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Checklist for Manufacturing Site Examination (acc.

to ISO 12215-4)

Manufacturer Name :
Address :

City

Phone number :

Zip Code:

Country :

Fax number:

Website:

Contact Person:

Code Letter

1.

e-mail:

+ = Yes

- = No

N/A = Not Applicable

FRP FIBRE-REINFORCED PLASTICS BOAT PRODUCTION

DATE

1.1 Workshop Conditions


1.1.1. General
1.1.1.1. Environment conditions are suitable for the buildings used for production and storage for construction
and equipped.
1.1.1.2. Minimize contamination and impairment of all production area are provided.
1.1.1.3. The workshops and equipments are properly maintained and kept in clean condition free from debris and
surplus material.

1.1.2. Temperature and Humidity


1.1.2.1. The moulding shaft temperature and humidity is maintained within the limits.
1.1.2.2. The temperature and humidity results for appropriate locations are monitored and kept.

1.1.3. Ventilation
1.1.3.1. Ventilation is provided in order to minimize accumulation of monomer fumes in the mould without
reducing the surface temperature of the mould and laminate.
1.1.3.2. Design of the ventilation system is changed by taking into account size of the laminating shop.

1.1.4. Dust Control


1.1.4.1. Minimize harmful accumulation of dust on moulds are provided.

1.1.5. Illumination
1.1.5.1. Harmful effects on the resin cure due to direct sunlight artificial lighting are prevented.

Form No: RCD 102 / 05th January 2015

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1.2

Material Storage and Handling

1.2.1. General Requirement


1.2.1.1. Storage areas are arranged and equipped for following material manufacturers requirements.
1.2.1.2. Material expiry date is controlled and kept records.

1.2.2. Resin
1.2.2.1. Resins are stored under controlled conditions in accordance with the resin manufacturers requirements.
1.2.2.2. Resin manufacturers recommendations for mixing and contioning are complied with prior to use.

1.2.3. Catalysts and Accelerators


1.2.3.1. Catalysts and accelerators are stored according to the material manufacturers requirements.

1.2.4 Fillers and Additives


1.2.4.1. Fillers and additives are stored in closed containers to protect from dust and humidity which are used in
the moulding process.

1.2.5. Reinforcing and Core Materials


1.2.5.1. Reinforcing and Core Materials are stored clean and dry conditions in accordance with the material
manufacturers recommendations.

1.3

Moulds

1.3.1. Construction
1.3.1.1. Moulds are constructed of a suitable material and adequately stiffened to maintain their shape
1.3.1.2. The materials are used in the construction of moulds affected the resin cure.

1.3.2. Preparation
1.3.2.1. The moulds are cleaned, dried and provided to stabilize at the workshop temperature.
1.3.2.2. The release agent is compatible with the mould surface, the resins applied in the laminating process and
with mould release films used previously.
1.3.2.3. The release agents containing silicon are used.

1.4 Resin Preparation


1.4.1 The requirements of the resin manufacturer are followed.
1.4.2 Blended resin is suitable for the laminating process.

1.5

Laminating process

1.5.1 Manual lay-up


1.5.1.1 The material type and unit weight of the first fibre reinforcement layer are chosen to provide for adequate
penetration of the reinforcement layer by the resin system used and reduce the effect of hydrolytic attack.
1.5.1.2 The lay-up sequence and degree of resin cure between plies are complied with the resin manufacturers
recommendations.

Form No: RCD 102 / 05th January 2015

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1.5.1.3 Moulds are arranged and access provided so that reaching each part of the mould with the tools used to
ensure consolidation and de-aeration of the laminate during lay-up.

1.5.2 Spray lay-up


1.5.2.1 Spray lay-up of resin and/or reinforcement fibres are limited to applications where consideration is given
to; exothermic heat by excessive wet laminate thickness, sagging or drainage of the laminate thickness, deaereation.
1.5.2.2 The weight of glass reinforcement is to be deposited between resin/glass consolidation depends upon the
complexity of the mould.
1.5.2.3. The uniformity of the laminate and glass content is checked at regular intervals.
1.5.2.4. The spray equipment is calibrated and checked for the desired setting for the resin/catalyst and
resin/reinforcement fibre ratios at the beginning of each working day.

1.5.3 Closed moulding


1.5.3.1. Application system of closed moulding is designed to ensure the correct distribution of resin in the
laminate.

1.5.4 Pre-impregnated laminates


1.5.4.1. Pre-impragnated laminates are stored, used and cured in accoedance with the material manufacturers
requirements.

1.6

Surface Coating

1.6.1 Coating Material


1.6.1.1. Gelcoat or another suitable coating is applied to provide some from solar radiation, hydrolytic attack and
abrasion which is the laminating resin when designed for this purpose.
1.6.1.2. The first layer of reinforcement is applied in accordance with the resin manufacturers specification
where gelcoat is used.

