The required cure time gen-
3.8 If cutting of reinforcing layers is unavoidable erally depends on the manufacturer's instructions.
in the case of complicated mouldings, then the cut Otherwise, a minimum cure time of 12 hours at 20 °C
edges shall overlap, or reinforcement strips shall be shall be observed for cold-setting systems.
provided. In the butt or seam region of laminates,
every reinforcing layer shall overlap by at least 25 mm 5.2 Resin systems which cure under pressure, UV
per 600 g/m². radiation and/or increased temperature shall be treated
in accordance with the manufacturer’s instructions.
3.9 Different components may be laminated
together only while they are not fully cured. Special 5.3 Immediately after curing, the components
attention shall be paid to crossings of laminates. should receive post-treatment at increased temperature
Chapter 1 Section 1 F Requirements for Materials and Production II - Part 2
Page 1–6 GL 2006

(tempering). The tempering time depends on the resin 6.2.2 The surfaces of the materials to be bonded
in question and the temperature attained within the together shall be dry and free of release agents (wax,
component during tempering, whereby this shall be grease, oil etc.), impurities (dust, rust etc.) and sol-
below the temperature for dimensional stability under vents. Especially when using solvents for cleaning
heat and shall be agreed on with GL. Cold-setting purposes, compatibility with the material and suffi-
systems which are not subsequently tempered shall be cient ventilation time shall be ensured.
stored for 30 days at a temperature of 16 °C, and for
correspondingly shorter periods at temperatures up to 6.2.3 Smooth surfaces shall be roughened either
25 °C. This period can be shortened with the consent mechanically (rough-grinding, sand-blasting etc.) or
of GL, provided the relevant manufacturer's specifica- chemically by etching. It is absolutely necessary that
tions regarding post-curing are available, or post- layers on the surface of the materials to be bonded that
curing values exist which are supported by experimen- exert a negative effect on the bonding process (e.g.
tal results. If such values are not available, then in skin-forming additives in polyester resins or residues
general the following tempering conditions can be of peel ply in the case of FRP, or oxide layers in the
used (polyester/epoxy resin): case of aluminium) be removed.
at least 16 h at 40 °C / 50 °C or
6.2.4 In many cases, an increase in the strength of
at least 9 h at 50 °C / 60 °C the bonded connection can be achieved by the use of
specially matched primers. The use of primers is par-
ticularly recommended for bonded joints which later
6. Adhesive bonding in service are relatively heavily stressed by environ-
mental influences.
6.1 Adhesive joints
6.2.5 The adhesive shall be processed in accor-
6.1.1 Adhesive joints for load-bearing parts shall dance with the manufacturer's instructions; the propor-
generally be verified by tests to be agreed on for each tion of fillers may not exceed the permitted limit.
individual case, unless comparable experience is When mixing the adhesive, its constituents shall be
available. mixed in such a way that they are evenly distributed,
care being taken to beat in as little air as possible.
Note
6.2.6 The adhesive shall be applied evenly and as
Particularly in the case of highly thixotropic adhe- bubble-free as possible to the materials to be joined. If
sives, prior proof of their suitability shall be given highly thixotropic adhesives are used, it is advisable to
with due consideration of the production process. apply a thin undercoat of the corresponding pure resin
to the surfaces to be joined.
6.1.2 A specification for production and testing
shall be compiled for the adhesive joints of load- 6.2.7 Following application of the adhesive, the
bearing structures. In particular, the nominal values materials to be joined shall be brought together with-
and tolerances of adhesive-layer thicknesses as well as out delay and fixed in place.
the maximum size and extent of permissible flaws
shall be defined. The adhesive layer thicknesses, toler- 6.2.8 A loading of the adhesive joint before the
ances and the maximum size and extent of permissible adhesive has cured sufficiently is inadmissible. For all
flaws shall be considered during the computational adhesive joints with thermosetting adhesives, subse-
verification of the adhesive joint. quent tempering of the joint is recommended; in the
case of cold-curing adhesives, tempering is necessary
6.1.3 Only adhesives with confirmed properties as a rule.
may be used for bonding. The adhesives may not have
any negative effects on the materials to be joined. 6.2.9 After curing, the adhesive joint shall be pro-
tected by suitable means against penetration by extra-
6.1.4 The possibility of contact corrosion (bond- neous media (e.g. moisture).
line corrosion) shall be countered by suitable means.

6.1.5 If FRP components are to be bonded and a

resin system differing from the laminating system is
F. Manufacturing Surveillance
used, the components shall be totally cured before
bonding.
1. General
6.2 Assembly process
1.1 For components made of FRP, manufacturing
6.2.1 The various surface pretreatments for syn- surveillance consists of the quality control of the basic
thetic materials and metals are for example compiled materials, production surveillance and the quality
in VDI 2229 and VDI 3821. inspection of the finished components.
II - Part 2 Section 1 F Requirements for Materials and Production Chapter 1
GL 2006 Page 1–7

1.2 In the case of manufacturing surveillance, a case of adhesive joints, the responsible supervisors
distinction is made between internal and third-party shall have an appropriate qualification in adhesives,
(external) surveillance. In the sense of these Rules, and the individuals performing the work shall have
third-party surveillance means periodic and random undergone suitable training.
checks by GL of the internal surveillance as well as of
the component quality. Note

