lamination instructions: volvo penta ips2* twin, triple

Fill with putty

Approx. 120 mm (4.72”)

Approx. 100 mm (4.0”)

Approx. 4 x 12 mm (0.5”)

Min. 50 mm (2”)

Min. 100 mm (4”)

Min. 50 mm (2”)

Lamination Instructions: Volvo Penta IPS2* Twin, Triple & Quadruple Installation, using Volvo Penta IPS Hull Mold Plugs or Pre-molded Inserts

Document N°: 47700598

Release date: 01-2010

General InformationLamination policyWhy 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 mini-mize 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 ground-ing where the drives are designed to shear off under certain conditions. Extensive full scale testing and calculations con-ducted by Volvo Penta show that forces generated in an under-water 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.

* IPS800/900Lamination Instructions: Volvo Penta IPS2* Twin, Triple & Quadruple Installation, using Volvo Penta IPS Hull Mold Plugs or Pre-molded Inserts

Glass information

E-LTM

A

B

A

A – A B – B 600 mm (24”)

B

Hull mold plug

E-BXM

Pre-molded hull insert

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)

Core information IMPORTANT! Core material must be off a material with

hardness ≥ 60 kg/m3 (3.8 lb/ft3) (also known as 60H) or similar.

IMPORTANT! The use of general hull core material does not yield any deviations from the instructions regarding Volvo Penta IPS reinforcements.

Volvo Penta IPS Hull Mold Plugs and Pre-molded InsertsWhen building a boat using a hull mold, the Volvo Penta IPS hull mold plugs are used for laminating the IPS seats.

If a Volvo Penta IPS system is to be installed into a boat of a general hull construction, pre-molded inserts are built into the existing hull. Pre-molded inserts can not be used for the center drive unit in triple installations.

Lamination instructions on this poster applies on both hull mold plugs and pre-molded inserts.

NOTE! Pictures in the following instructions show Volvo Penta IPS hull mold plugs.

See separate poster: Installation Reference Volvo Penta IPS2: Hull Insert and Engine Foundation or Installation Manual for placing of Volvo Penta IPS hull mold plugs/inserts.

Rekommended layup

Layer no Mats Total density, g/m2(oz/yd2)

Lamination thickness, mm (in.)

1 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

2 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

3 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

4 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

5 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

6 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

7 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

8 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

9 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

10 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

10.1 (Quad**) E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

11 E-BXM (+45°/-45°) 1075 (31.7) 1.4 (0.06)

12 E-BXM (+45°/-45°) 1075 (31.7) 1.4 (0.06)

13 E-BXM (+45°/-45°) 1075 (31.7) 1.4 (0.06)

14 E-BXM (+45°/-45°) 1075 (31.7) 1.4 (0.06)

15 E-BXM (+45°/-45°) 1075 (31.7) 1.4 (0.06)

15.1 (Quad**) E-BXM (+45°/-45°) 1075 (31.7) 1.4 (0.06)

15.2 (Quad**) E-BXM (+45°/-45°) 1075 (31.7) 1.4 (0.06)

16 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

17 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

18 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

19 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

20 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

21 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

22 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

23 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

24 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

25 E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

25.1 (Quad**) E-LTM (0°/90°) 1075 (31.7) 0.9 (0.04)

Requirements:

≥ 25 ≥ 26 875 (792.8) ≥ 25 (1.0)

≥ 29 (Quad**) ≥ 31 175 (919.6) ≥ 30 (1.2)

IMPORTANT! Alternative directed fiber mats (not CSM) of density less than 1075 g/m2 (31.7 oz/yd2) may be used 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).

IMPORTANT! Secondary bondings must be avoided for the lamination.

NOTE! If Volvo Penta pre-molded hull inserts are used, the lamination layers are added to the insert thickness.

IMPORTANT! A mat overlap of minimum 50 mm (2”) on the hull mold plug/insert must be ap-plied.

IMPORTANT! To ensure good mat con-tour fit, mat density of the first layers must not exceed 1075 g/m2 (31.7 oz/yd2).

Extend mats higher than marking on plug. If inserts are used, extend mats up to top of insert.

IMPORTANT! The bonding surfaces of the pre-molded ring must be lightly grinded (even if it is already grinded when supplied from Volvo Penta) and cleaned from surface contaminates before it is used.

Cross sections

First layer Layers 2–25

IMPORTANT! The mat lengths must be extended for every layer to ensure proper slope, see cross section fig-ure. First layer must extend minimum 100 mm (4”) from the hull mold plug.

If pre-molded inserts are used, make sure mats are ex-tended minimum 100 mm (4”) from end of insert flange.

IMPORTANT! Each layer must be extended minimum 50 mm (2”) from the previous layer.

NOTE! In order to avoid thicker areas each layer should be rotated.

NOTE! Transom thickness, same as bottom, applies 600 mm (24”) from bottom and up.

Grind a wedge in the hull to approx. half the thickness. This will ensure a good at-tachment area.

Approx. slope 1:12

Filling irregularities

Grinding hullPre-molded inserts only

IMPORTANT! Putty must be high glass fiber content mix.

IMPORTANT! Putty must not be used in the v-groove be-fore step is completed.