1.6.2 Spray Surface Coating


1.6.2.1. The spray equipment is calibrated and checked for the desired settings for the resin/catalyst ratios and the
spray pattern at the beginning of each working day or prior to the start of single part work to ensure
consistent application.

1.7

Manufacturing requirements, sandwich construction

1.7.1 Sandwich construction using female moulds


1.7.1.1. Core surface cavities and other irregularities are removed and coated with filter, resin or sandwich
adhesive according to the material manufacturers specification and depending on the following skin layup.
1.7.1.2. A sufficient amount of resin or adhesive is used in the bond to fill the gaps when using scored core
material.
1.7.1.3. Sufficient resin is in or on the laminate to achieve a bond between the laminate and core material without
resin deficiency of the laminate when bonding core material to a wet laminate.
1.7.1.4. The materials are kept in contact while curing to ensure a structurally sufficient bond and to avoid air
entrapment.

Form No: RCD 102 / 05th January 2015

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1.7.2 Sandwich construction using male moulds


1.7.2.1. Joints, scores and voids in the core material are filled or fixed to each other before application of the skin
laminate.
1.7.2.2. Laying the core material which is bent or deformed to such an extent that the properties of the core are
affected.
1.7.2.3. Irregularities on the cure surface and the joints are removed.
1.7.2.4. The core surface is primed where required before application of the laminate

1.8

Laminate curing

1.8.1 Open-mould process


1.8.1.1. The laminate cure schedule follows the resin manufacturers requirements.
1.8.1.2. The laminate cure schedule is documented.
1.8.1.3. The curing schedule for sandwich laminates take into account the thermal influence of the core material
1.8.1.4. Processes temperature are documented.
1.8.1.5. The post cure temperature is compatible with the temperature limits of the release agent.
1.8.1.6. The post cure temperature does not effect the gelcoat for the single skin or sandwich laminate.

1.8.2 Closed-mould process


1.8.2.1. The curing schedule for the closed-mould technique takes into account the thermal influence of material,
mass and construction of the mould.

METAL CRAFT PRODUCTION, STEEL AND ALUMINIUM

DATE

2.1 Storage and handling


2.1.1. Suitability
2.1.1.1. The materials used in the production of craft built of steel or aluminium alloys are complied with the
requirements of ISO 12215-3.

2.1.2. Identification and Marking


2.1.2.1. Materials are fully identifiable throughout and storage and production process.
2.1.2.2. Each deliveryof material is accompanied with the appropriate documentation which is ensured by the
builder.
2.1.2.3. The builder maintains purchasing documents containing a clear description of material ordered for hull
construction referring to the appropriate standards and specifications.
2.1.2.4. Non-conforming material is separated form the acceptable material.
2.1.2.5. Defective materials are disposed of in accordance with the builders conformity assurance procedure.
3.1.2.3. The builder establishes and maintains a procedure to ensure that material and consumables used in the
construction process are identified from arrival in the yard.

Form No: RCD 102 / 05th January 2015

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2.1.3. Storage
2.1.3.1. Materials are stored in accordance with the material manufacturers requirements
2.1.3.2. Storage arrangements are such as to prevent deterioration through adverse environmental conditions and
poor handling.
2.1.3.3. Welding consumables are stored in suitable conditions in accordance with the material manufacturers
recommendations.

2.2. Workshop Conditions


2.2.1. During construction the craft is protected form the weather and climatic influences.

2.3. Construction
2.3.1. Preparation
2.3.1.1. Steel is cleaned and cleared of millscale and rust prior tp fabrication of the small craft.
2.3.1.2. The preparation of materials follows recognized industry practice.

2.3.2. Procedure for welded construction


2.3.2.1.

General

2.3.2.1.1.
The requirements of this subclause are applicable to steel and aluminium alloys using
appropriate welding processes.

2.3.2.2.

Documentation

2.3.2.2.1.
Details of welding connections of the main structural members are contained in construction
plans and/or descriptions.

2.3.2.3

Welding Equipment

2.3.2.3.1.

The welding plant and equipment are suitable for the purpose intended.

2.3.2.4.

Welder Qualifications

2.3.2.4.1.

Welding operators are qualified for the type of work.

2.3.2.5.

Welding Environment

2.3.2.5.1.

Welding is provided to protection from wet, windy or cold weather.

2.3.2.6.

Preparation for Welding

2.3.2.6.1.

The preparation of plate edges are accurate and free from harmful defects

2.3.2.6.2.

Joints are fitted up or aligned without using excessive force before welding.

2.3.2.6.3.

Parts are set up and welded to keep minimum contraction stresses.

