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1. INTRODUCTIONEven under the best of conditions, H. Where does it occur? In the gel coat film? Against
problems can occur due to accidents, mistakes and unan- the mold? On the back side? Within the film?
ticipated changes. Listed are some of the various problems
I. What is the code, batch number, and date of the
that can occur and how to solve them. Also remember that
gel coat with which the problem is occurring? Were
the gel coat is affected by the laminate, and good gel coat
good parts sprayed from this batch or drum?
will not compensate for a poor laminate.
2. PROBLEM DIAGNOSISTo isolate and diagnose the J. Was anything done differently, such as a change in
problem, give consideration to the following: catalyst level, spray operator, method of application, or
weather conditions?
A. What does the defect look like?
B. Where does it occur? All over, random, isolated K. How would someone else identify or describe the
side or section? defect?
C. Is it on all parts, some of the parts, or just one? L. What were the weather conditions at the time the
part was sprayed?
D. When did it first occur? Or when was it first ob-
served? M. What corrective steps were taken and were they
E. Does it match up to a defect in the mold? effective?
F. When were the defective parts sprayed? N. Check the material or laminate that was applied to
1) Did it occur during a particular shift? Or from a or on the gel coat.
particular spray operator?
Listed on the following pages are common gel coat prob-
2) Was it during a particular part of the day lems and their usual solutions.
when it was hot, cold, damp, or other?
G. Did the problem occur through all spray stations or Photographs illustrating many of these problems are also
just one in particular? included.
Thin gel coat . .................................................... Use a minimum of 12 mils, wet. Discontinuous gel coat
After or during lamination, or a second film.
application of gel coat ..................................... Insufficiently cured gel coat ............................. Catalyst level too high or too low. Temperature too low.
Gel time too long. Time between coats or lamination
insufficient. Moisture or contamination in the mold.
Craterswhile spraying . ....................................... Chunks in the gel coat ..................................... Dirt in the gun or material. Material old and starting to
gel; rotate stock. Strain (filter) the gel coat.
Equipment ......................................................... Clogged gun (clean). Improper atomizing air setting
(too low).
Delamination
In spots . ............................................................ Contamination .................................................. Check for dust, solvents, moisture, catalyst getting onto
the gel coat surface. Excess mold release wax floating
through to the gel coat surface, creating areas that will
not adhere.
Large area ........................................................ Gel coat too fully cured .................................... Check for high catalyst level. Letting the gel coat cure too
long, such as overnight; skin coat, rather than leave on
the mold for long periods of time. Excess mold release
wax or wax in the gel coat.
Contamination .................................................. Solvent wiping, then waxing (around taped off areas),
Unbalanced laminate ...................................... Dry fiberglass.
Dull or soft spotsat random . .............................. Gel coat uneven ............................................... Poor breakup; use three passes.
Catalyst poorly mixed into either gel coat
and/or laminate ............................................... Mix catalyst thoroughly or make equipment adjust-
ments for good catalyst mix. Equipment surging
(material pump and/or atomizing air). Improper cata-
lyst settings (high or low). Gun held too close to mold.
Trapped solvent in gel coat and/or laminate Check cleaning procedure. Check catalyst level with
equipment using solvent reduced catalyst.
Trapped water in gel coat and/or laminate .. Drain lines and correct the problem.
Insufficient catalyst ........................................... Confirm correct catalyst concentration.
Fisheyes (see Photo #14, page 59) . ....................... Water, oil, or silicone contamination .............. Drain air lines. Check mold release wax. Excess and/or
fresh coat of wax is worse.
Dust/dirt on mold ............................................. Check lubricating materials used within the equip-
ment. Use tack rag.
Gel coat film too thin ........................................ Use 18 2 mils in three passes.
Low viscosity material ...................................... Old materialrotate stock.
Jagged tape lines . .................................................. Gel coat starting to gel . ................................... Use less catalyst (do not go below recommended
minimum). Use double tape process. Use good tape
recommended for fine lines.
Pinholes (see Photo #17, page 59).......................... Insufficient atomization .................................... Too high gel coat delivery rate. Not enough atomizing
pressure.
Porosity (see Photo #18, page 59)........................... Entrapped air .................................................... Wrong air pressure. Too high tens to yield fine porosity;
too low will produce larger, surface porosity.
Wrong catalyst................................................... Check gel coat vendor for recommendation.
No catalyst ........................................................ Check catalyst supply and alignment.
Gel coat film thickness ..................................... Applied too thick; use 18 2 mils wet. Apply in two to
three passes.
Formulation ....................................................... Improper viscosity and/or resin solids. Check with
vendor.
Water or solvent . .............................................. Check for contamination.
Pump cavitation . .............................................. Check pump for air leaks.
Excessive mixing .............................................. Mix once a day for 10 minutes only.
Sags and runs ......................................................... Excessive gel coat ............................................ Apply 18 2 mils, wet.
Spray techniques .............................................. Atomizing air is pushing and blowing the gel coat. Not
enough styrene is being volatilized.
Low viscosity .................................................... Check viscosity and thixotropic properties. Over-
agitated. Material was reduced, but should not have
been.
Mold wax .......................................................... Silicone content too high.
Other .................................................................. Jarring the mold before gelation.
Softness .................................................................... Soft gel coat film which be easily matted . ..... Incomplete cure of gel coat.
Check catalyst levels, contaminants and film thickness.
3. Bleeding 4. Blisters
(Caused by catalyst drop)