General information Placement of Volvo Penta IPS hull inserts Lamination instructions Volvo Penta IPS * Twin & Quadruple installation, using Volvo Penta IPS hull insert 1 Lamination policy 2 Glass information E-BXM E-LTM E = E-Glass L = Longitudinal direction (0°) T = Transverse direction (90°) LT = 0°/90° Biaxial BX = +45°/-45° Biaxial or Double Bias M = Chopped strand mat (CSM) See separate poster; Installation Reference, Volvo Penta IPS Hull Insert and Engine Foundation or Installation Manual for placing of Volvo Penta IPS hull inserts Why use Volvo Penta hull requirements? The purpose of this lamination poster is to guide the design and integration of the Volvo Penta IPS system into the hull structure. These requirements emphasize the stringer design and hull construction requirements established by Volvo Penta to minimize the risk of water intrusion in the event of groundings. Normal scantling rules (e.g., ISO 12215) focus on variables such as propeller thrust, steering forces, mass of machinery, etc. The Volvo Penta IPS hull requirements focus on ensuring an adequate structure to keep the hull intact in a hard grounding where the drives are designed to shear off under certain conditions. Extensive full scale testing and calculations conducted by Volvo Penta show that forces generated in an underwater collision or grounding are more than 10 times higher than protection afforded by following traditional scantling rules. IMPORTANT! The Volvo Penta IPS is designed to function as an integrated part of the hull and laminate structure. The strength of the entire system is dependant on the integrated strength of the IPS and the hull and laminate structure. The strength of the hull structure is dependant upon a number of factors including shape, fiberglass quality and strength, type and quality of resin, lamination conditions, laminator skill, etc. The ultimate responsibility to ensure that all Volvo Penta IPS hull are produced consistently with these requirements rests exclusively with the boat builder. 3 Core information IMPORTANT! Core material must be off balsa, plywood or plastic foam material with hardness ≥ 60 kg/m3 (3.8 lb/ft3) (also known as 60H) or similar IMPORTANT! This instruction replace prevoius lamination instructions found in drawing no. 3591073 IMPORTANT! The use of general hull core material does not yield any deviations from the instructions regarding Volvo Penta IPS reinforcements * IPS350/400/450/500/550G/600 47700597 - 1(6) 09-2009
E = E-GlassL = Longitudinal direction (0°)T = Transverse direction (90°)LT = 0°/90° Biaxial BX = +45°/-45° Biaxial or Double BiasM = Chopped strand mat (CSM)
See separate poster; Installation Reference, Volvo Penta IPS Hull Insert and Engine Foundation or Installation Manual for placing of Volvo Penta IPShull inserts
Why use Volvo Penta hull requirements?
The purpose of this lamination poster is to guide the design and integration of the Volvo Penta IPS system into the hull structure. These requirements emphasize the stringer design and hull construction requirements established by Volvo Penta to minimize the risk of water intrusion in the event of groundings.Normal scantling rules (e.g., ISO 12215) focus on variables such as propeller thrust, steering forces, mass of machinery, etc. The Volvo Penta IPS hull requirements focus on ensuring an adequate structure to keep the hull intact in a hard grounding where the drives are designed to shear off under certain conditions. Extensive full scale testing and calculations conducted by Volvo Penta show that forces generated in an underwater collision or grounding are more than 10 times higher than protection afforded by following traditional scantling rules.
IMPORTANT!The Volvo Penta IPS is designed to function as an integrated part of the hull and laminate structure. The strength of the entire system is dependant on the integrated strength of the IPS and the hull and laminate structure. The strength of the hull structure is dependant upon a number of factors including shape, fiberglass quality and strength, type and quality of resin, lamination conditions, laminator skill, etc. The ultimate responsibility to ensure that all Volvo Penta IPS hull are produced consistently with these requirements rests exclusively with the boat builder.
3
Core information
IMPORTANT! Core material must be off balsa, plywood or plastic foam material with hardness ≥ 60 kg/m3 (3.8 lb/ft3) (also known as 60H) or similar
IMPORTANT! This instruction replace prevoius lamination instructions found in drawing no. 3591073
IMPORTANT! The use of general hull core material does not yield any deviations from the instructions regarding Volvo Penta IPS reinforcements
* IPS350/400/450/500/550G/600
47700597 - 1(6) 09-2009
NOTE! Mats should be extended at least 150 mm (6”) up on the aft bulkhead (transom)
IMPORTANT! If narrower mats are used a mat overlap of minimum 50 mm (2”) on the hull insert must be applied
Lamination of Volvo Penta IPS hull insertsLamination layers
Mat contour fitCross sections
NOTE! Pictures do not show correct scale
IMPORTANT! Alternative directed fiber mats (not CSM) of density less than 1500 g/m2
(44.3 oz/yd2) may be used from layer # 4 as long as minimum requirements for number of layers, total density and total mat thickness are met. All mats must be of both type +45°/-45° and 0°/90°. These mats should be altered in similar way as in recommended layup (see table above).
4
6
8 Result in hull
IMPORTANT! If vacuum infusion is used a total thickness of minimum 21 mm (0.8”) must still be met
IMPORTANT! The mat lengths must be extended for every layer to ensure proper slope, see cross section figures. First layer must extend minimum 100 mm (4”) from the hull insert.