1.3 GL reserves the right to carry out inspections Training as adhesive bonding worker / adhesive bond-
in the production facilities without giving prior notice. ing specialist according to DVS / EWF 3305 is desir-
The manufacturer shall grant inspectors access to all able.
areas used for production, storage and testing and shall
present all documentation concerning records and tests 3.4 The batch numbers of the materials used in
carried out. the component shall be given in the production docu-
mentation, in order that they can be traced back to the
1.4 The scope of third-party surveillance can be manufacturer if need be. Reinforcing layers introduced
reduced in the case of production facilities that have a into the laminate shall be checked off immediately
certified quality management system. during the production process, with indication of the
fibre direction.
2. Incoming inspection
3.5 From every batch of reaction resin com-
2.1 The characteristic values and properties of pound, a sample shall be taken and tested. If mixing is
the materials shall be verified by the manufacturer by performed continuously, one sample per batch and
means of inspection documents. The following inspec- production step is sufficient. These samples shall be
tion documents according to EN 10204 (ISO 10474) randomly checked for their degree of curing. The
are required as a minimum: results shall be recorded.
EN 10204-2.2 Fibre products, gelcoat resins, paints 3.6 On request by GL, reference laminates of
EN 10204-2.3 Laminating resins, prepregs, core ma- about 50 × 50 cm shall be produced in parallel. This
terials, adhesives shall result in confirmation of the material values used
as a basis for the strength calculations.
2.2 During the incoming inspection, the goods
shall at least be checked for any damage and for com- 4. Structural tests
pliance of the details in the certificates with the re-
quirements. Material values shall be checked by ran-
dom sampling. 4.1 During production and on completion of
production, the component shall be subjected to visual
2.3 The goods shall be stored in accordance with inspections. In particular, attention shall be paid to
the requirements of the manufacturer and these Rules. voids, delamination, warping, discoloration, damage
etc. In addition, the general quality, e. g. surface fin-
ish, shall be assessed.
3. Production surveillance

3.1 Details of the production process shall be laid 4.2 By means of suitable testing procedures, the
down by specifications which also contain specimen quality of the components shall be determined, if
documents for production and testing of the compo- possible during production, and at the latest on com-
nents. The tasks and responsibility of the production pletion of production. Special attention shall be paid to
and quality control departments shall be defined the bonding and to the degree of curing of the compo-
clearly. nent.

3.2 As the work progresses, the individual pro- 4.3 Following agreement with GL, individual or
duction steps shall be signed by the employees re- random tests shall be carried out on finished compo-
sponsible for each stage on the basis of the prescribed nents under static and/or dynamic loads.
documentation.
4.4 GL shall be informed about repairs of any
3.3 The individuals entrusted with production faults relevant to the strength of the component, and
shall be trained in accordance with their task, and shall the procedure used to carry out the repair shall be in
work under professionally qualified supervision. In the accordance with Section 3.
II - Part 2 Section 2 A Inspection and Testing of Fibre Composite Materials Chapter 1
GL 2006 Page 2–1

Section 2

Inspection and Testing of Fibre Composite Materials

A. Requirements – If the test results are inadequate for three or

more specimens, the test can be repeated on
newly produced specimens, provided that GL
1. General
agrees to this.
1.1 In accordance with the Rules and Guidelines – If even one sample yields inadequate results
of Germanischer Lloyd (GL), the materials used for while repeat-testing, then approval is not possi-
manufacturing components made of FRP under the ble.
supervision of GL shall be approved by GL. Approv-
als are granted for the following materials: 1.6 If the material fulfils the GL requirements,
– gelcoat and/or laminating resins then a statement of material approval is issued by GL-
HO. This is generally valid for four years, whereby
– reinforcing materials extensions are possible.
– prepregs
1.7 GL-HO shall be notified immediately of all
– core materials modifications or other changes to the material. Deci-
sions regarding the further validity of the material
– adhesives approval is made on an individual basis.

1.2 Applications for approval by Germanischer 1.8 A constant material quality shall be provided
Lloyd Head Office GL-HO shall be made by the mate- by the manufacturer through suitable QM measures. If
rial manufacturer or an agent. Together with the appli- this is not ensured, GL reserves the right to suspend,
cation, the following shall be submitted to GL-HO: or withdraw, the approval.
– a declaration in writing by the applicant that the
tested materials comply with those for which the 1.9 GL reserves the right to demand and/or carry
approval is requested, and that the sample is out spot tests of the material properties during the
manufactured in accordance with the Rules and period required for material approval. If, in doing so,
Guidelines of Germanischer Lloyd there is no adequate comparison with the required
values, the material approval can be suspended or
– product description withdrawn by GL.
– safety data sheet
1.10 The approval refers only to the approved
– storage and processing instructions material. The applicability of this material in connec-
tion with other approved materials shall be demon-
– copy of the test certificate of a recognized test- strated independently by the manufacturer, or the user,
ing body, i.e. an accredited testing laboratory or in a suitable manner. In cases of doubt, GL reserves
a notified testing body. the right to require a check of the properties of the
material combination.
1.3 The tests shall be carried out in accordance
with the standards mentioned in this rule. However,
comparable standards of other countries are also ac- 2. Thermosetting resins
ceptable after agreement with GL-HO in each individ-
ual case. 2.1 General

1.4 The minimum properties required by GL for 2.1.1 The basic requirements listed under 1. apply
the tests shall be fulfilled by all specimens. for material approval.

