CLASS PROGRAMME

Type approval
DNVGL-CP-0083 Edition March 2016

Polyester resin, vinylester resin, gelcoat

and topcoat

The electronic pdf version of this document, available free of charge

from http://www.dnvgl.com, is the officially binding version.

DNV GL AS
FOREWORD

DNV GL class programmes contain procedural and technical requirements including acceptance
criteria for obtaining and retaining certificates for objects and organisations related to
classification.

© DNV GL AS March 2016

Any comments may be sent by e-mail to rules@dnvgl.com

This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this
document. The use of this document by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibility
for loss or damages resulting from any use of this document.
CHANGES – CURRENT

Changes - current
This is a new document.

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 Contents
CONTENTS

Changes – current.................................................................................................. 3

Section 1 General.................................................................................................... 5
1 Introduction.........................................................................................5
2 References........................................................................................... 6
3 Documentation.....................................................................................7

Section 2 General requirements..............................................................................8

1 Design requirements............................................................................8
2 Requirements to production and quality control arrangement............. 8
3 Description of type testing.................................................................. 9
4 Requirements to material.................................................................... 9
5 Gelcoats and topcoats....................................................................... 13
6 Requirements to marking of product................................................. 13

Appendix A Table for entry of type test results.................................................... 14

Changes – historic................................................................................................ 17

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SECTION 1 GENERAL

Section 1
1 Introduction

1.1 Objective
The objective of this class programme (CP) is to give a description for type approval (TA) of polyester resin,
vinylester resin, gelcoat and topcoat.
The general requirements for obtaining type approval is given in class programme DNVGL CP 0338 - DNV GL
type approval scheme.
The procedures and requirements described in this CP are applicable for obtaining DNV GL TA certificate
based on requirements in the Society's rules and standards, i.e.:
— DNV GL rules RU SHIP Pt.2 Ch.3
— DNVGL ST 0189, Lifeboats and Rescue Boats
— DNVGL ST 0342, Craft.
Guidance note:
This class programme is not applicable for obtaining EU Marine Equipment Directive (MED) certificates. Visit www.dnvgl.com for
information on MED certification.

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1.2 Scope
This CP gives a description of the procedures and requirements related to documentation, design and type
testing applicable for TA of polyester resin, vinylester resin, gelcoat and topcoat.
This CP does not set the design requirements to the polyester resin, vinylester resin, gelcoat and topcoat.
TA is based on compliance with design requirements given in the rules and standards. The CP describes how
to document compliance with the requirements in order to obtain a TA certificate for the equipment. This
includes, where relevant, technical requirements for how the type tests shall be performed.
This class programme includes requirements for:
— resins for structural laminates
— resins for fire retardant laminates for use in lifeboats
— gelcoats and topcoats
— fire retardant gelcoats and topcoats for use in lifeboats.
The approval of polyester and vinyl ester is divided into two different quality grades. Grade 1 and Grade 2
corresponds to grade A and grade B in ISO 12215-1:
Grade 1: Quality with good water resistance.
Grade 2: Quality with normal water resistance.
One type approval certificate will be valid for one quality of the actual product with the possibility to include
variants.
For polyester- and vinyl ester resins this means:
Grade: One base resin.
Variants: Different additives such as accelerators and thixotropic agents to modify the resin properties. All
variants shall fulfil the requirement to the same grade. Modification to reduce styrene emission is normally
considered as a new Grade.
As a minimum, the following properties will be printed in the type approval certificate:
— tensile strength
— fracture elongation

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— Barcol hardness

Section 1
— heat deflection temperature (HDT)
— water absorption
— density
— curing procedure used for type testing.
Deviation from the requirements may be accepted on a case-by-case basis and will be stated in the
certificate.
One type approval certificate is normally limited to one manufacturer at one production site, however, other
arrangements may be agreed with the Society.
Type tests as specified in Sec.2 [3] shall be carried out and verified in one of the following ways:
— at a DNV GL laboratory
— at a recognized and independent laboratory or a laboratory accepted by DNV GL
— at the manufacturer’s premises in the presence of a surveyor.

1.3 Application
DNV GL rules RU SHIP Pt.2 Ch.3 require that polyester- and vinylester resins, gelcoats and topcoats are type
approved in accordance with this CP for equipment to be installed on classed vessels.
A TA certificate in accordance with this CP will confirm compliance with the requirements in the DNV GL rules
as specified in [1.1]. The TA certificate will not confirm compliance with requirements in other parts of the
rules. In case additional requirements in other parts of the rules shall be covered by the TA certificate, this
shall be specified in the application for TA and will be stated in the TA certificate.