2.3.2.7.

Cleanliness

2.3.2.7.1.

Welded surfaces are cleaned, dried and free from grease and other contaminants

2.3.2.8.

Acceptance Criteria

2.3.2.8.1.

Finished welds are sound and free from cracks and harmful defects.

2.3.2.8.2.

Weld defects are removed and repairs carried out.

Form No: RCD 102 / 05th January 2015

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2.4 Steel/aluminium transition joints


2.4.1. Explosion-bonded composite transition joints are used for connecting aluminium to steel.
2.4.2. Explosion-bonded composite transition joints are used in strict compliance with the joint manufacturers

specification.
2.4.3. Bimetallic joints are protected to prevent galvanic corrosion.

2.5. Adhesive bonding of structure


2.5.1. The adhesive manufacturers recommendations are followed in respect to the joint system, comprising

surface preparation, the adhesive, bonding, curing processes and environmental conditions.
2.5.2. Bonded joints method are documented.

2.5.3. Bonded joints are designed to avoid tension on the joints which cause peeling forces tending to open the
joint, unless tests and calculations.
2.5.4. Glued joints are protected against sunlight and environmental effects.

2.6. Steel/Wood and Aluminium/Wood Connection


2.6.1. Surfaces are protected from corrosion of steel or aluminium in contact with wood in a damp or marine

environment.
2.6.2. Surfaces are primed and painted or coated with a substantial thichness of a suitable sealant.

2.7. Surface Coating


2.7.1. Metal is given protection for its intended use by an surface treatment and/or coating.

3.

ALUMINIUM CRAFT PRODUCTION, SPECIFIC REQUIREMENTS

DATE

3.1 Building Environment


3.1.1 Aluminium are welded when damp or wet in order to avoid hydrogen inclusions in the welds.

3.2. Storage
3.2.1. Aluminium are stored in dry places, clear of the ground.
3.2.2. Stored materials are prevented to contact with other stored materials.

3.3. Tools
3.3.1. The tools in contact with the metal used in aluminium production are merked for use aluminium only
where a builder is working with both aluminium and steel.

3.4. Corrosion prevention


3.4.1. Areas of the hull structure that are permanently or temporarily submerged are protected by means of
coating or cathodic protection.

Form No: RCD 102 / 05th January 2015

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4.

WOODEN BOAT PRODUCTION

DATE

4.1 Workshop Conditions


4.1.1 The premises used for production and storage are suitable and equipped to provide the conditions
necessary for fault free bonding by adhesives.
4.1.2. The workshop and equipment are maintained in a clean and efficient condition.

4.2. Material
4.2.1. Material Storage
4.2.1. Timber is stored in dry and well ventilated premises where it is protected from direct sunlight and
excessive moisture.

4.2.2. Glues, adhesives


4.2.2.1. Adhesives are suitable for the intended purpose.

4.2.3. Fastening elements


4.2.3.1. Fastening elements for load bearing parts of the construction are corrosion resistant or hot dipped
galvanized.

4.3. Manufacturing
4.3.1. General
4.3.1.1. Manufacturing takes place in an environment that takes into account the requirements and limitations
specified by the manufacturer of the material.

4.3.2. Glued connections


4.3.2.1. The moisture content of the wood is checked before gluing
4.3.2.2. Glued areas are free form any contamination that impair the strength of the bond.

4.3.3. Preventation of deterrioration


4.3.3.1. Wooden craft is constructed in such a way that water collects in areas.
4.3.3.2. Wooden craft is constructed in such a way that natural ventilation.

4.4. Surface treatment


4.4.1. A protective coating or surface treatment is applied to finished surfaces not intended to be left bare.
4.4.2. Any coating or treatment reacts with the adhesives.

Form No: RCD 102 / 05th January 2015

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5.

BOAT PRODUCTION USING OTHER MATERIALS

The manufacturing of small craft using other materials than those described in clauses 1 to 4 shall follow similar
procedures especially with regard to
-

6.

Material manufacturer requirements


Suitability for the purpose intended
Identification storage and handling of materials
Workshop conditions
Suitable construction procedure
Acceptance criteria

QUALIFICATION OF PERSONEL

DATE

6.1 Personnel Requirements


6.1.1 The construction of small craft is carried out by personnel with the necessary boat building skills for the
specific materials used and manufacturing process applied.

6.2 Responsibility
6.2.1 The person responsible for proper execution of the work has the appropriate knowledge verified by
certificates or professional experience in specific job.

7.
7.1

FINAL INSPECTION

DATE

Completion of structural work is inspected and a report produced which is signed by the responsible person
and added to the technical documentation of the craft.

Notlar Remarks

Place :

Date :

Form No: RCD 102 / 05th January 2015

Surveyor :

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