1.5 In the case of inadequate test results of indi- 2.1.2 A general description of the thermosetting
vidual specimens, attention shall be paid to the follow- resin, its processing conditions as well as the proper-
ing (for a basic number of 6 tests): ties of resin in the processing state shall be submitted.
The basic properties of the cured thermosetting resin
– If one or two specimens yield inadequate results, shall be verified by the test certificate of a recognized
the tests shall be repeated with twice as many testing body. These values shall fulfil specified mini-
specimens. mum requirements.
Chapter 1 Section 2 A Inspection and Testing of Fibre Composite Materials II - Part 2
Page 2–2 GL 2006

2.1.3 Cold-setting unsaturated polyester (UP) res- 2.4.2 For gelcoat and topcoat resins, the following
ins and cold-setting epoxy (EP) resins are specifically additional information shall be submitted:
described below. Other types of resins can also be
approved after consultation with GL-HO, whereby the – abrasion resistance
required minimum properties are specified by GL-HO (DIN 53754 - ISO 9352) 3 samples
on an individual basis. However, they shall at least – resistance against seawater, fuels, hydraulic oil,
comply with those of UP resins. weak acids and alkalis (DIN EN ISO 175)
2.2 Description 2.4.3 With regard to the properties, the following
shall be verified by the test certificate of a recognized
2.2.1 A description of the thermosetting resin shall
testing body. For this purpose, specimens shall be
be submitted in order to allow an unequivocal identifi-
used which are produced in accordance with the sub-
cation:
mitted processing guidelines. The specimens shall be
– resin type and state cured and tempered for 16 h at 40 °C (polyester res-
ins) or 16 h at 50 °C (epoxy resins). For gelcoat and
– purpose topcoat resins, only the first four properties shall be
– manufacturer verified:
– trade name – density (DIN EN ISO 1183, method A),
3 specimens
2.2.2 In addition, the following shall be indicated:
– water absorption (following DIN EN ISO 175,
– storage conditions Specimen 50 mm × 50 mm × 4), 3 specimens
– environmental conditions for processing – dimensional stability under heat
– type and proportion of allowed additives (DIN EN ISO 75-2, method A), 3 specimens

– curing conditions, tempering – tensile strength, fracture strain, modulus of elas-

ticity in tension (DIN EN ISO 527-2, test piece
2.3 Properties in the processing state and dur- 1 B), 6 specimens
ing curing
– bending strength
The properties shall be determined in accordance with (DIN EN ISO 178), 6 specimens
the following standards:
– modulus of elasticity in bending
– density (DIN EN ISO 1675) (DIN EN ISO 178), 3 specimens
– viscosity (DIN 53015 - DIN EN ISO 2555) 2.4.4 The mechanical properties are normally de-
– reactivity: termined at standard climate 23/50 (23 °C / 50 %
relative humidity). If the intended operating tempera-
UP resins: acid number
ture range of the resin is not between – 20 °C and
(DIN EN ISO 2114)
+ 50 °C, further testing temperatures shall be agreed
EP resins: epoxy equivalent on with GL-HO.
(DIN EN ISO 3001)
2.4.5 The testing speed in the case of tensile and
– WP resins: Monomer proportion
bending tests shall be selected in such a way that a
(DIN EN ISO 3251)
specimen or edge-fibre strain of about 1 % / min is
– gel time (temperature increase) ensured. This shall be documented in the test report.
(DIN 16945, Section 6.2, 6.3 - DIN EN ISO The modulus of elasticity shall be determined as a
2535) secant modulus between 0,05 % and 0,25 % strain.
The water absorption shall be specifically determined
– curing shrinkage (DIN 16945, Section 6.5)
at 23 °C after 24 ± 1 h and 168 ± 2 h.
2.4 Properties in the cured state
2.5 Minimum properties
2.4.1 The following properties shall be submitted
for all thermosetting resins in the cured state: 2.5.1 For resin products consisting of UP resins,
the following minimum properties are specified for
– density use as laminating resins (values for gelcoat resins in
– water absorption brackets):
– strength, modulus of elasticity in tension, and tensile strength: 40 MPa (––)
tensile fracture strain
fracture strain: 2,0 % (3,0 %)
– strength and modulus of elasticity in bending
modulus of elasticity: 2700 MPa (––)
– dimensional stability under heat (tension)
II - Part 2 Section 2 A Inspection and Testing of Fibre Composite Materials Chapter 1
GL 2006 Page 2–3

bending strength: 80 MPa (––) 3.1.4 Due to the great number of the fibre reinforc-
ing products on the market, only the most common
dimensional stability ones can be listed. Products not covered (e.g. com-
under heat: 60 °C (60 °C) plexes, hybrids), can also be approved, following
agreement with GL-HO.
The water absorption after 168 h shall not exceed
70 mg for laminating resins and 60 mg for gelcoat
resins. 3.2 Description