1.4 Renewal
Provided an approval of manufacturer certificate (see DNVGL CP 0425 Manufacturer of Fibre Reinforcements)
which is still valid for at least one year is available, an exemption from the obligation concerning retention
and renewal surveys listed in the class programme DNVGL CP 0338 Type Approval scheme will typically
apply.

2 References
Standards referred to in this document:
— ISO 9001:2008, Quality management systems - Requirements
— EN 59 (1977) Glass reinforced plastics. Measurement of hardness by means of a Barcol impressor.
— ISO 62 (2008) Plastics - Determination of water absorption
— ISO 75-2 (2004) Plastics - Determination of temperature of deflection under load - Part 2: Plastics and
ebonite
— ISO 178 (2010) Plastics - Determination of flexural properties
— ISO 527-1 (1993) Plastics - Determination of tensile properties - Part 1: General principles
— ISO 527-2 (1993) Plastics - Determination of tensile properties - Part 2: Test conditions for moulding and
extrusion plastics
— ISO 1675 (1985) Plastics - Liquid resins - Determination of density by the pyknometer method
— ISO 2535 (2001) Plastics - Unsaturated-polyester resins - Measurement of gel time at ambient
temperature
— ISO 2555 (1989) 2) Plastics - Resins in the liquid state or as emulsions or dispersions - Determination of
apparent viscosity by the Brookfield Test method
— ISO 2884-1 (1999) Paints and varnishes - Determination of viscosity using rotary viscometers - Part 1:
Cone-and-plate viscometer operated at a high rate of shear
— ISO 3251 (2008) Paints, varnishes and plastics - Determination of non-volatile-matter content

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— ISO 3521 (1997) Plastics - Unsaturated polyester and epoxy resins - Determination of overall volume

Section 1
shrinkage
— ISO 12215-1 (2000) Small Craft - Hull construction and scantlings - Part 1: Materials: Thermosetting
resins, glass-fibre reinforcement, reference laminate
— ASTM D2583 (2007) Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol
Impressor
— ASTM D2863 (2010) Standard Test Method for Measuring the Minimum Oxygen Concentration to Support
Candle-Like Combustion of Plastics (Oxygen Index)
— ASTM D5528 (2001/2007) Standard Test Method for Mode I Interlaminar Fracture Toughness of
Unidirectional Fibre-Reinforced Polymer Matrix Composites.

3 Documentation
For TA of polyester- and vinylester resins, gelcoats and topcoats the following additional documentation shall
be submitted by the manufacturer at initial type approval, and updated at renewal (general documentation
requirements are given in DNVGL CP 0338). The documentation shall, to the extent possible, be submitted
as electronic files. The manufacturer shall keep one (1) copy of type approval documentation in their own
file. The documentation that forms the basis for the TA shall be easily available for the Society's surveyors at
the TA applicant’s premises. When documentation is submitted in paper format, normally two copies of the
documentation shall be submitted to the Society. No documentation will be returned to the company applying
for TA.
Please number documentation according to below list to facilitate review:
1) Type designation, i.e. product name (grade) with list of variants to be included in and stated on the type
approval certificate
2) basis for approval. A reference to applicable rules and standards, see [1], which the product shall comply
with
3) product description (type of base resin, fillers etc.)
4) field of application and special limitations of the product (curing procedure, laminating technique/
procedure, shelf life, compatibility/non-compatibility with other materials, etc.)
5) product specification, including data sheets (TDS and MSDS) for all variants
1
6) description of production processes, including standard operating procedures (SOP).
7) description of quality assurance system or copy of ISO 9001 certificate
1
8) quality plan for material intended to be installed on board ships
9) test results (from tests already carried out) with references to standards, methods etc.
1
10) information regarding marking of the product or packaging
11) any relevant certificates with their issue number and/or date (e.g. quality management system
certificate)
2
12) list of test and measuring equipment, including calibration certificates.
13) in-service experience, if available
14) witnessed type test results and surveyor's initial assessment report shall be submitted when completed.

1
Will be verified by initial assessment prior to issuance of type approval certificate
2
Will be verified by surveyor during type testing

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SECTION 2 GENERAL REQUIREMENTS

Section 2
1 Design requirements
The polyester- and vinylester resins, gelcoats and topcoats shall comply with the relevant requirements given
in Sec.1 [1.1].

