Estimating Costs
Although I am presenting some of the “negative” aspects of preventative Barrier-Coating, please remember that I HAVE DONE MY OWN boats.Previously, I indicated that Stripping, Cleaning, Drying, and then Barrier-Coating a hull is a nasty, time consuming, and fairly EXPENSIVE job.Assuming an undamaged (mostly “Dry”)and fairly clean hull, I’d charge something on the order of $100 to $110 per foot (LOA) to Sand (basic), Clean, and Epoxy Barrier-Coat to (the MINIMUM) 10 Mils thickness. BUDGET For a 30 Foot Sailboat:I’d expect to use about 2 Gallons of Epoxy (@$200/Gal.), plus some consumables (sand paper, solvents, etc); totaling something like $600 Materials.I’d estimate my labour at about 40 to 48 Hours (@ $55/Hour for “Painting”); for a total of about $2,200 - $2,640.Materials (@ $600) + Labour (@ $2,600) = $3,200 Total PLUS any Yard Charges (Which may be considerable - Haulout, Daily Storage, Blocking, etc). Now, having applied the barrier-coat, you’re still faced with the Anti-Fouling job (about $15/Ft?). The above budget did not include the cost of any repairs (nicks, gouges, or BLISTERS), or extraordinary stripping/cleaning.As you can see, even a Do-It-Yourselfer is looking at considerable expense (perhaps $35/Foot), and time (a week’s holidays working, PLUS dry-out time out of use). Some Basic Instructions from “ Barrier Coating - New or Repaired Hulls” (Gougeon Brothers - WEST System Epoxy)1. If the bottom has not yet been painted, wipe the entire surface with a cloth dampened with a silicone remover or solvent to remove remaining mold release agents or waxes. If the bottom has been painted, the paint must be completely removed with chemical strippers (*1) and/or sanding prior to coating.2. Abrade the gelcoat surface below the waterline with 30-grit sandpaper. When completed, there should be no glossy areas. Mask freeboard at the waterline(*2) with masking tape.3. For optimum moisture exclusion, we recommend a total in excess of 600 microns (23 Mils) of epoxy, which is easily achieved with six coats (about 4 Mils/Coat).Note: For best results, apply at 21Deg.C to 27 C, @ 40-60% relative humidity.The first coat should be applied with no additives. Each successive coat should include 20 to 25% WEST SYSTEM 422 filler (an aluminium-based barrier coat additive, which increases the epoxy’s resistance to moisture permeability) blended with the resin/hardener.All coats may be applied in one day. Apply the next coat as soon as the first coat will support its weight. If epoxy is allowed to cure overnight, wash with water and 855 Cleaning Solution, then sand before re-coating. If an impression can be left in the coating with your fingernail then the epoxy can be over-coated without washing and sanding. Do not thin WEST SYSTEM epoxy; doing so will seriously diminish the epoxy's moisture barrier effectiveness.4. Thoroughly sand with 220-grit sandpaper before application of the antifouling paint. Follow the paint manufacturer's instructions for final surface preparation and applicationFor further information on osmosis in GRP boats see:"Gelcoat Blisters: Diagnosis Repair and Prevention”(*1) I DO NOT recommend the use of “Chemical Strippers”!(*2) I Recommend Barrier-Coating above the waterline (at least 4 - 6").Some further notes:THICKNESS:There are two standard measurements used to describe the film thickness of a coating, Mils and Microns. Microns are from the metric system and are equal to 0.001 millimetres, while Mils are from the imperial system and are equal to 0.001 inches. Since 25.4 millimetres equals one inch then 25.4 Microns is equivalent to a Mil; hence 254 Microns equal 10 Mils.APPROXIMATE COVERAGE:Assuming a barrier-coating thickness of about 10 mils (0.010"), a gallon of Solvent-Free Epoxy will cover about 160 Square Feet.Some “typical” approximate wetted surface areas (Area below the water line = Length x Beam x .85):28 racer/cruiser = 250 sf30 racer/cruiser = 270 sf36 cruiser = 330 sf41 cruiser = 435 sf53 cruiser = 590 sfThe 30 Ft. sailboat might require about 1.69 Gallons (270 ÷ 160) of epoxy, to achieve a 10 mil coating. Two gallons would provide a 10 mil overall thickness, with an additional coating at the waterline/bootstripe. Applied at 4 to 6 mils per coat, you’ll require a minimum of 2 to 3 coats. Remember, thicker (to about 25 to 30 mil) is better.And an other opinion on the efficacy of Barrier-Coating:<i>” ... Drying will lower the moisture content of the hull and may also remove some water content from the "osmosis" residues. However, as it is the remaining acid residue that causes the chemical process - and removing water only make the acid stronger - the long term effect will be devastating ...<i> AND <i> ... A water barrier coat is often claimed to effectively prevent outside water from re-entering the laminate. This is supposed to slow down the re-start of "osmosis" after a "conventional" repair.First, there is no such thing as an effective water barrier coating.Second, even a dried laminate still contains sufficient amounts of moisture to feed the process, especially in laminates which containwoven roving ...”<i>http://www.hotvac.com/what/default.aspandhttp://www.hyab-osmocure.com/osmocure_frame4.htm