Rules for Classification and Construction

VI Additional Rules and Guidelines

9 Materials and Welding

5 Guidelines for the Approval of Reaction Plastics and Composite Materials

for the Seating and Repair of Components

Edition 2006
 The following Guidelines come into force on June 1st, 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
Table of Contents
VI - Part 9 Table of Contents Chapter 5
GL 2006 Page 3

Section 1 Approval of Reaction Plastics and Composite Materials for the Seating and Repair
of Components
A. General ....................................................................................................................................... 1- 1
B. Approval Conditions .................................................................................................................. 1- 1
C. Approvals ................................................................................................................................... 1- 3
D. Realization of Seatings and Repairs ........................................................................................... 1- 4
VI - Part 9 Section 1 B Approval of Reaction Plastics and Composite Materials for
GL 2006 the Seating and Repair of Components
Section 1
Approval of Reaction Plastics and Composite Materials for
the Seating and Repair of Components
A. General
1. Scope
These Guidelines define the provisions for the manu-
facturing, approval and application of reaction plastics
and composite materials for the seating of machinery
and ship installations including grouting of rudder
bearings and stern tubes as well as repair of compo-
nents.
The usual kinds of application are casting, injecting
and scraping.
2. Definitions
For the purpose of these Guidelines of Germanischer
Lloyd (GL), the following definitions apply:
2.1 Reaction plastics
Reaction plastics generally consist of two components
as well as eventually further additions and are harden-
ing by a chemical reaction between them. An element
of the surrounding atmosphere may be included in the
reaction as well. In the following reaction plastics will
be designated as material.
2.2 Thermosetting resins
Thermosetting resins are reaction plastics capable of
being processed before the chemical hardening.
2.3 Composite material
A composite material is a construction material con-
sisting of two or more different materials. Here com-
posite materials are considered which consist of reac-
tion plastics and embedded fibres or other solids.
These composite materials have quasi-isotropic char-
acteristics where the fibres are distributed in homoge-
nous form, have limited size and can be of metallic,
ceramic, mineral or polymer form. In the following
composite materials as well as reaction plastics ac-
cording to 2.1 will be designated as material.
2.4 Basic materials
Basic materials are the metallic and non-metallic ma-
terials of which the components to be seated or re-
paired are made of and which are directly bonded to
the materials according to 2.1 and 2.3.
Chapter 5
Page 1–1
2.5 Material manufacturer
A material manufacturer is the company which manu-
factures the ready-to-use dispersion of the materials
from the initial components. The material manufac-
turer defines also the application procedure and possi-
ble application ranges for his material.
The material manufacturer may be at the same time an
application enterprise according to 2.7.
2.6 Licensed material producer
A licensed material producer is a company which has
got a license for the production of the materials ac-
cording to 2.1 and/or 2.3 from the material manufac-
turer according to 2.5.
2.7 Application enterprise
An application enterprise is an enterprise which car-
ries out the seating and/or repair work with the materi-
als according to 2.1 and/or 2.3 observing the applica-
tion procedure defined by the material manufacturer
according to 2.5.
2.8 Authorized application company
An authorized application company is a company
which is authorized by the material manufacturer
according to 2.5 or by an application enterprise ap-
proved by GL according to 2.7 for the application of
the GL approved materials according to 2.1 and/or 2.3.
B. Approval Conditions
The following approval conditions have to be met:
1. Approval conditions for the materials
1.1 Definition of the application range
The intended ranges and possibilities for application
are to be defined, considering detailed parameters
depending on the specific application as for instance:
– ranges of application
– basic materials, compare definition in A.2.4
– temperature ranges for the application
Chapter 5 Section 1 B Approval of Reaction Plastics and Composite Materials for
Page 1–2 the Seating and Repair of Components
1.2 Definition of the individual components of
the materials
The definition has to be established in a way to allow
a definite identification of the material:
– trade designation
– manufacturer
– description of the individual components
– storage ability and storage conditions
– safety data sheet
1.3 Definition of the application conditions
The following information, at a minimum, has to be