1. Grind a wedge from outside in hull.

2. Laminate transition.

3. Grind to a smooth area.

IMPORTANT! Core material must be off a material with density ≥60 kg/m3 (3.8 lb/ft3) or simi-lar.

IMPORTANT! Adjust core dimensions to meet final ring measurement requirements (see figure).

Placing reinforcement rings

1

Lamination layers

Grinding and laminating hull

Laminating the plug/insert43

2

6

Result in hull mold5

Bottom thickness requirementsRefer to step Zones of requirement.

7

8

Placement of Volvo Penta IPS Hull Mold Plugs/Inserts

Lamination of Volvo Penta IPS Hull Mold Plugs/Inserts

Placement of Reinforcement RingsOutside Hull LaminationVolvo Penta IPS pre-molded inserts only

Final measurements requirements Ring core dimensions

NOTE! Pictures do not show correct scale.** Volvo Penta IPS quadruple installations

4

Hull mold plug/insert

Inner laminate, see

Outer laminate, see 11

4

Ring core137 ±10 mm (5.4” ±0.4)

157 ±10 mm (6.2” ±0.4)

Insert

Insert

Insert

Hull

Hull

Hull

IMPORTANT! Within zone A, both Volvo Penta requirements found in “Lamination of Volvo Penta IPS hull mold plugs/Inserts” ( ) and gen-eral scantling rules applies. Minimum required hull bottom thickness within this zone is given by the thickest requirement of these.

2

Zone A

950 mm (37.4”)

1250 mm (49.2”)

4

17

NOTE! The reinforcement ring core can be made of several segments.

Fill with putty

Min. 100 mm (4”)

Min. 50 mm (2”)

Min. 50 mm (2”)

4770

0598

01-

2010

Placing reinforcement beams

IMPORTANT! Core material must be off a material with density ≥60 kg/m3 (3.8 lb/ft3) or similar.

IMPORTANT! Drainage holes in any rein-forcement beam must not have a diameter larger than 25 mm (1”).

13

Lamination layers14

Placement of Reinforcement Beams and Engine Bed

Lamination of Reinforcement Beams Laminating reinforcement beams

IMPORTANT! There must be an min. extension of 50 mm (2”) for each layer to ensure prop-er slope. First layer must extend mini-mum 100 mm (4”) from the beam core.

15

Fill with putty


Construction of engine bed

Final Result After Lamination

Final geometry16

Zones of requirement17

IMPORTANT! Within zone A, both Volvo Penta require-ments found in “Lami-nation of Volvo Penta IPS hull mold plugs/Inserts” ( ) and general scant-ling rules applies. Minimum required hull bottom thickness within this zone is given by the thickest requirement of these.

2 4

IMPORTANT! Zone B refers to the lamination of the reinforcement rings and the rein-forcement beams. See requirements in steps

and

9 12

14 15

Zone A Zone A Zone AZone B Zone B Zone B

See Installation Manual and drawings for engine bed construction and dimensions.

Result in hull mold12

Filling transitions


Laminating reinforcement rings

First layer Layers 2–12

NOTE! In order to avoid thicker areas each layer should be rotated.

NOTE! Mats should be extended up on the aft bulkhead (transom) when applicable.

Mat contour fit

Ensure good mat contour fit. Extend mats higher than marking.

Cross section

IMPORTANT! The mat lengths must be ex-tended for every layer to ensure proper slope, see cross section figure. First layer must extend minimum 100 mm (4”) from the ring core.

IMPORTANT! Minimum 50 mm (2”) overlap must be applied between the mats. This yields even if narrower mats are used.

1110

Lamination layers

Layer no

Mats Total density, g/m2(oz/yd2)


1–12 E-BXM (+45°/-45°) or E-LTM (0°/90°), or both alternated

Max. 1075 (31.7) -

Requirements:

≥ 12 ≥ 12 900 (380.5) ≥ 12 (0.5)

Layer no

Mats Total density, g/m2(oz/yd2)


1–12 E-BXM (+45°/-45°) or E-LTM (0°/90°), or both alternated

Max. 1075 (31.7) -

Requirements:

≥ 12 ≥ 12 900 (380.5) ≥ 12 (0.5)

IMPORTANT! Alternative directed fiber mats (not CSM) of density less than 1075 g/m2 (37.1 oz/yd2) may be used as long as minimum requirements for number of layers, total density and total mat thickness are met.


IMPORTANT! Alternative directed fiber mats (not CSM) of density less than 1075 g/m2 (37.1 oz/yd2) may be used as long as minimum requirements for number of layers, total density and total mat thickness are met.


9

Lamination of Reinforcement Rings

Aft beams: 3 x 120 mm (4.7”)

Side beams: 4 x 120 mm (4.7”)

950 mm (37.4”)

1250 mm (49.2”)

1250 mm (49.2”)

1250 mm (49.2”)

950 mm (37.4”) 950 mm

(37.4”)

45°

A A

CC

A – A

C – C

NOTE! If inserts are used, extend mats to top of inserts.

IMPORTANT! Make the height of the rein-forcement beams so that it corresponds to the already laminated reinforcement ring.

Ring coreReinforcement beam

lamination instructions: volvo penta ips2* twin, triple

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