EVALUATION OF DIRECT RESIN APPLICATOR AND HVLP GELCOAT EQUIPMENT IN LARGE FIBERGLASS BOAT CONSTRUCTION

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1 EVALUATION OF DIRECT RESIN APPLICATOR AND HVLP GELCOAT EQUIPMENT IN LARGE FIBERGLASS BOAT CONSTRUCTION 6/16/94 Hatteras Yachts Division of Genmar industries High Point, North Carolina Submitted By Robert C. Arthur

2 PROJECT SUMMARY The fiberglass industry has for years chosen airless equipment to spray polyester resin and gelcoat during large part construction. The interest in applying resin and gelcoat with less emissions and less waste has led to the development of a whole series of new equipment and equipment technologies. This project s goals were to evaluate an HVLP (high volume low pressure) gelcoat gun and a direct application resin roller. This resin roller was specifically made for our two-pot polyester resin system. The evaluation includes applicability of the equipment to our production process, emissions reduction, waste reduction and labor impact. Due to delays in contract approval and equipment arrival, and the need for further development of the new equipment after initial tests, we were not able to do as thorough an evaluation as we would have liked during the time allotted. There is a general desire to continue the evaluation to determine variance in emissions and to develop a more thorough process and labor impact study. The waste reduction centered around the reduction of overspray. Overspray does not produce a large quantity of waste in itself. However, the overspray coats other surfaces around the parts being constructed. In order to prevent this contamination, all surfaces are covered with disposable covers. This is where a large volume of waste from overspray is produced. The actual overspray for airless gelcoating a hull runs.3 pounds per foot of hull length. This results in 16.2 pounds overspray on a 54 foot hull and 11.7 pounds on a 39 foot hull. The overspray on a hull is less than on a superstructure or flying bridge which runs.55 pound per foot of length. This results in 29.7 pounds overspray on the 54 foot super and 21.5 pounds on a 39 foot super. Overspray on a 54 foot hull and super was reduced by 25% (operator estimate) by using HVLP gelcoat equipment. This means that overspray is reduced by 11.5 pounds and a material savings of $ for just hull and superstructure. The material savings alone would be $ a year. This does not include labor or materials for removing disposable surface coverings. - Page 1 -

3 Resin overspray follows the same fractions as does gelcoat. The biggest difference is due to building laminate up in layers; the spraying function occurs four separate times. Therefore, resin overspray for a completed hull is 1.2 pounds per foot of length so a 54 foot hull generates 64.8 pounds of overspray and a 39 foot 46.8 pounds. The 54 foot super generated and the 39 foot super 86 pounds. The resin roller generated no overspray so the savings on a 54 foot hull and super is pounds or a dollar savings of $ on these parts. The savings on the 39 foot hull and super would be $ This would be an annualized savings of $10,178 if labor had not been adversely affected. Due to the short trial period, we could not determine the full labor impact of each piece of equipment. Indications are that there is no labor increase with the HVLP gun. If you were to just use the gelcoat overspray reduction to determine payback, it would be 15 months. We feel that this is not an accurate method to determine payback since clean-up labor and mold covers are not reflected. We cannot determine payback on the resin roller due to labor impact. Initial trials indicate that labor increases. These increase varied from 25% to 40%. Further use of this equipment is needed to get past learning curves and fine tune the equipment to document more closely actual labor impact. HVLP gelcoat equipment looks very promising. The more technical detailed report attached proves both pros and cons. The gun produces less overspray and porosity. It also provides a more controllable and softer fan. The resin roller worked neatly. Styrene levels were reduced. Roller handle should be sized for the part on which you are working. The static mixer head ports should be large enough to allow a large flow of resin when the handle is depressed. The roller works very well on flats and sloping turns. It does not work well in tight radii with lots of shape. - Page 2 -

4 PROJECT DESCRIPTION The purpose of this project was to evaluate HVLP (high volume low pressure) gelcoat equipment and direct application resin equipment. Our goal was to determine applicability of this equipment for building large fiberglass parts and its effectiveness of reducing styrene emissions. Gelcoat Equipment Our standard gelcoat equipment is airless equipment. This equipment operates by using high pressures to push gelcoat through a small orifice. Typical incoming air pressures are 90 psi to the pump. The pump works at a 33:l ratio, therefore, line pressure to the orifice is 2970 psi. When the gelcoat exits the orifice, it atomizes and is forced into small droplets. The pressure forms a wide fan used for mold coating. The high pressure and small area of the droplet release styrene and the turbulence generates ove rspray. - HVLP The HVLP equipment operates on a slightly different principle. The gun is developed so that lower pressure is needed to spray the gelcoat through the orifice. (In our trials on small parts, we often could run the incoming air pressure at 60 psi or 1980 psi at the hose.) Once the gelcoat leaves the orifice, a low pressure fan of air completes atomization and encapsulates the fan on its way to the mold surface. This generates a soft spray due to its lower velocity, reducing bounce back at the mold surface. This softer fan reduces turbulence and therefore overspray. Gelcoat Application Gelcoating at Hatteras, High Point, is accomplished by using rolling equipment - Page 1 -

