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Blisters
The blistering of gel coated, FRP structures has received much attention in recent years. The
defect manifests itself as a localized raised swelling of the laminate in an apparently random
fashion after a hull has been immersed in water for some period of time. When blisters are
ruptured, a viscous acidic liquid is expelled. Studies have indicated that one to three percent of
boats surveyed in the Great Lakes and England, respectively, have appreciable blisters. [4-29]
There are two primary causes of blister development. The first involves various defects
introduced during fabrication. Air pockets can cause blisters when a part is heated under
environmental conditions. Entrapped liquids are also a source of blister formation. Table 4-2
lists some liquid contaminate sources and associated blister discriminating features.
Table 4-2 Liquid Contaminate Sources During Spray-Up That Can Cause Blistering
[Cook, Polycor Polyester Gel Coats and Resins]
Water Air lines, improperly stored No real odor when punctured; area around
material, perspiration. blister is whitish or milky.
Solvents Leaky solvent flush system, Odor; area sometimes white in color.
overspray, carried by wet rollers.
Oil Compressor seals leaking. Very little odor; fluid feels slick and will not
evaporate.
Uncatalyzed Resin Malfunctioning gun or ran out of Styrene odor and sticky.
catalyst.
Even when the most careful fabrication procedures are followed, blisters can still develop over
a period of time. These type of blisters are caused by osmotic water penetration, a subject that
has recently been examined by investigators. The osmotic process allows smaller water
molecules to penetrate through a particular laminate, which react with polymers to form larger
molecules, thus trapping the larger reactants inside. A pressure or concentration gradient
develops, which leads to hydrolysis within the laminate. Hydrolysis is defined as
decomposition of a chemical compound through the reaction with water. Epoxide and
polyurethane resins exhibit better hydrolytic stability than polyester resins. In addition to the
contaminants listed in Table 4-2, the following substances act as easily hydrolyzable
constituents: [4-30]
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Blisters Marine Composites
Stabilizers;
Promoters;
Catalysts; and
Uncross-linked resin components.
Blisters can be classified as either coating blisters or those located under the surface at
substrate interfaces (see Figure 4-18). The blisters under the surface are more serious and will
be of primary concern. Some features that distinguish the two types include:
Diameter to height ratio of sub-gel blister is usually greater than 10:1 and
approaches 40:1 whereas coating blisters have ratios near 2:1;
Sub-gel blisters are much larger than coating blisters;
The coating blister is more easily punctured than the sub-gel blister; and
Fluid in sub-gel blisters is acidic (pH 3.0 to 4.0), while fluid in coating
blisters has a pH of 6.5 to 8.0.
Figure 4-18 Structure Description for a Skin Coated Composite with: Layer A = Gel
Coat, Layer B = Interlayer and Layer C = Laminate Substrate [Interplastic, A Study of
Permeation Barriers to Prevent Blisters in Marine Composites and a Novel Technique for
Evaluating Blister Formation]
Both types of blisters are essentially cosmetic problems, although sub-gel blisters do have the
ability to compromise the laminate's integrity through hydrolytic action. A recent theoretical
and experimental investigation [4-31] examined the structural degradation effects of blisters
within hull laminates. A finite element model of the blister phenomena was created by
progressively removing material from the surface down to the sixth layer, as shown in Figure
4-19. Strain gage measurements were made on sail and power boat hulls that exhibited severe
blisters. The field measurements were in good agreement with the theoretically determined
values for strength and stiffness. Stiffness was relatively unchanged, while strength values
degraded 15% to 30%, usually within the margin of safety used for the laminates.
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Chapter Four PERFORMANCE
Figure 4-19 Internal Blister Axisymetric Finite Element Model [Kokarakis and Taylor,
Theoretical and Experimental Investigation of Blistered Fiberglass Boats]
The fact that the distribution of blisters is apparently random has precluded any documented
cases of catastrophic failures attributed to blistering. The Repair Section (page 285) of this
document will deal with corrective measures to remove blisters.
As was previously mentioned, recent investigations have focused on what materials perform
best to prevent osmotic blistering. Referring to Figure 4-18, Layer A is considered to be the
gel coat surface of the laminate. Table 4-3 lists some permeation rates for three types of
polyester resins that are commonly used as gel coats.
Table 4-3 Composition and Permeation Rates for Some Polyester Resins used
in Gel Coats [Crump, A Study of Blister Formation in Gel Coated Laminates]
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Blisters Marine Composites
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Chapter Four PERFORMANCE
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