NOTE! Ensure good mat contour fit. Extend mats up to the top off hull insert
IMPORTANT! Secondary bondings must be avoided for the lamination
NOTE! All pictures in this poster show a standard 2 degree toe-in installation
47700597 - 2(6) 09-2009
5 Grind hullNOTE! Grind a wedge in the hull to approximate half the thickness. This will ensure a good attachment area.
7 Outside hull lamination
NOTE! Grind and laminate from outside to avoid weak points
Sectional view
Sectional view
Lamination of reinforcement ringsLamination layers11
Result in hull mold14
Mat contour fitIMPORTANT! Minimum 50 mm (2”) overlap must be applied between the mats. This yields even if narrower mats are used
NOTE! Mats should be extended up on the aft bulkhead (transom) when applicable
13
NOTE! In order to avoid thicker areas each layer should be rotated
IMPORTANT! Alternative directed fiber mats (not CSM) of density less than 1500 g/m2 (44.3 oz/yd2) may be used as long as minimum requirements for number of layers, mat density and total mat thickness are met
12 Sectional view
IMPORTANT! Putty must be high glass fiber content mix
IMPORTANT! The mat lengths must be extended for every layer to ensure proper slope, see cross section figure. First layer must extend minimum 100 mm (4”) from the ring core
Cross section
NOTE! Ensure good mat contour fit. Extend mats all to the upper edge of hull insert
IMPORTANT! Secondary bondings must be avoided for the lamination
47700597 - 3(6) 09-2009
Placement of reinforcement rings
Result in hull mold
Top view
9
NOTE! The reinforcement ring core can be made of several segments
IMPORTANT! Core material must be off balsa, plywood or plastic foam material with density ≥60 kg/m3 (3.8 lb/ft3)
Final measurement requirements
Sectional view
IMPORTANT! Adjust core dimensions to meet final ring measurementrequirements (see figure)
10
IMPORTANT! Dimension the core so that final ring measurement requirements are met, see
Lamination of reinforcement beamsLamination layers
Attachment of engine bed
17
See Installation Manual and drawings for engine bed constructionand dimensions
19 IMPORTANT! Attachment of the engine bed stringers must be made to the forward part of the reinforcement ring and approximately at a 90 degree angle from the ring
18
W2 ≈ W1IMPORTANT! Maintain the width of the engine bed stringers all the way up to the reinforcement ring
IMPORTANT! Alternative directed fiber mats (not CSM) of density less than 1500 g/m2 (44.3 oz/yd2) may be used as long as minimum requirements for number of layers, mat density and total mat thickness are met
IMPORTANT! Fill transition first with putty of high fiber content mix to ease the mat layup
Construction of engine bed
IMPORTANT! If lamination mats are divided into several segments a minimum overlap of 50 mm (2”) must be applied
IMPORTANT! Mat length must be extended for each layer. There must be is a minimum extension of 50 mm (2”) for every layer to ensure a proper slope. First layer must extend minimum 100 mm (4”) from the beam core (see figure to the right)
IMPORTANT! Secondary bondings must be avoided for the lamination
47700597 - 4(6) 09-2009
Placement of reinforcement beamsResult in hull mold
16
20
Sectional view
IMPORTANT! Beams must be long enough to meet both reinforcement ring and inner transom bulkhead or compartment sides
IMPORTANT! The aft beam must be placed aft of the reinforcement ring and in line with the centerline of the hull insert
IMPORTANT! Drainage holes in any reinforcement beam must not have a diameter larger than 25 mm (1”). For the aft reinforcement beam the hole should be placed in the center of the beam
15
IMPORTANT! Core material must be off balsa, plywood or plastic foam material with density ≥60 kg/m3 (3.8 lb/ft3) or similar 9
Quadruple installations
Lamination of Volvo Penta IPS hull insertsSee procedure as for Twin Volvo Penta IPS installation; ⇒ 8-4
Placement of reinforcement ringsSee procedure as for Twin Volvo Penta IPS installation; ⇒ 9 10-
Placement of Volvo Penta IPS hull insertsSee separate poster; Installation Reference, Volvo Penta IPS Hull Inserts and Engine Foundation or Installation Manual for placing of Volvo Penta IPS hull inserts23
24
26
25 Result in hull
47700597 - 5(6) 09-2009
Final result after laminationZones of requirements21 22Final geometry
IMPORTANT! Within zone A, both Volvo Penta requirements found in "Lamination of Volvo Penta IPS hull inserts" ( ) and general scantling rules applies. Minimum required hull bottom thickness within this zone is given by the thickest requirement of these.
8-4
IMPORTANT! Zone B refers to the lamination of the reinforcement rings and the reinforcement beams. See requirements in and14-11 18-17
Quadruple installations
Lamination of reinforcement beamsSee procedure as for Twin Volvo Penta IPS installation; ⇒ 17 18-
Attachment of engine bedSee procedure as for Twin Volvo Penta IPS installation; ⇒ 19
Construction of engine bedSee Installation Manual for engine bed construction and dimensions
Final resultFinal geometry Zones of requirements
31 32
33 34
35 36
Result in hull
IMPORTANT! Within zone A, both Volvo Penta requirements found in "Lamination of Volvo Penta IPS hull inserts" ( ) and general scantling rules applies. Minimum required hull bottom thickness within this zone is given by the thickest requirement of these.
IMPORTANT! Zone B refers to the lamination of the reinforcement rings and the reinforcement beams. See requirements in and
8-414-11 18-17
47700597 - 6(6) 09-2009
Placement of reinforcement beamsSee procedure as for Twin Volvo Penta IPS installation; ⇒ 15 16-29 Result in hull
See procedure as for Twin Volvo Penta IPS installation; ⇒ 11 14-Lamination of reinforcement rings