2 Requirements to production and quality control arrangement

The manufacturer should have a quality system that meets ISO 9001 standards, or equivalent. If this quality
standard is not fulfilled, the extent of type testing and assessments will be specially considered.
The quality control arrangement in production shall be checked with respect to:
— control of incoming materials
— scope of quality control, i.e. proof that test methods, test quantity and test equipment comply with the
applicable standard EN or ISO
— traceability and marking system
— production records
— storage condition and procedure.
The extent of the manufacturer's quality control during production shall as a minimum be according to Table
1.

Table 1 Manufacturer's quality control for polyester and vinyl ester in liquid condition.

1) Minimum level
Control on: Test standard Acceptance Criteria Frequency of control
of verification

Production log
Density ISO 1675 msv available during Each batch
assessment

ISO 2555 (1989)

2) Production log
(Brookfield) or
Viscosity msv ± 250 mPas available during Each batch
ISO 2884-1) (Cone/
assessment
plate)

DIN 16945, item Production log

Monomer content 4.10 msv ± 2% available during Each batch
ISO 3251 assessment

for curing time at room

temp.:
<60 minutes: msv ± 5
minutes Production log
3)
Gel time ISO 2535 available during Each batch of variants
60-120 minutes: msv ± 10
initial assessment
minutes
>120 minutes: msv ± 15
minutes

1) Other standards may be agreed upon with the Society prior to testing
2) for polyester and vinyl ester resins the following parameters should be used; Viscometer type A, rotational
frequency 10, temperature 23°C. Viscosity can be accepted with msv 20%
3) specify activator and initiator and % of each

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The manufacturer shall carry out delivery testing of each consignment. Measured values shall be filed and

Section 2
made available to the surveyor.
Tolerances for base resin and each variant shall be specified.

3 Description of type testing

The extent of type testing covers both the liquid resin properties in Table 1, or on an equivalent level, and the
cured resin properties in [4.4] and [4.5]. These tests shall ensure that the product properties are as stated
by the manufacturer.
Type testing results from all variants shall be submitted to the Society for evaluation, including a summary of
the type tests results in the enclosed table, App.A. If there are several similar variants a less extensive test
programme can be agreed upon with the Society.
Other standardised test methods than those given for the respective materials may be used upon agreement.
Liquid properties of resins will be checked according to product specification at DNV GL assessment.

4 Requirements to material

4.1 Resin properties

The manufacturer's description of product shall contain information about which manufacturing methods
the resin is suitable for; i.e.: lamination by hand lay-up, spraying, resin transfer moulding, vacuum bagging
method etc. The resin shall have good wetting properties and shall cure satisfactory at normal room
temperature, or at other specified curing condition.

4.2 Resin in solid condition

The requirements in this sub-section complies with the requirements in ISO 12215-1 (Small Craft - Hull
construction- and scantlings - Part 1: Materials: Thermosetting resins, glass-fibre reinforcement, reference
laminate), grade A and grade B.
For preparation of test samples the curing system shall be specified with type of accelerator and initiator and
% of each. Use of standard MEKP (active oxygen 9.0-9.2%) is preferable. The test samples for each variant
shall be made of the finished resin product and cured with one of the following curing procedures:
Normal curing: 24 hours at 23°C, followed by:
a) post curing: 24 hours at 50°C, or
b) post curing for resins with H.D.T. higher than 85°C: 24 hours at 60°C, or
c) curing systems requiring high temperature cure can be approved after special consideration.
Resin in solid condition shall be tested according to Table 2 at initial approval and at change of specification.
During Renewal Assessment some of the properties shall be confirmed by retesting, as indicated in Table 2.

Table 2 Testing of mechanical properties of the cured end product

Number of Acceptance criteria/data format Minimum level of

1)
Property Test standard
parallels Grade 1 Grade 2 Society verification

Initial assessment
3
Density ISO 1675 min. 3 msv msv g/cm Renewal
assessment

Volumetric curing shrinkage ISO 3521 min. 3 msv msv % Initial assessment

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 Acceptance criteria/data format

Section 2
1) Number of Minimum level of
Property Test standard
parallels Grade 1 Grade 2 Society verification

Initial assessment
2) mean mean
Ultimate tensile strength ISO 527-1 min. 9 MPa Renewal
min. 55 min. 45
assessment

Initial assessment
msv msv
Tensile modulus ISO 527-1,2 min. 9 MPa Renewal
min. 3000 min. 2700
assessment

Initial assessment
mean mean
Fracture elongation ISO 527-1,2 min. 9 % Renewal
min. 2.5 min. 1.5
assessment

mean mean
Ultimate flexural strength ISO 178 min. 5 MPa Initial assessment
min. 100 min. 80

msv msv
Flexural modulus ISO 178 min. 5 MPa Initial assessment
min. 2700 min. 2700

