Attachment_2_-_Repair_Details_for_Sailing_Vessel_Friendship_of_Salem.pdf

Repair Details for Sailing Vessel Friendship of Salem

Unless stated differently in a specific line, the following apply to work under this contract:

For hull repairs under this contract all hull layer repairs will be laminated using Douglas fir, unless otherwise specified. Where the wood grain has slope, the slope will be alternated each layer. Unless otherwise specified, West System 105, System Three General Purpose or equivalent, 2-part epoxy resin with compatible hardeners and fillers, will be used as an adhesive on hull laminate layers; except for the outer planking layer above the wale where Sikaflex 291, 3M 5200 or equivalent one part marine adhesive polyurethane caulk that remains permanently flexible and watertight may be substituted. The climate in the areas of repairs will be monitored and managed to ensure proper curing of epoxies, caulks, sealants and paints.

Surfaces that are sealed or covered with cured epoxy will have the “blush” from the epoxy curing process removed prior to proceeding with lamination or sealing to this surface. For all repairs the exterior surfaces will be prepared and painted with marine oil paint to match existing paint scheme. Interior surfaces will be finished in the same manner as existing. Those that are sealed with clear-coat epoxy will be treated with a 3:1 sodium borate solution, allowed to dry 48 hrs.

minimum, and then coated with clear-coat epoxy. Once dry, the treated surface will be sanded, brushed or wiped as recommended by the manufacturer prior to adhesives, paints or sealants being applied to the surface. The epoxy manufacturer’s recommended procedures will be followed in all instances.

New and exposed existing wood surfaces, not including those that will be laminated to another surface, will be coated with a borate/sodium borate preservative, such as Bora Care, Tim-bor or equivalent. The selected product will be applied and allowed to dry as recommended by the manufacturer. Once dry, the treated surface will be sanded, brushed or wiped as recommended by the manufacturer prior to adhesives, paints or sealants being applied to the surface. All end grain and faying surfaces will be treated with 3:1 sodium borate solution, let dry a minimum of 48 hrs., and then coated with two coats of clear epoxy prior to bedding and caulking.

One sample of two cut-off wood pieces laminated together with epoxy and marked with the date will be provided for every day that hull layers or framing members are being laminated. This sample should consist of two 1 foot-long pieces of wood glued together with epoxy, having a minimum six inch overlap on the glued surface. These pieces will be 2 inches wide and ½ inch thick with the unglued portions extending on opposite ends of the sample. This sample will be made using the same epoxy, wood and fasteners from that day’s work and will be allowed to cure in the same environment as the work. Each sample will be labeled with the date of its assembly, and what it represents. Once cured, the sample will be given to the NPS staff designated to collect the control samples.

In replacing layers of hull planking required details of scarf joints and exceptions, are as follows:

A. Scarphs will be 12:1 except where interference prevents this, in which case they can be between 6:1 and 12:1

B. On the same planking layer, adjacent scarphs must be staggered by at least ½ a scarph length, with the scarph location repeating not more than once every 3 planks. On batten layers, planks may be staggered in groups of 3. SEE DRAWING/PHOTO.

C. On the diagonal 3/8 inch layers, staggered butt joints may be used in place of scarf joints provided the area of the next outer layer overlaps the repairs on the next inner layer by 1 foot or more. In areas where 1 foot overlaps or staggers are not possible, these may be reduced, with surveyor approval, and typically require the additional a 2 inch backing block laminated inboard of the inner hull layer at the affected location.

D. Where scarph joints are used on the batten or diagonal layers, scarphs must not be located on top of those on any inner layer.

E. On all horizontal layers, butt joints may be used if butts are staggered by 5 or more feet horizontally and separated by 4 planks vertically.

F. On all outer layers above the wale, butt joints shall be used in existing locations, and scarphs can be used in other locations.

If temporary fasteners (in addition to those specified below) are used to ensure adhesion while epoxy is curing, these will be removed once cure is achieved. Use Stainless Steel 316 fasteners for any that will be left in place in laminations and other locations. Where fasteners are removed after lamination, these holes will be filled with epoxy or a wood plug and epoxy. On the outer diagonal layer above the wale, and the outer batten layer below the top of the wale, 2 fasteners at each frame section, of sufficient length to secure into the frames, will be used and not removed.

Between frames, at 1’ intervals, fasteners of sufficient length to secure approx. 5/8” into the inner batten layer will be used and not removed. All outer layer planks will be secured with counter-bored stainless steel wood screws covered with wooden bungs using existing schedule.

Existing hull layers typically, and other laminates occasionally, contain embedded steel fasteners.

Exterior surfaces will be prepared for painting above the bottom edge of the wale and sheathed in fiberglass prior to bottom painting below the wale. Interior surfaces will be sealed with clear-coat epoxy.

Fiberglass 10 oz. e-cloth will be applied using epoxy (as specified above) as the binder. There will be 2 layers of cloth from the wale plank down to 12” above the keel, 3 layers from the keel up 12” and 4 layers on the keel. One coat of clear epoxy will be applied over fiberglass and will have its blush removed and be sanded before painting.

If areas where deteriorated wood needs to be sealed or filled without being replaced, the wood will be treated with a sodium borate wood preservative (Boracare, Tim-bor or similar), dried, saturated with a 2-part penetrating epoxy and be sanded to remove the blush prior to filling, sealing or painting. Remaining voids will be filled with 2-part structural epoxy putties or wood dutchmen. This type of repair is only applicable to areas one foot or more above the waterline, is generally limited to areas less than 1 square foot, on not more than 1 solid or laminate layer, and must be approved by the COR on a case-by-case basis.

Areas to be painted under this contract shall be scraped, sanded with 80 grit or finer, cleaned and caulked prior to painting. Caulking of seams or checks less than 3/16” will be done with caulk above the waterline and a marine polyurethane adhesive/sealant below the waterline. Seams or checks 3/16” or larger, and any caulking on horizontal or near-horizontal surfaces (less than a 2:10 grade) shall always be filled with marine polyurethane sealant (3M 5200, Sikaflex 291.)

Flexible structural marine epoxies may be substituted with COR approval. Seams will be filled to full depth. All caulking will be allowed to cure fully prior to painting.

Lamination and construction details and specifications in this document come from the original design plans as well as a variety of surveys, changes and approvals documented in:

• 2017 stem repair as outlined in Visit Report #5 dated December 15th, 2017 and Addendum to Visit Report #5 dated December 27th, 2017 by Paul Haley, Marine Surveyor

• 2017 stem repair photos from James Knightly #1-5.

• Repair Survey and plans from Paul Haley, Marine Surveyor, dated December 2011 and

All surveys, reports and addendums will be provided upon request.