defined for the application conditions:
– flammability
– viscosity
– density
– reactivity (acid number respectively epoxy
equivalent)
– instruction for application procedure
– ambient conditions for the application
– gelling time, temperature sequence
– curing conditions, tempering
– minimum curing time before taken into opera-
tion respectively loading, against different am-
bient temperatures
– permissible minimum and maximum heights of
chocks, layer thickness respectively casting slot
measures
– shrinkage
– surface treatment of basic materials
1.4 Definition of the material characteristics in
cured condition
1.4.1 Selection of characteristics
On the basis of the application range GL defines the
material characteristics which have to be proven.
The tests have to be carried out by recognized material
testing institutes. The results are to be stated in de-
tailed test reports.
The minimum and maximal acceptable values of the
characteristic parameters including the testing condi-
tions will be defined thereby for the intended applica-
tion in co-operation between the material manufac-
turer and GL.
1.4.2 Characteristics
The selection of the material characteristics, as de-
fined in 1.4.1, has to be made from the following
compilation:
VI - Part 9
GL 2006
– modulus of elasticity (compression) according to
ISO 604
– surface hardness according to EN 59 and re-
quired minimum hardness according to Barcol
before loading and fixing of the seating screws
– tensile strength according to ISO 527
– tensile shear strength according to EN 1465
– compression strength according to ISO 604
– shear strength according to ASTM D732
– adhesive strength to the basic material
– compatibility with the basic material
– shear modulus according to DIN 53399
– breaking elongation according to ISO 527
– bending strength according to ISO 178
– notch impact strength according to ISO 180
– shrinkage according to ASTM D635 or DIN
53464
– flammability according to ASTM D635 or ISO
R1210
– compressive deformation under load according
to ASTM D621
– for seatings:
loading time 24 h
test temperature [°C]: –30/+23/+50/+70/+100
loading [N/mm2]: 3,5/7/14/28
– coefficient of thermal expansion according to
DIN 53752
– coefficient of friction against steel: specimen ma-
chined / cast-in, with/without separating agents
– resistance to media of the application range in
question according to ISO 175
– thermal resistance according to ISO 75
– further parameters, as applicable
1.5 Further statements
– details of after treatment
– ability to recycling
2. Approval conditions for the material
manufacturer
2.1 Production facilities
The material manufacturer has to proof the suitability
of his production plant.
2.2 Quality assurance
The material manufacturer has to ensure the constant
quality of the material by applying a recognized qual-
VI - Part 9 Section 1 C Approval of Reaction Plastics and Composite Materials for
GL 2006 the Seating and Repair of Components
ity management system concerning the manufacturing
process and the material in question.
2.3 Production locations
The production locations of the material manufacturer
have to be reported to GL. It has to be ensured, that
the quality management system defined in 2.2 is relia-
bly applied also at these locations.
If new production locations of the material manufac-
turer are added or locations are closed, this has to be
reported to GL immediately.
3. Approval conditions for licensed material
producers
3.1 License conditions
In the case that a GL approved material manufacturer
intends to give a production license for an approved
material to a producer outside of his enterprise, this is
subject to approval by GL in advance.
3.2 The licensee has also to meet the conditions
according to 2.1 to 2.3.
4. Approval conditions for application enter-
prises
4.1 Equipment
Application enterprises shall have suitable equipment
which enables a professional storage and application
of the material. Besides others, the following docu-
ments have to be presented:
– summery of the applied materials
– intended ranges of application
– description of the application procedure and of
specimens and tests accompanying the applica-
tion
– storage and treatment rooms
– equipment for application and possibilities for
after treatment
4.2 Personnel
Application enterprises must have trained personnel
which follows the framework conditions specified in
the Approval Certificate and which is able to perform
the application in a professional way. The qualifica-
tion and the area of responsibility of the personnel
have to be reported.
4.3 Quality assurance
The application enterprise has to ensure the constant
quality of the material by applying a recognized qual-
ity management system.
Chapter 5
Page 1–3
5. Conditions for authorized application
companies
5.1 Authorization
An approved application enterprise may authorize
application companies, but has to notify GL promptly.
5.2 Conditions
An authorized application company has also to meet
the conditions according to 4.1 to 4.3 and to prove
compliance with to the authorizing enterprise.
5.3 Further authorization
An authorized application company may authorize