3.2.1 A description is necessary which allows an

2.5.2 The following minimum properties apply to unequivocal identification of the reinforcing material:
resin products consisting of EP resins:
– fibre material
tensile strength: 55 MPa (––)
– reinforcement type (mat, fabric etc.)
fracture strain: 2,5 % (3,5 %)
– manufacturer
modulus of elasticity: 2700 Mpa (––)
(tension) – trade name

bending strength: 100 Mpa (––) 3.2.2 In addition, the following is required:
– form of supply
dimensional stability
under heat: 70 °C (70 °C) – storage conditions
The water absorption after 168 h for laminating and – processing instructions
gelcoat resins shall not exceed 50 mg.
3.2.3 The filament and its treatment/sizing shall be
2.5.3 The abrasion resistance properties and the submitted:
resistance properties to extraneous media in the case – filament diameter (DIN 53811 - ISO R 137)
of gelcoat resins may be determined by the applicant.
– coupling agreed or sizing
– The abrasion resistance determined in the test
(sliding abrasion rate) shall be adequate. – resin compatibility

– The properties stipulated in DIN ISO 175 shall In the case of glass fibre products, the average fila-
be determined after 24 h and 168 h at 23 °C. ment diameter shall be at maximum 19 µm.
Taking these properties into account and follow-
ing agreement between GL-HO and the appli- 3.2.4 In the case of reinforcing products consisting
cant, the following classification is made: of a combination of different fibre materials and/or
filaments, all fibre types shall be indicated.
– Resistant
3.2.5 If, in the case of textile glass reinforcing
– Conditionally resistant products, no E-glass or R-glass is used in accordance
with DIN 1259-1, then an alkali oxide content (DIN
– Not resistant
ISO 719) of less than 1 % shall be verified by means
of a test certificate from a recognized testing body.
3. Reinforcing materials
3.3 Properties of the reinforcing products
3.1 General
3.3.1 Rovings
3.1.1 The basic requirements listed under 1. apply – number of the filaments in the roving
for material approval.
– roving fineness (ISO 4602)
3.1.2 A general description of the reinforcing mate- When rovings are used as gun rovings (DIN 52316 -
rial and of the filament shall be provided. Basic prop- ISO 3375), the stiffness shall be additionally verified
erties of laminate specimens taken from the reinforc- by the certificate of a recognized testing body.
ing material shall be verified by the test certificate of a
recognized testing body. These values shall fulfil 3.3.2 Mats (continuous and chopped-strand mats)
specified minimum requirements.
– fibre length (for chopped-strand mats)
3.1.3 The following applies to fibre reinforcements – linear density of the fibre (ISO 1889)
made of glass and carbon. Products with other rein-
forcing fibres, e.g. aramide, can also be approved, – weight per unit area (ISO 3374)
following agreement with GL-HO, whereby the mini- – layer thickness (ISO 3616)
mum properties are then specified on an individual
basis. – binder (see 3.3.5)
Chapter 1 Section 2 A Inspection and Testing of Fibre Composite Materials II - Part 2
Page 2–4 GL 2006

3.3.3 Fabric alignment. Depending on number of the reinforcing

directions, the laminates shall have approximately the
– linear density of the fibres, warpwise and weft- following thicknesses: unidirectional laminates 2 mm,
wise (ISO 1889) bi-directional laminates 4 mm and multi-directional
– count, warpwise and weftwise (EN 1049-2) laminates 5 mm.
– weight per unit area (ISO 4605) 3.4.4 Appropriate test panels shall be prepared by
– fabric thickness (ISO 4603) fibre resin spraying for the use of gun rovings. The
length of the gun rovings in this case shall be 35 mm.
– weave (DIN 61101-T2)
3.4.5 The gun prescribed number of specimens
3.3.4 Non-woven fabric shall be cut out of the test panels for each test. In do-
ing so, specimens shall be taken from each reinforcing
– lay up
direction of the laminate in order to test the mechani-
– weight per unit area of the individual layers and cal properties. For products with randomly distributed
of the non-woven fabric (ISO 4605) reinforcing directions, specimens shall be taken from
any two directions, but at right angles to each other.
– non-woven fabric thickness
(ISO 4603) 3.4.6 The specimens shall be tested in accordance
– binder (see 3.3.5) with DIN EN ISO 291 after at least 16 h under stan-
dard climate conditions.
In addition if a non-woven fabric contains mat or
fabric layers, then the linear density and, where ap- 3.4.7 The following properties shall be verified by
propriate, the fibre length shall be indicated. the test certificate of a recognized testing body:

3.3.5 A difference shall be made between chemical – fibre content (DIN ISO 1887, carbon DIN EN
and mechanical bond types. In the case of chemical 2564), 3 specimens
bond types, the binder, the percentage weight (glass – tensile strength, fracture strain, modulus of elas-
ISO 1887, carbon DIN 29965) and its solubility (DIN ticity in tension (DIN EN ISO 527-4, test piece
52332) shall be indicated. In the case of mechanical III), 6 specimens
bond types, the type of weave shall be indicated.
– bending strength, modulus of elasticity in bend-
3.3.6 In the case of reinforcing products with dif- ing (DIN EN ISO 14125, Method A), 6 specim-
ferent fibre materials, the percentages of materials ens
used in the respective reinforcing directions shall be Deviating from the standard the modulus of elasticity
indicated. in tension shall be determined as a secant modulus
between 10 % and 50 % of the fracture strain.
3.4 Laminate properties of the reinforcing
products In addition, for carbon fibres, the compressive strength
and the modulus of elasticity in compression shall be
3.4.1 For laminate production, it is strongly rec- demonstrated (carbon, Draft DIN EN 2850, test piece
ommended that GL-approved cold-setting UP resins A1 with gauge length 8 mm).
are to be used. After curing, the specimens shall be
tempered for 16 h at 40 °C. If, for special reasons, 3.4.8 The testing speeds shall be selected in such a
other (also warm-setting) thermosetting resins are to way to ensure a strain rate of 1 % / min in the test
be used, then this shall be agreed in advance by GL- piece or the edge fibre. The testing speed shall be
HO. indicated.