Measured Initial assessment

3) EN 59 msv msv
Barcol hardness on all test Renewal
ASTM D2583 4) min. 35 min. 35
specimens assessment

mean mean
Heat deflection temperature ISO 75-2 min. 3 °C Initial assessment
min. 70 min. 60

5) mean mean
Water absorption ISO 62 min. 3 mg Initial assessment
max. 80 max. 100

1) Other standards may be agreed upon with the Society prior to testing
2) test samples for tensile testing: ISO 527-2/1A or 1B/(1 - 5); test specimen 1A or 1B and test speed 1 to 5 mm/min
3) resin may deviate from these values, provided a minimum value of 30 is met and the manufacturer can demonstrate
adequate cure
4) Barcol hardness shall be measured on each specimen and shall comply with manufacturer's specified value
5) test sample 50 x 50 x 4 mm (± 1 x 1 x 0.2). Distilled water. Exposure time 28 days at 23°C. Resin may deviate
from these values, provided the water ageing properties are documented
Legends:

msv = manufacturer’s specified value, verified to be within ±10% of mean of type test results
mean = manufacturer's specified mean value, based on a minimum 2/3 of tested specimens

Comments to testing of cured resins:

Due to the nature of cured resins these may include pores and other defects, which may not be detrimental
in a fibre reinforced laminate, but in specimens for tensile testing (strength and fracture elongation) these
defects may give a rather large scatter in results and thereby large standard deviation. Similar effects may
be the result of machining/cutting of specimens, giving crack initiators. In order to compensate for this, one
third of tested specimens may be taken out from calculations. A minimum of 6 specimens shall, however, be
used when calculating the mean figure. If more than one third of samples need to be discarded a new full set
of tests to be carried out.
Removing of outliers:
— only outliers that are essentially different should be removed

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— the outliers should either be removed due to an identified cause or should be removed in order of the

Section 2
absolute distance from the mean value (first for all specimens tested, then for those left after first
removal of outliers)
— the outliers are removed one at the time and the statistical model is updated until maximum 1/3 of the
tested specimens are removed.

4.3 Requirements to low styrene emission (LSE) resins

Resins containing waxes or other substances (like DCPD resins or blends of DCPD), which might lower
external adhesive capacity shall be subjected to the delamination test according to Table 3:
Production of test piece:
2
1) a laminate consisting of five (5) layers of 450 g/m emulsion/powder bounded chopped strand mat
(CSM) with excess resin in the upper surface. Curing procedure: 48 hours at 23°C
2
2) a new laminate consisting of five (5) layers of 450 g/m emulsion/powder bounded CSM is built on the
first without any form of upper surface treatment
3) curing procedure as selected in [4.2]. Fibre weight fraction to be 35% ± 5%.
Production of reference piece:
2
1) a laminate consisting of ten (10) layers of 450 g/m emulsion/powder bounded CSM. Curing procedure
as selected in [4.2]. Fibre weight fraction to be 35% ± 5%.

Table 3 Interlaminar strength of LSE resins, double cantilever beam test.

1) Number of Minimum level

Property Test standard Requirements
parallels of verification

Min. 80% of mean strength in reference

Interlaminar Initial DNV GL
ASTM D5528, piece.
fracture toughness, 2) min. 5 assessment
Mode 1 The fracture shall not be a typical brittle
DCB Change of specification
fracture with smooth surfaces

1) Other standard may be agreed upon with the Society prior to testing
2) double cantilever beam test with high loading rate

4.4 Fire retardant resins for use in lifeboats

The finished resin including all fillers shall fulfil the requirements for liquid resin in Table 1, or on an
equivalent level, and cured resin in Table 2, Grade 2 and the requirements to combustibility in Table 4.

Table 4 Combustibility testing of fire retardant resin

1) Minimum level
Property Test standard Requirements
of verification

2) Initial DNV GL assessment

Combustibility ASTM D2863 Oxygen index min. 23
Change of specification

ISO 5660-1. Cone calorimeter

Fire retardant method Initial DNV GL assessment
3, 4) Average ignition time > 40 s
resins Also ref. LSA Code, MSC/Circ. Change of specification
1006

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 Minimum level

Section 2
1)
Property Test standard Requirements
of verification

Area of flame impingement should

not support combustion more than Initial DNV GL assessment
LSA Code, MSC/Circ. 1006
30 s after being removed from the Change of specification
burner

1) Other standard may be agreed upon with the Society prior to testing
2) since both ignition and flame resistance is covered by LSA Code, MSC/Circ. 1006 this test is voluntary and for
comparison with existing approvals
3) laminates to be prepared as per LSA Code, MSC/Circ. 1006
4) only laminates with coating (e.g. gelcoat or topcoat) shall be UV-exposed before testing according to ISO 5660-1, as
laminating resins are not designed to be UV-resistant

A finished resin with water absorption of 100-150 mg per test sample may be approved for use in lifeboats
with a comment in the certificate stating that:
“The water absorption is outside the requirements. Area of application will be evaluated during approval of
classified objects.”