5 carts. On small parts, the cart is rolled close to the molds and gelcoat applied. Large parts, such as superstructures and hulls, are sprayed from above, using a basket held in place by cranes. From this cherry picker bucket, three different gelcoats are applied to the hull mold and two different gelcoats on all other parts. On these large parts it was necessary to carry in-line pressures to 90 psi, however, overspray still remained lower than with airless equipment. In this evaluation, only one HVLP gelcoat gun was purchased. This gun was used on the equipment that sprayed the most gelcoat through production. Styrene levels were impossible to obtain due to the use of both HVLP and standard airless equipment on all parts. Gelcoat EauiDment Testinq After we set up the HVLP gun, which included the addition of several hoses to our existing equipment, we began with small parts. The spray was soft and the operators found that application of the gelcoat was more uniform. The gelcoat flowed more evenly on the surface with a finish much flatter and smoother than we get with our airless equipment. Operators compared the finish to a painted surface. The operators commented that they got far less gelcoat on them and the odor of styrene and catalyst was reduced. Visual inspection of overspray yielded an estimated reduction of around 25%. The actual overspray for airless gelcoating a hull runs.3 pounds per foot of hull length. This results in 16.2 pounds overspray on a 54 foot hull and 11.7 pounds on a 39 foot hull. The overspray on a hull is less than on a superstructure or flying bridge which run.55 pound per foot of length. This results in 29.7 pounds overspray on the 54 foot super and 21.5 pounds on a 39 foot super. Overspray on a 54 foot hull and super was reduced by 25% (operator estimate) by using HVLP gelcoat equipment. This means that - Page 2 -

6 overspray is reduced by 11.5 pounds and a material savings of $ for just hull and superstructure. This does not include labor or materials for removing disposable surface coverings. The operators preferred the new HVLP gun over their conventional equipment. They indicated that the spray was easier to control, and the pattern was more uniform. The operators are confident that with the proper size tips there would be no labor increase. There are some concerns and improvements that need to be incorporated in the substitution of an HVLP gun on airless equipment. One improvement that needs to be incorporated is an easier method to check gelcoatlcatalyst ratio. The HVLP gun injects catalyst within the first inch of the spray pattern versus 12 inches on the airless equipment. The advantage of this is a more thorough catalyst mix and a reduction of catalyst odor. The disadvantages are; the lack of ability to catch the catalyst stream to determine the catalyst ratio and the proximity of catalyst and gelcoat tips which allowed the gelcoat to cure from part-to-part and stop up the gun. The only way to check catalyst levels now is to measure catalyst and gelcoat separately. Binks is presently working on a solution to this problem. The catalyst injection system creates another problem that must be overcome. The catalyst stream is not atomized on the HVLP gun as it is on airless equipment. The catalyst is atomized on the airless equipment through a check valve. The check valve vibrates and the operator uses this vibration as a check to assure catalyst is being sprayed. The HVLP gun does not have this set up, and since the catalyst is injected so near to the gun, visual inspection is very difficult. Binks does not have a system to alert the operator if there is a lack of catalyst. We have found a company that is developing - Page 3 -

7 a catalyst alarm system that should address this problem. The alarm system should be available in late June at a cost of approximately five hundred dollars. The size of our molds and the resulting high cost of cleanup, scrap, and time delays from uncatalyzed gelcoat application make it imperative that we have a catalyst warning system for the operator. - Resin Amlication Our standard procedure for applying resin on large fiberglass parts is by spray. We use a two-component resin gun which sprays two fans which impinge approximately 12" from the tips. These fans carry a catalyzed resin on one side and a promoted resin on the other side. At the impingement point, the mixing of the fans allows for the full catalyzation of the resin. Pressures on these guns must be high enough for full fan development. This occurs by using a 21 :1 pump operating at 50 psi line pressure yielding a delivery pressure of 1050 psi (without loss due to hose length). This fan generates styrene loss and overspray. The direct application equipment is a pressurized system similar to the power paint rollers presently being advertised for home use. Our system is considerably more complex due to the fact the resin system must be catalyzed in order to cure. This creates a need to mix components before application. On the system we tried, this mixing is accomplished in two steps, both internal. The first step is through an internal impinge- ment head, mixing catalyzed resin and promoted resin. It is then forced through a static mixer tube and onto the resin roller head. The resin flows from the resin head in a swift, steady stream but is never atomized (or sprayed). Testina Resin Roller Initial start-up of the resin roller highlighted an immediate problem. The hose from - Page 4 -