3.4.2 For rovings, tensile test specimens shall be 3.4.9 Testing shall be carried out in a standard
prepared for all fibre materials in accordance with climate 23/50 (23 °C / 50 % relative humidity). If the
DIN 29965, Section 4.1.3.5. The test certificate of a operating temperatures of the fibres are not between
recognized testing body shall be submitted to verify – 20 °C and + 50 °C, then additional testing tempera-
the tensile strength, the fracture strain and the modulus tures shall be agreed on with GL-HO.
of elasticity as the mean values from six tests carried
out in accordance with DIN 65382. Furthermore, the 3.5 Minimum properties
tensile strength and the modulus of elasticity shall be
determined in accordance with DIN 65469 on flat 3.5.1 For approval, fibre reinforced products shall
specimens prepared for testing under tension. fulfil specified minimum values for the mechanical
properties. The influence of the fibre volume content
3.4.3 For all other reinforcing products, laminate on the properties has been taken into account when
test panels shall be prepared in accordance with specifying the values. The values refer to the 0° direc-
DIN EN 2374, Section 5.3 (Method C). In doing so, tion in the case of a uniform lay up. If necessary, a
the reinforcing products shall be arranged in identical correction to the actual lay up shall be done.
II - Part 2 Section 2 A Inspection and Testing of Fibre Composite Materials Chapter 1
GL 2006 Page 2–5

3.5.2 The minimum values of all mechanical prop- 3.5.4 For reinforcing products with different fibre
erties to be verified are determined by means of the materials in one direction, the values of the material
following equation together with the values given in with the lower minimum properties shall be fulfilled.
Table.2.1:
3.5.5 The minimum values for fabric are 95 % of
⎡ ⎛ ϕ ⎞⎤ the specified values for 0° / 90° lay up.
X min = α ⎢ X ref ⎜ ⎟⎥
⎣ ⎝ 0, 4 ⎠ ⎦ 3.5.6 The stiffness of the gun rovings to be verified
in accordance with DIN 52316 shall not be below
Xmin = minimum required value 130 mm.
Xref = reference value for fibre volume content 3.5.7 The linear relationship between the property
ϕ = 0,4 and fibre volume content assumed when specifying
minimum values does not apply for all properties, and
α = factor for lay-up
shall therefore not be used to extrapolate measured
ϕ = fibre volume content 0,2 ≤ ϕ ≤ 0,6 values.

Deviations from the above specification are allowed 4. Prepregs

for laminates with glass mats or gun rovings; in these
cases, the minimum values for a percentage fibre 4.1 General
weight content of 0,25 ≤ ψ ≤ 0,35: are:
4.1.1 The basic requirements listed under 1. shall
− tensile strength : apply for material approval.
RZ = 1278ψ 2 − 510ψ + 123 [ MPa ] 4.1.2 Since prepregs are based on resin systems
which cure under heat, consultation with GL-HO
− Young 's modulus (tension) : concerning the curing process of the resins is required.

E = ( 37ψ − 4, 75 ) ⋅ 103 [ MPa ] 4.1.3 The testing of cured prepreg laminates is

identical with the laminate testing of fibre reinforced
products. Taking into account the resin system, the
− bending strength : minimum characteristic values shall be agreed on with
R B = 502ψ 2 + 106,8 [ MPa ] GL-HO.

4.1.4 Unidirectional non-woven prepregs and

3.5.3 In the case of multidirectional lay up of the woven prepregs are considered within the framework
reinforcing products, the values shall be proved at of these Rules. Other prepregs can also be approved,
least for one direction (preferably 0°). following agreement with GL-HO.

Table 2.1 Coefficients for the determination of the minimum properties

Xref α
Fibre Propert [MPa]
0° 0° / 90° 0° / ± 45° 0° / 90° / ± 45°
Tensile strength 500 1,00 0,55 0,50 0,45
Glass Young's Modulus of elasticity 26.000 1,00 0,67 0,57 0,55
Bending strength 650 1,00 0,55 0,45 0,40
Tensile strength 900 1,00 0,55 0,50 0,45
Modulus of elasticity 80.000 1,00 0,55 0,45 0,42
Carbon Bending strength 725 1,00 0,55 0,45 0,40
Compressive strength 600 1,00 0,55 0,50 0,45
Modulus of elasticity
compression 70.000 1,00 0,55 0,50 0,45
Chapter 1 Section 2 A Inspection and Testing of Fibre Composite Materials II - Part 2
Page 2–6 GL 2006