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 Section 2
5 Gelcoats and topcoats
The gelcoat and topcoat shall be produced of base polyester that fulfils the requirements in [4.4] Grade 1
and Table 5.

Table 5 Properties of gelcoat/topcoat

1)
Property Test standard Requirements Minimum level of verification

2) 3) Initial DNV GL assessment

Fracture elongation ISO 527-1, 2 min. 2.0%
Change of specification

Complete covering shall be achieved

Initial DNV GL assessment
Covering within a thickness of maximum 400
Change of specification
mm of cured resin

1) Other standards may be agreed upon with the Society prior to testing
2) test of elongation shall be carried out only for gelcoat/topcoats containing more than 15% minerals and other filling
compounds
3) test sample shall be made of base resin covered with 400 µm cured gelcoat on each side and cured according to
procedure in [4.1]

5.1 Fire retardant gelcoats and topcoats for use in lifeboats

Fire retardant gelcoat and topcoat shall be produced of a base resin that fulfils the requirements to fire
retardant resins in [4.4] and shall be able to withstand long-term exposure to weathering without any visible
signs of crazing, outwash of matter or dramatic colour change.

6 Requirements to marking of product

The product or package shall be marked. The marking shall at least include the following information:
— manufacturer’s name and address or trade mark
— production plant
— product name (grade)
— storage instruction
— production date/batch number
— quality guarantee period, if any.
The marking shall be carried out in such a way that it is visible, legible and indelible. The marking of product
shall enable traceability to the type approval certificate.

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APPENDIX A TABLE FOR ENTRY OF TYPE TEST RESULTS

Appendix A
Please fill in the table and submit to the Society for evaluation.

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 Polyester resin, vinylester resin, gelcoat and topcoat
Class programme — DNVGL-CP-0083. Edition March 2016

Manufacturer's name and address: Product: name:

Renewal of cert. no:

Manufacturer's
Property Test method Requirement Type Test results
Specification

Std.
Uncured resin Average
deviation

ISO 2555
Viscosity msv ± 250 mPas
ISO 2884-1

Monomer content ISO 3251 msv ± 2%

for curing time at room temperature:

<60 min.: msv ± 5 min
Gel time ISO 2535
60-120 min.: msv ± 10 min
>120 min.: msv ± 15 min

Cured resin Grade 1 Grade 2

Density ISO 1675 msv (g/cm3) msv (g/cm3)

DNV GL AS

Volumetric curing shrinkage ISO 3521 msv (%) msv (%)

ASTM D2583
Barcol hardness msv min. 35 msv min. 35
EN 59

H.D.T. ISO 75-2 mean min. 70°C mean min. 60°C

Water absorption ISO 62 mean max. 80 mg mean max. 100 mg

Ultimate tensile strength ISO 527-1,2 mean min. 55 MPa mean min. 45 MPa

msv min. 2700

Tensile modulus ISO 527-1,2 msv min. 3000 MPa
MPa

Fracture elongation ISO 527-1,2 mean min. 2.5% mean min. 1.5%

Ultimate flexural strength ISO 178 mean min. 100 MPa mean min. 80 MPa

msv min. 2700

Flexural modulus ISO 178 msv min. 2700 MPa
MPa

Gelcoats

Covering requirement Max. 400 μm in cured condition

LSE resins: Interlaminar fracture Minimum 80% of mean strength of

ASTM D5528, Mode I
Page 15

toughness reference piece

Appendix A
 Polyester resin, vinylester resin, gelcoat and topcoat
Class programme — DNVGL-CP-0083. Edition March 2016

Manufacturer's name and address: Product: name:

Renewal of cert. no:

Elongation of gelcoat ISO 527-1,2 Minimum 2.0%

Fire retardant resins for lifeboats

Combustibility ASTM D2863 Oxygen index, minimum 23

DNV GL AS

Page 16

Appendix A
CHANGES – HISTORIC

Changes – historic
There are currently no historical changes for this document.

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 DNV GL
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