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Overview
Introduction to repairing GRP Principal Products Required Choice of Hardener Filler Ingredients Preparation Guideline for Filling on Different Substrates Co bination !uantities of Resin and Filler Ingredients Ordering Resin S"ste and Fillers #easuring out $po%" Resin and Hardener b" &eight 'sing $po%" Filler in Fairing Curing &or(ing with Cured $po%" Filler
*or marine use especially$ epo"y resin based fillers are far superior to those based on polyester resin as they are inherently more water resistant$ shrink less during curing$ are more adhesive and have a higher degree of toughness and strength. #lthough epo"y!based fillers cost more they are the only type recommended for boat hulls. he epo"y resin and hardener can be supplied with filler additions pre!mi"ed into one or both components as a 'formulated' filler$ but most professional users working on a large scale prefer to create their own mi" by using a liquid epo"y resin system and low density filler 'powders'. his gives the user considerably more control over application and working properties over a wide range of working conditions. he user can vary the quantity of filler added to create 'thick' or 'thin' mi"es. he resin system will have a number ,usually at least -. of different hardeners$ each of which will offer different levels of reactivity when mi"ed with the resin component. his approach is referred to as the /recipe/ method. Resin systems have roughly the same working properties ,pot!life$ gel time etc.. when used with their fast hardeners. he gel times of systems using fast hardeners range from about 01!02 minutes. 3owever$ the term 'slow' for a hardener is only relative$ such that the gel time for one system's slow hardener may be much longer than another system's slow hardener ,e.g. from 04 minutes to -51 minutes.. he reader is advised to consult the data sheets of the products and note the 'gel times' of the proposed hardener and resin mi"es$ as this will give a relative inde" of working time of the final resin'hardener'filler mi"es.
Choice of Hardener
#ppropriate selection of hardener can give mi"es with different degrees of reactivity or speed. *inal choice of resin system and speed of hardener will largely depend on size of mi" required$ ambient temperature$ nature of substrate and total thickness of filler required. 6t is worth noting that it is possible to blend hardeners from the same system to produce intermediate gel times. 7ften$ it is possible to use the same resin system that is being used to build the component. his saves the inconvenience of buying a second system but it may not be the most cost!effective approach$ as another system maybe cheaper.
Filler Ingredients
+hereas the resin system will control the working characteristics$ mechanical and chemical properties of a filler$ the filler ingredients will dictate how easy the filler will be to apply and finally sand down to provide a fair smooth finish. he 'hollow sphere' type of filler is the only type which will create a filler mi" with the two desirable characteristics of being both lightweight and relatively easy to sand. his type of filler can also be used for structural adhesive purposes$ especially for low density fillet bonding. 3owever$ the glue mi" created is relatively weak and therefore it should be restricted to certain types of wood bonding. 3ollow spheres are often described as /microspheres/ and are very effective at reducing the density of the mi" by displacing resin. #s the microspheres have a hard$ resin resistant 'shell' the resin does not penetrate the 'interior' of the bubble. #lthough the user is free to add whatever filler proportion serves his particular needs$ there is a ma"imum practical additive level for each type of filler powder. here must always be sufficient resin present to coat each microsphere and bond one microsphere to the ne"t$ effectively creating a type of 'foam'. he greater the proportion of the filler ingredient added$ the lower the density of the filler mi" will become. 6f too much filler powder is added to the resin ,beyond the point where all microspheres are effectively coated.$ the mi" will become 'dry' and 'pasty'$ and difficult to work. 6t also may not bond well to the surface to which it is being applied. he two principal types of hollow bubble filler are phenolic microballoons and glass bubbles. able 0 compares the characteristics of filler mi"es.