4.2 Prepreg properties 5.2.2 The manufacturer shall provide details of the
maximum permissible processing temperatures and
4.2.1 A description is necessary which allows an the operating temperature limits. The long-term oper-
unequivocal identification of the prepreg: ating temperature shall at least cover the range
–20 °C to +50 °C.
– fibre material
– resin system 5.2.3 The test certificate of a recognized testing
body verifying the following properties shall be sub-
– reinforcement type mitted:
– trade name
– apparent density (ISO 845);
– manufacturer sample thickness ≥ 25 mm, 3 specimens
– storage conditions, processing guidelines – water absorption (ISO 2896), 3 specimens
4.2.2 The following properties shall be submitted – compressive strength (ISO 844), 6 specimens,
for the non-cured prepreg material: vertical to the plane of the test panel
– mass per unit area (DIN 53854)
– modulus of elasticity (compression) (ISO 844),
– resin percentage by weight 3 specimens, test piece III, vertical to the plate
(DIN 29971, Section 5.1.1.4) plane of the panel
– layer thickness (DIN 53855-1) – shear strength (DIN 53294), 6 specimens
– resin flux percentage by weight – shear modulus (DIN 53294), 6 specimens
(DIN 65090, Section 5.1.1)
5.2.4 The specimens shall be tested without foam
4.2.3 The following are necessary for the reinforc-
skin. The testing shall take place in a standard climate
ing material:
23/50 (23 °C/50 % relative humidity). Testing proce-
– filament diameter (DIN 53811 - ISO 137) dures are given mainly for rigid foams, whereas in the
case of tough foams GL-HO shall be consulted if there
– count (EN 1049-2)
is any doubt.
– bond type (only woven prepregs)
5.2.5 The following minimum properties are spe-
cified for an apparent density of 60 kg/m3 and
5. Core materials
200 kg/m3:
5.1 General
60 kg/m3 200 kg/m3
5.1.1 The basic requirements listed under 1. shall
apply for material approval. Compressive strength [MPa] 0,6 3,5
5.1.2 A general description of the core material Modulus of elasticity 40 200
shall be submitted. The basic properties shall be veri- (compression) [MPa]
fied by the test certificate of a recognized testing body.
Shear strength [MPa] 0,5 2,6
5.1.3 Rigid foam materials and cross-grained balsa Shear modulus [MPa] 15 65
are considered specifically as a core material within
the framework of these Rules. Cores made of other Water absorption [vol.-%]
2 2
materials can also be approved, following agreement (after 28 Days)
with GL-HO.

5.2 Rigid foams 5.2.6 In the case of other apparent densities, linear
interpolation of the densities shall be used to deter-
5.2.1 The following information is necessary for a mine strengths and moduli.
general description:
– basic material and additives 5.3 Cross-grained balsa wood
– trade name
5.3.1 The requirements for cross-grained balsa
– manufacturer wood are specified in Chapter 2 – Wood, Section 2.
– resin systems suitable for bonding/coating
5.3.2 Adhesion of balsa wood shall not be impaired
– storage conditions by impregnation.
II - Part 2 Section 2 A Inspection and Testing of Fibre Composite Materials Chapter 1
GL 2006 Page 2–7

6. Adhesives 6.4 Properties in the cured state

6.1 General 6.4.1 The following mechanical properties shall be

verified by the certificate of a recognized testing body
6.1.1 The basic requirements listed under 1. shall (on 6 specimens respectively):
apply for material approval.
– tensile lap-shear strength (DIN EN 1465)
6.1.2 A general description of the adhesive shall be
provided. Basic properties of the cured adhesive shall – peeling resistance (ISO 11339)
be verified by the test certificate of a recognized test- – dimensional stability under heat
ing body. (DIN EN ISO 75-2, Method A)
6.1.3 The following specifically considers cold- In addition, a long-duration shear tension test (based
setting and hot-setting thermosetting adhesives as well on EN 1465) shall be carried out. In doing so, the
as hot-melt adhesives. Other adhesives, provided that sample is subject to loads in a standard climate 23 °C /
they can be used for processing of FRP (e.g. expan- 50 % relative humidity at 60 % of the mean tensile
sion adhesives) can also be used, following agreement lap-shear strength for 192 ± 2 h.
with GL-HO.
6.4.2 The testing shall be carried out for two dif-
6.2 Description ferent conditioning states of the specimens:
6.2.1 A description of the adhesive shall be submit- – 24 ± 1 h after curing at 23 °C and storage at
ted in order to allow an unequivocal identification of 50 % relative humidity
the adhesive:
– 1000 ± 12 h storage in distilled water at 23 °C
– type of adhesive
– manufacturer 6.4.3 For each test and conditioning state, speci-
mens with adhesive layer thicknesses of 0,5 mm and
– trade name 3 mm shall be used.
– storage conditions
6.4.4 All tests shall all be carried out in a standard
– processing and curing guidelines climate 23 °C / 50 % relative humidity. In addition,
– volume shrinkage after exceeding the gel point the tensile lap-shear strength shall be verified at 50 °C.
– glass transition temperature (ISO 11357/2)
6.5 Minimum properties
6.2.2 In the case of adhesive films with backing,
the backing material shall be specified. 6.5.1 The following properties shall be achieved
for directly tested specimens as well as specimens
6.3 Properties of the adhesive tested after wet storage:
– tensile lap-shear strength: 12 MPa
6.3.1 In the processing state, the following infor-
mation shall be provided: – peeling resistance: 2 N/mm
– density (DIN EN ISO 1675) – dimensional stability under heat: 65 °C
– viscosity (DIN 53019)
6.5.2 Strain in creep shall be below 0,18 mm in the
6.3.2 In the case of two-component thermosetting long-duration shear tension test for an adhesive layer
resins which cure at room temperatures, the pot life thickness of 0,5 mm and below 1 mm for an adhesive
(DIN 16945, Section 6.3) shall also be indicated. layer thickness of 3 mm.
II - Part 2 Section 3 B Repair of Components Chapter 1
GL 2006 Page 3–1