8 the static mixer head to the handle of the resin roller was only ten feet long. The hose was awkward to use this close to the bulky static mixer head (see diagram) for our application, so a twenty-five foot hose was installed instead. Gel times were then checked to confirm that complete mixing of the resin was taking place. Sample laminates were made, and laminate thicknesses were comparable to spray lay-up samples. The first part produced was a fiberglass bulkhead approximately 70 square feet in area. This part is usually produced by spraying resin. The application went smoothly. There was a very notable reduction in the styrene smell. During typical spray application, the floor gets a mist of resin overspray and becomes tacky. While using the resin roller, overspray was eliminated, and the floor only got a couple of drops from the mold edge wet-out. The testing was carried out first on large flat parts, then migrated to large more complex parts. Area samples were taken to determine styrene levels around the flat molds while using spray gun and then while using the resin roller. The first of the more complicated parts was a superstructure (commonly known as the deck). This is a very complicated part with small deep radii and tight corners. This trial ended after three and a half hours. The workers became exasperated due to the inability to reach into the tight radii and recesses. The hull was the next complex part tried. The 39 foot hull has a surface area of approximately square feet. Most of the hull consists of large rolling planes with tight radii at the sheer and in the keel. The keel is approximately 4 inches wide, 20 feet long and was wet out by the roller with no problem. This trial went far better than the superstructure. The first notable improvement to make this equipment more suitable for a hull would be to have a shorter resin roller handle. The 4 2 roller handle was awkward - Page 5 -

9 in the hull. Due to the size of the part, laminators stand on staging in the hull while laminating, and the long handle kept hitting the staging. A shorter, approximately 24", roller handle would have been much easier to use. The roller wet-out the glass adequately and in many instances was used to press the glass in place. There was a significant reduction of styrene smell by the laminators. Overspray did not exist; typical spray application would have yielded a 4 foot wide layer of tacky resin surface around the hull. Resin overspray for a completed hull is 1.2 pounds per foot of length so a 54 foot hull generates 64.8 pounds of overspray and a 39 foot hull 46.8 pounds. The 54 foot super generated pounds and the 39 foot super 86 pounds. The resin roller generated no overspray so the savings on a 54 foot hull and super is pounds or a dollar savings of $ on these parts. The savings on the 39 foot hull and super would be $ This would be an annualized savings of $1 0,178 if labor had not been adversely affected. Stvrene Impact The levels of styrene were compared using spray and resin roller. On flat decks, area styrene levels were reduced by 85%. In the hull, the wet-out laminator's styrene exposure was reduced by 25%. This reduction in the hull may have actually been greater than documented, but another large part was being sprayed adjacent to the hull. - Labor The late arrival of our contract and delays in equipment arrival did not provide us with enough time to get very accurate labor numbers. We never got past the learning stages of equipment use. Initial trials do indicate that it is not as efficient as spray-up. - Page 6 -

10 , The increases in labor including the loss of efficiency due to unfamiliarity of equipment was 25% to 40%. Waste Reduction As the resin roller was put to use, we reviewed methods to reduce resin waste in other facets of the fiberglass construction with this equipment. One thought was to use air to purge the resin lines at the end of the production day, thus reducing resin waste. It must be noted, that due to the size of our parts, our lines are one hundred feet long. The Binks representative was under the impression that it was not necessary to flush the hoses each day. Their development of the equipment was based on the need to flush only the internal mixing equipment to the end of the roller. However, using a two-part system means that one hose is catalyzed and not promoted. This means that the catalyzed resin in this hose can cure overnight, with the loss of the hose. So a thorough solvent wash is the only safe bet. Although this avenue has not been fully explored, it does not look promising. The resin overspray was eliminated when using the roller. The projected savings on the hull and superstructure for a 54 foot boat is pounds or $ per boat. The savings for large parts on a 39 foot boat is pounds or $ Conclusion Both the direct resin roller and the HVLP gelcoat gun show favorable results in waste reduction. The resin roller lends itself to large parts providing they are relatively free of tight radii and very deep recesses. The labor impact needs further study. Styrene levels can be decreased by 25% to 85% depending on shape and size of parts. When the HVLP gelcoat gun is retrofitted to an airless system, an additional allowance should be made for controls. The equipment works well, but the catalyst - Page7 -

11 . system should have a method to assure catalyst is being metered to the gelcoat. The gun handles well, and the fan produces far less overspray. - Page 8 -

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