Table 1. Comparative Properties of Fairing Mixes Created from Different "Hollow Sphere" Ingredients
Ranking rder !#$ightest "#Heaviest !#Softest "#Hardest !#*asiest "#Diffi%)lt !#Highest "#$owest !#Cheap "#*xpensive
! Phenoli% Mi%ro&alloons Phenoli% Mi%ro&alloons Phenoli% Mi%ro&alloons 'lass ()&&les 'lass ()&&les
" 'lass ()&&les 'lass ()&&les 'lass ()&&les Phenoli% Mi%ro&alloons Phenoli% Mi%ro&alloons
$po%" FRP
his may or may not have used nylon peel ply incorporated into the last laminate layer. 6f it had$ then tear away the peel ply and simply apply the filler. 6f no peel ply was used then sand the surface thoroughly with 91 grit production paper and clean with a fast evaporating solvent such as clean acetone.
Mi"es of lower density can be created for other applications e.g. to create a low density 'syntactic' foam for filling rather than fairing purposes. 3ere the mi" may have a higher filler loading to allow application by trowel in specific areas. #s a specific e"ample a Microballoon mi" for this purpose can be made with a density of 1.2 g'cc rather than one nearer 1.; g'cc used for fairing. *airing mi"es are required to be more mobile because of the greater area to be covered and to suit the tools and application equipment used. )ote the inclusion of colloidal silica to the mi" in every case. #lthough added in relatively small volume compared to the primary filler ingredient$ colloidal silica serves the very useful function of giving additional non!sag properties to the mi". his is a particularly desirable for vertical or sloping surfaces where some 'sagging' in a filler mi" may be e"pected whilst the filler is still in a workable state$ before sufficient hardening has taken place. he following material weights , able -. will create one litre of low density epo"y filler.
7ne litre of filler$ if spread evenly$ will produce an average 0mm thickness over an area of a square metre. Generally$ for filling and fairing on rough surfaces$ sufficient quantities of resin system and fillers should be ordered to allow for an average thickness of -mm ,- litres of filler mi" per sq.m.. his will allow for uneven surfaces and losses through sanding.
and Fillers
he following information will be useful when ordering suitable epo"y resin system and filler ingredients to create fairing mi"es using Microballoons. he quantities indicated in able 5 will produce a low density filler mi" sufficient to cover the area shown to an average thickness of 0.1mm.
Table 3. Material ;)antities re;)ired to prod)%e a low density filler mix s)ffi%ient to %over the area shown to an average thi%kness of !,4mm,
1rea 2 !4 "4 94 34 24 +t of Resin < Hardener =kg> "," 3,3 6,6 !9," !:,7 "",4 +t of Mi%ro&alloons =kg> 4,7: !,99 ",77 9,?? 2,9" 7,72 +t of Colloidal Sili%a =kg> 4,47 4,!! 4,"" 4,99 4,33 4,22
a> Overall Fairing + the removal of high spots in order to %reate a fair shape whi%h &lends perfe%tly into the overall shape, &> *ocali,ed Fairing + making small areas s)%h as fastening holes or lo%al voids smooth to the to)%h and )ndete%ta&le,
b) *ocali,ed Fairing
#pply the filler with a spatula or metal straight edge. # higher loading of primary filler is often used together with colloidal silica$ to create a stiffer filler mi" for this type of filling.
Curing
#ll epo"y filler mi"es will sand most easily when fully cured because a fully polymerised epo"y will not soften as a result of the heat generating abrasive action. (ince most filler mi"es are sanded before being fully cured$ a coarser grade of paper will be necessary in order to avoid 'clogging'. +arm
conditions with$ ideally$ low humidity help the epo"y components to react most effectively. Please note that when sanding non fully cured epo"y care should be taken to ensure minimal skin e"posure to the sanding dust and that dust masks should be warn. Please see each resin system's instruction sheet for details.
Smooth Filler
Stiff or Flexi&le (oard 1&rasive Paper sheet or a&rasive dis%, *le%tri% or air powered random or&ital sander
)ote< he lower the 'grade' number the larger the grit particle and the lowest density of cutting particles.