Section 3

Repair of Components

A. General 2. Prerequisites

1. Requirements for operation and personnel 2.1 In the case of repairs which affect the struc-
tural integrity of the component, a repair plan shall be
established and approved by GL before the start at any
1.1 Repairs shall only be performed by work- repair work. If the same repair is to be carried out
shops which are approved by GL for the repair of several times, a general repair plan can be established
components made from fibre-reinforced thermosetting and submitted to GL for approval.
resins.
2.2 Repairs to the gelcoat resin and (minor) re-
1.2 The shop approval for manufacturing compo- pairs which do not fall under 2.1 shall be standardized
nents made of fibre-reinforced plastics using the hand and approved by GL according to the standardized
lay-up method includes approval for repairing the procedure.
parts within that production facility. For repairs out-
side of the production facility (i.e. in the field), an
extension of the shop approval is required. 2.3 For the approval of a repair according to 2.1,
all design and repair drawings needed to assess the
repair of the component shall be submitted to GL. The
1.3 The repairs shall only be carried out by per- repair plan will be examined by GL-HO and approved
sons with proven professional knowledge. This pro- if found suitable.
fessional knowledge shall in general be verified by
certificates of the corresponding training courses. If
such certificates are not available, the minimum re- 2.4 A report is required for each repair and has to
quirement shall consist of training completed for a be signed by the head of the repair team.
technical profession, in conjunction with internal
training and several months of experience. 2.5 Only materials approved by GL shall be used
for the repair.
1.4 The head of the repair team is responsible for
proper execution of the repair and shall be named 2.6 The thermosetting resins used for repair shall
explicitly in the shop approval. His professional be at least equivalent to the original thermosetting
knowledge shall be verified by certificates of the cor- resin used for production. To ensure low residual
responding training courses and professional experi- stresses in the area to be repaired, the use of fast-
ence of several years. In addition, a procedure test - to setting highly reactive thermosetting resins shall be
be carried out at the shop under supervision of GL - is avoided. Unless the original thermosetting resin is
required. used, the elongation at break of the thermosetting
resins used for the repair shall be at least 2,5 %.
1.5 The shop approval is granted by GL Head
Office (GL-HO) on the basis of the information to be 2.7 If the materials and laminates used for the
submitted with Form F 506 and the report submitted repair are not identical to those employed when the
by the GL surveyor. The form deals with the follow- component was manufactured, compatibility and
ing points: equivalence of that particular combination of materials
to the original ones shall be verified with respect to
– general information on the shop their properties.
– personnel
– internal quality management
B. Procedure
– incoming inspection
– storage of the materials for repair in the shop 1. Preparation
and during field work
– mechanical processing capabilities 1.1 Damaged material, or material which no
longer exhibits complete bonding, shall be removed
– production equipment from the area to be repaired.
Chapter 1 Section 3 B Repair of Components II - Part 2
Page 3–2 GL 2006

1.2 The region adjacent to the damaged area shall area to be repaired and sufficient illumination are both
be chamfered. The chamfer ratio (chamfer length ls to ensured.
chamfer thickness ts) depends on the tensile strength
of the repair material, σMat, in the chamfer direction, 1.10 For repairs in the field, measures shall be
and the permissible shear stress τ. The minimum taken against moisture as well as direct UV radiation.
chamfer ratio shall be calculated by means of the
following formula:
1.11 The component temperature, at least within
σMat ls the repair area, shall be kept within the range permit-
= ⋅x ted in 2.1.
τ ts

x = 1 for hand laminate 1.12 The mixing ratio of resin to hardener shall be
maintained as precisely as possible (in the case of
x = 1,05 in case of tempering epoxy resins, the relative deviation from the mixing
ratio shall not exceed 3 %). The actual mixing ratio
x = 1,15 for curing under vacuum and tempering
and the quantities used shall be recorded in a dosing
report.
The permissible shear stress shall be 9 N/mm2 for
repairs in the shop and 7 N/mm2 for repairs in the
field. 2. Execution

1.3 The minimum overlap length for each layer

2.1 During the repair work and the curing period,
shall not be less than 10 mm on all sides.
a surrounding air and a component temperature be-
tween 16 and 25 °C as well as a maximum relative
1.4 Because of the required draping ability humidity of 70 % shall be maintained. If the resin or
needed (for curved surfaces and in the chamfered joint adhesive manufacturer has not specified other permis-
area; see Fig. 3.1), the weight per unit area of the sible values, these values shall apply.
reinforcing materials used for repair work shall, as far
as possible, not exceed 600 g/m2 per layer (more lay-
ers with less weight per unit area are better than only a 2.2 Calibrated thermometers and hygrometers
few layers with a high weight per unit area). shall be used for monitoring in the vicinity of the
repair or at a position agreed upon with GL.

2.3 It shall be ensured that no changes in elonga-

tion occur in the laminate during the repair.