further application companies, if the conditions 4.1 to
4.3 are met and are surveyed by the authorizing com-
pany. The data concerning the fresh authorization has
to be reported promptly to GL via the approved appli-
cation enterprise.
5.4 It has to be ensured, that at GL Head Office a
complete listing of all application companies can be
kept.
C. Approvals
1. Inquiry for approvals
Inquiries for approvals have to be addressed by mate-
rial manufacturers and application enterprises to the
Head Office of GL.
2. Material approval
If the adherence of the conditions according to B.1. is
proven in the approval order with satisfying test re-
sults, GL may grant a material approval.
With consent and co-operation of a material manufac-
turer a material approval may be inquired also by an
application enterprise. In this case the material manu-
facturer has to guarantee for the validity of the mate-
rial approval that all relevant information, which has
an influence on the data defined for the approval, are
transferred to the owner of the material approval. With
consent of the owner of the material approval the
material approval may also be quoted by further appli-
cation enterprises.
3. Manufacturer approval
If the adherence of the conditions according to B.2. or
B.3. is proven in the order for approval, GL may grant
a manufacturer approval. The manufacturer approval
is to be exclusively applied for by the material manu-
facturer.
Chapter 5 Section 1 D Approval of Reaction Plastics and Composite Materials for
Page 1–4 the Seating and Repair of Components
4. Application approval
If the adherence of the conditions according to B.4. is
proven in the order for approval, GL may grant an
application approval.
5. Combined approval
The approvals according to 2. to 4. may be, if neces-
sary, summarized in one Certificate.
6. Validity of approvals
6.1 The validity of the approvals is 5 (five) years.
6.2 GL reserve the right to survey the quality
management system of approved enterprises and com-
panies during the validity of the approval. If the re-
sults of the survey are not successful, the approval
may be withdrawn by GL.
6.3 GL reserve the right to ask for or to execute
checks of the material characteristics during the valid-
ity of the approval. If the results are not satisfying in
comparison to the approved values, the approval may
be withdrawn by GL.
6.4 In case of changes of the material or of the
application procedures, which have influence on the
data defined for the approval, a new approval or ex-
tension of the approval has to be applied for at GL.
7. Extension of approvals
7.1 An extension of approvals has to be inquired
at GL Head Office at least three months before expiry
of the validity.
7.2 On request by GL an actual documentation
has to be submitted. If the review of this documenta-
tion does not show noteworthy deviations in the com-
position of the material as well as of the applied
manufacturing and application procedures, the ap-
provals may be renewed for further 5 (five) years.
D. Realization of Seatings and Repairs
1. Materials
All materials to be used for seatings and repairs have
to be suitable for the intended application and have to
be approved by GL.
VI - Part 9
GL 2006
These materials are only to be used in conjunction
with basic materials with which they exhibit long-term
compatibility and due to which the basic material does
not undergo a change.
2. Seating
For seating work Part 4 – Diesel Engines, Chapter 3 –
Guidelines for the Seating of Propulsion Plants and
Auxiliary Machinery, has to be observed.
3. Repairs
Planned repair activities for components which affect
or might affect the Class of the ship have to be re-
ported in advance to GL. On request of GL appropri-
ate repair procedures and plans have to submitted for
approval, see also GL Rules I – Ship Technology, Part
0 – Classification and Surveys, Section 2, B.3.
The use of materials shall not lead to inadmissible
alterations of the construction and in particular func-
tion, lifetime and strength of the construction are not
to be impaired.
In principle repair work has to be classified as tempo-
rary. Its durability has to be surveyed by GL after a
suitable time and has to be attested if need be.
4. General requirements
4.1 Seatings and repairs are only to be performed
by application enterprises approved by GL and by
their authorized application companies respectively.
4.2 The application procedures of the material
manufacturer have to be observed and have to be
documented in appropriate work instructions and
quality plans respectively.
4.3 If the dispersion of the individual compo-
nents of the material is done by the application enter-
prise or the application company, the composition has
to be documented and a reference specimen has to be
taken from each mixture.
4.4 The application of the quality management
system of the application enterprise and application
company, respectively, has to ensure the prescribed
storage and the professional application of the mate-
rial.
5. Surveillance by GL
Seating and repair work is to be carried out under
supervision of GL Surveyors.