Crack In Mast

[sandsailor]

i've done a couple of these myself

contact an aluminum fab shop they can come out with a tig welder and have it looking like new in no time with out the mess may cost a couple hundred bucks but well worth it

 

[nasmiller]

My mast has a 12" crack at the lower section of this 50 ft mast. (see photo) Is there a risk sailing with Genoa with this condition. Has anyone ever had this type of crack repaired with welding ?

On our 2005 42CC Beneteau Oceanis, in late June, 2011, we developed a crack in our mast similar to the one you show in your picture. The crack is 11 1/4 inches long and starts 8 inches from the bottom (step). It showed up after crossing Lake Michigan from Pentwater to Manitowoc WI. Not only is there a vertical crack, but it appeared to be bulged around the mast at that spot, so we elected to have the mast removed and ordered a new spar. We very much want to find out why the mast cracked. Do you know what caused your mast crack? Our insurance company's hired engineer guessed that ours was caused due to freezing water inside the mast, but we do not agree that this is the case based on the crack location and other indicators. We are very interested in sharing information with others that have experienced this problem to find out why this occurred. Please email me directly to discuss this offline if anyone who reads this has a similar story.

 

[Steve Dion]

Have you been in touch with the spar mfg? This would seem like the prudent thing to do. Sometimes they have programs for issues like this that are NOT considered recalls.

Who made the spars on these vessels?

 

[zeehag]

will need to sleeve and weld?...mine are wood, so a crack like that is a unstep and glue and alladat kind of mess.....

 

[nasmiller]

Spar made in France

Have you been in touch with the spar mfg? This would seem like the prudent thing to do. Sometimes they have programs for issues like this that are NOT considered recalls.

Who made the spars on these vessels?

The original mast was made in France (Beneteau or Beneteau contractor). It is no longer being made so the replacement mast that we ordered will be slightly different and was made by US Spars in Gainesville FL. We will likely pursue some avenue to recoup some of the replacement cost.

 

[RAD]

I'm in agreement with the engineer cause if the mast got water inside and turned to slush do to frigid cold that would keep it from draining and over time this slush would build up and allow the water to freeze and interesting is that both masts cracked just above the deck and both boats are Great Lakes area boats

just sharing my 2 cents

 

[Hermit Scott]

If it's deck stepped I guess water would be the most likely culprit. Judging where the crack is I would bet it is a keel stepped mast. I would guess stress crack from repetitive loading(underengineering). Rig tension probably has something to do with it.
I would TIG weld it immediately. Wouldn't worry about drilling holes, but I would not sail that boat like it is AT ALL. If I had to sail it before I welded it, I would drill the holes the other guys talked about and put a plate over that whole area and screw it to the mast with plenty of screws.
Other than replacing it, the sleeve idea seems to be appropriate enough. IF I had the mast on the ground I would consider adding 1/4"X4" aluminum strap to be TIG welded starting a few feet below deck to 3' above the deck on both sides of the mast, if it is keel stepped. Also I might use very very low heat along the top horizontal weld, high heat only along the sides. Because the horizontal weld along the top would be the next place the mast would crack.
If you have good insurance have them replace the mast sighting that welded masts are ugly. lol
Does anyone know if this boat is keel or deck stepped?

 

[RichH]

Have you been in touch with the spar mfg? This would seem like the prudent thing to do. Sometimes they have programs for issues like this that are NOT considered recalls.

Who made the spars on these vessels?

Good advice from Steve. The most common and effective repair is usually cutting off the cracked area and getting a short piece of the same OEM section, plus a slip-on insert to hold the two pieces together which are then all riveted together.
If welding seems to be the 'economical choice' seek out an experienced aluminum welder who is CERTIFIED to weld "ASME code" vessels

 

[Douglast]

if the sails are down from the top of the mast enough (fractional) is there a possibility of just cutting the lower affected section off and attaching the step and then just shorten the forestay/backstay and shroud rigging..??..i know this could be a real dumb post on my part..but heck its been raining almost 4 straight weeks and im getting cabin fever..

 

[FourPoints]

it looks like freezing damage to me, it's bulging out, it doesn't show the signs of compression fatigue.

I would look for getting a sleeve and welding if it is deck stepped, but if it is keel stepped, replace the whole spar, you need flexability there and the weld will fail when flexed.

 

[Hermit Scott]

The problem with replacing it with exactly what is there now is the exact same thing is probably going to happen again. You may be better off fixing the problem on this mast rather than replacing it with a new one. Unless this has happened a lot on this mast and the problem is corrected.
It does appear to be bulging out but that does not necessarily mean it is because of freezing or something pushing from the inside. The cross-section of the extrusion can be such that, when flexed it always separates out there instead of caving in.
The cold can contribute to the cracking with out water in the mast. So two masts crack on the great lakes, it is brass bra cold up there.
FourPoints-what are the signs of compression fatigue?

 

[sandsailor]

Call out a reputable welder and back off on the back stay pressure

 

[sandsailor]

I can tell you thats a stress crack and your lucky its still standing

 

[woodster]

there is another possiabilty...it very well could be a flawed extrusion from the start....... while it is a possiable answer and if indeed it was that sorta would make ya wonder about the quality controll department in that factory....

regards

woody

 

[FourPoints]

FourPoints-what are the signs of compression fatigue?

short ripples and crumple shapes, normally associated with a sharp bend or crease, not a large spread out bulge that has a smooth and consistant curvature.


I used my considerable art skills below to demonstrate...

sharp crease from compression fatigue
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smooth bulge from internal pressure
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[Hermit Scott]

Google "crack in mast from freezing" and there is a picture on there that's on someone's cruising site and there is a picture that looks almost exact to what the original post is.

 

[Hermit Scott]

Here is what they had to say about it on splendidjourney.blogspot.com
"The verdict is they are going to take the mast down because there is some question as to whether or not any damage from the freezing has been done to the inside of the mast. Their plan is to make a sleeve, insert it inside the mast and then weld the crack. This process will most likely take two weeks."
My guess was wrong. I wasn't wrong, just my guess