2.4 The lay-up at the prepared area to be repaired

Fig. 3.1 Chamfered joint area for a repair shall be performed by means of the hand lay-up
(schematic) method, as far as possible in the same sequence that
was applied for the original laminate. The fibre orien-
1.5 In order that the stress magnification associ- tation shall be identical.
ated with a chamfered joint is as low as possible, at
least three reinforcing layers should be used for each 2.5 Attention shall be paid to providing good
area to be repaired. impregnation of the reinforcing material. Voids shall
be avoided.
1.6 The area to be repaired shall be cleaned and
grinded thoroughly, e.g. by using sandpaper with a
2.6 A mat or fabric with a weight per unit area of
grain of 80 or 120.
approx. 225 g/m2 maximum 450 g/m2 for boats) and a
low percentage fibre weight content (approx. 30 %)
1.7 If the laminate has been in direct contact with shall be used as the final layer.
water for a lengthy period, the laminate shall be dried
properly before repair work is started.
2.7 The laminate shall be given sufficient surface
1.8 As far as possible, the area to be repaired protection by means of a coating resin. If the repair
shall be relieved of the stress caused by its own areas are subjected to increased moisture levels, a high
weight. In the case of repairs performed in the field, resistance to hydrolysis is required of the coating
special arrangements shall be taken if necessary to resin.
prevent the occurrence of external loads (e.g. caused
by vibration). 2.8 If unsaturated polyester or vinyl resins are
used for the topcoat, inhibition problems shall be
1.9 For repairs in the field, the workplace shall be avoided by excluding atmospheric oxygen (e.g. by
arranged in such a way that good accessibility to the adding paraffin or using foil coverings).
II - Part 2 Section 3 D Repair of Components Chapter 1
GL 2006 Page 3–3

3. Curing – date and location of the repair (address of the

shop or location in the field)
3.1 During the curing process, it shall be ensured
– start time of repair
that no changes in elongation take place in the lami-
nate. – position and type of damage

3.2 Repaired components shall only be subjected – repair plan and approval No.
to loads or put into further operation after the thermo- – climatic conditions during repair and the curing
setting resin has cured sufficiently. period (and the wind speed, in case the work
was not performed within a closed room)
3.3 If no explicit values are quoted for the curing
process by the manufacturer of the thermosetting resin – materials used (with batch number)
system, the following time periods shall apply for
cold-setting resin systems: – mixing ratios for thermosetting resin systems;
dosing report
– for a constant temperature of 16 °C:
at least 72 h, – lay up (number of layers and orientation)

– for a constant temperature of 25 °C: – any deviations from the repair plan
at least 38 h. – duration of the repair
3.4 If the repaired component was tempered – curing time
during manufacture, the area to be repaired shall also
be tempered after setting, if no proof is provided to – signature of the head of the repair team
show that this is not necessary.
Note:
To assist in describing and explaining the repair,
sketches or pictures may be added to the repair re-
C. Documentation
port.

1. Repair report

1.1 The repair report shall at least contain the D. Enclosures

following points:
– Example of a repair report
– designation of the component and, if applicable,
its identification number – Example of an survey report
Chapter 1 Section 3 D Repair of Components II - Part 2
Page 3–4 GL 2006

Survey Report for

Repair of FRP-Components

Component:
(Manufacturer)

GL-Register-No. (Ships)
Site (WEC)
Other identification No.

Owner Site of repair Date of repair Surveying date

Examination of suitability of workshop

• Shop approval by GL? yes no

• Name of head of the repair team:

.................................................................................................

• Head of repair team named explicitly in the shop approval? yes no

• Repair team familiar with Rules of Repair of Components? yes no

Repair Surveillance

• Repair plan approved by GL? yes no

• Have the requirements for repair of FRP-components been followed? yes no

• Deviations from GL’s Rules or from the repair plan yes no

(e.g. materials, climatic conditions, execution)?

Description:
....................................................................................................................................................................

....................................................................................................................................................................

....................................................................................................................................................................

• Repair report enclosed? yes no

Place/Date: .................................. Signature ...............................................

GL-Surveyor
II - Part 2 Section 3 D Repair of Components Chapter 1
GL 2006 Page 3–5

Repair Report for FRP-Components

Component Data

Designation: ................................................................................................................................................

GL-Register No.: .................................................... Site: ................................................................

(for ships) (for WEC)

Owner: Other identification

..................................... ........................................... No. ..................................................................

Details of Repair:

Site (of the repair): ....................................................................... Date: ...........................................

Climatic conditions during repair (every 3 h)

Time Temperature Relative humidity (Wind speed)

Begin:

End:

Materials used: Batch number GL-approval

Resin system ....................................................................................... yes no

Topcoat ....................................................................................... yes no

Adhesive ....................................................................................... yes no

....................................................................................... yes no
Reinforcement material ....................................................................................... yes no
....................................................................................... yes no

Dosing report

Lot-No. Resin Curing agent Accelerator Time

Chapter 1 Section 3 D Repair of Components II - Part 2
Page 3–6 GL 2006

Position and type of damage (if necessary sketches or pictures on separate page(s))

Description of deviations from the repair plan (if relevant)

Maximum and minimum temperature between start of the repair and commissioning of the repaired
component

max.: .......................................... [° C] min.: ................. ............................... [° C]

Commissioning of the repaired component

Date:.................................................... Time: .........................................................

Place/Date .................................... ...............................................

Stamp of Company Signature of the head of the
repair team