STANDARD FOR CERTIFICATION

No. 2.9 Type Approval Programme No. 1-501.9

POLYESTER RESIN, VINYLESTER RESIN, GELCOAT AND TOPCOAT

OCTOBER 2009

DET NORSKE VERITAS

Veritasveien 1, NO-1322 Hvik, Norway Tel.: +47 67 57 99 00 Fax: +47 67 57 99 11

FOREWORD
DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life, property and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification and consultancy services relating to quality of ships, offshore units and installations, and onshore industries worldwide, and carries out research in relation to these functions. Standards for Certification Standards for Certification (previously Certification Notes) are publications that contain principles, acceptance criteria and practical information related to the Society's consideration of objects, personnel, organisations, services and operations. Standards for Certification also apply as the basis for the issue of certificates and/or declarations that may not necessarily be related to classification. A list of Standards for Certification is found in the latest edition of Pt.0 Ch.1 of the Rules for Classification of Ships and the Rules for Classification of High Speed, Light Craft and Naval Surface Craft. The list of Standards for Certification is also included in the current Classification Services Publications issued by the Society, which is available on request. All publications may be ordered from the Societys Web site http://webshop.dnv.com/global/. The Society reserves the exclusive right to interpret, decide equivalence or make exemptions to this Standard for Certification. Amendments and Corrections This document is valid until superseded by a new revision or withdrawn. Minor amendments and corrections will be published in a separate document normally updated twice per year (April and October). For a complete listing of the changes, see the Amendments and Corrections document located at: http://webshop.dnv.com/global/, under category Standards for Certification. The electronic web-versions of the DNV Standards for Certification will be regularly updated to include these amendments and corrections.

Amendments and Corrections This document replaces the January 1999 issue. Main changes: Appendices B and C have been removed. The last paragraph in section 1 has been rewritten to be aligned with the current situation. Note 1 in Table 4-3 has been modified.

Comments may be sent by e-mail to rules@dnv.com Comprehensive information about DNV and the Society's services is found at the Web site http://www.dnv.com Det Norske Veritas Computer Typesetting (Adobe FrameMaker) by Det Norske Veritas

If any person suffers loss or damage which is proved to have been caused by any negligent act or omission of Det Norske Veritas, then Det Norske Veritas shall pay compensation to such person for his proved direct loss or damage. However, the compensation shall not exceed an amount equal to ten times the fee charged for the service in question, provided that the maximum compensation shall never exceed USD 2 million. In this provision "Det Norske Veritas" shall mean the Foundation Det Norske Veritas as well as all its subsidiaries, directors, officers, employees, agents and any other acting on behalf of Det Norske Veritas.

Standard for Certification - No. 2.9, October 2009 Type Approval Programme No. 1-501.9 Page 3

CONTENTS
1. 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 SCOPE OF SERVICES ........................................... 4 PROCEDURE .......................................................... 4 Application for Type Approval ...................................4 Quotation .....................................................................4 Assessment of Type Approval documentation ...........4 Initial Survey of product and production facilities including witnessing of Type Tests .............................4 Assessment of survey report and Type Test results.....4 Issuance of Type Approval Certificates ......................4 Certificate Retention Survey after two (2) years .........4 Application for renewal after four (4) years ................4 3. 4. 4.1 4.2 4.3 4.4 4.5 4.6 DOCUMENTS TO BE SUBMITTED.................... 5 REQUIREMENTS ................................................... 5 Basis for Type Approval ............................................. 5 Scope of Type Approval ............................................. 5 General requirements .................................................. 5 Requirements to resins for structural laminates .......... 6 Gelcoat and topcoat ..................................................... 7 Requirements to packaging and marking of product .. 7

APPENDIX A TYPE APPROVAL OF POLYESTER AND VINYLESTER PRODUCTS .............................................. 8

DET NORSKE VERITAS

Standard for Certification - No. 2.9, October 2009 Type Approval Programme No. 1-501.9 Page 4

1. Scope of services
Det Norske Veritas (DNV) Type Approval is based on the ISO/ IEC Guide 2 (1991) definition: Approval of conformity with specified requirements on the basis of systematic examination of one or more specimens of a product representative of the production. The requirements are specified in Rules and/or standards referred to in this Type Approval programme. This Type Approval programme outlines the procedure and conditions for obtaining, maintaining and renewing a Type Approval. DNV Certification Notes No. 1.2 (2009) describes the Type Approval in general. Type Approved products will be listed in DNVs Register of Type Approved Products.

Type Tests as specified in section 4.4 and 4.5, are to be carried out and verified in one of the following ways: at a DNV laboratory at a recognised and independent laboratory accepted by DNV at the manufacturers premises in the presence of a DNV surveyor. The Initial Survey report and Type Test results are to be submitted to DNV Approval Office for evaluation.

2.5 Assessment of survey report and Type Test results

The assessment of Initial Survey report and Type Test results verifies compliance with the requirements/determines the values to be stated on the Type Approval Certificate (if applicable).

2. Procedure
The Type Approval procedure normally consists of the following steps: application for Type Approval quotation assessment of Type Approval documentation initial Survey of product and production facilities including witnessing of Type Tests assessment of survey report and Type Test results issuance of Type Approval Certificates certificate Retention Survey after two (2) years application for renewal after four (4) years.

2.6 Issuance of Type Approval Certificates

When the assessment of Type Approval documentation, Type Testing and survey of production and quality control arrangement is successfully completed a Type Approval Certificate will be issued to the manufacturer of the product. The certificate is normally given a validity period of four (4) years, with a Certificate Retention Survey after two (2) years.

2.7 Certificate Retention Survey after two (2) years

The objective of the Certificate Retention Survey is to verify that the product design, material composition and the product marking are not altered since issuance of the Type Approval Certificate. Certificate Retention Survey is to be carried out two (2) years after issuance of Type Approval Certificate. The main elements of the Certificate Retention Survey are to: ensure that Type Approval documentation is available review design, materials, performance and production process (as specified in section 4.3) with respect to possible changes, in order to ensure compliance with Type Approval documentation and/or referenced material specifications ensure traceability between manufacturers product marking and the DNV Type Approval Certificate as stated in section 4.6 witness tests/inspection on factory samples, selected at random from the production line (where practicable) or storage, if specified in section 4.4 and 4.5. The Certificate Retention Survey report shall conclude that either: a) the Type Approval Certificate shall be retained, or b) the Type Approval Certificate shall be modified/recalled due to the changes in the basis for approval. The Certificate Retention Survey report shall be submitted to the manufacturer and to DNV Approval Office.

Explained in detail:

2.1 Application for Type Approval

The Type Approval should be applied for in writing to DNVs local office. The application shall include Type Approval documentation as specified in section 3.

2.2 Quotation
A quotation will be given by DNV approval office, to be confirmed by the client.

2.3 Assessment of Type Approval documentation

The Type Approval documentation is assessed by DNV Approval office to verify that it is in conformity with the specified requirements.

2.4 Initial Survey of product and production facilities including witnessing of Type Tests
The objective of Initial Survey is to verify that the production, quality control arrangement, product design, material composition and the product marking is according to the Type Approval documentation. The main elements of a DNV Initial Survey are to: ensure that production and quality control arrangement are according to requirements as specified in section 4.3.2 and as stated in Type Approval documentation submitted by manufacturer witness Type Tests, as specified in section 4.4 and 4.5 ensure traceability between manufacturers product marking and the type designation as stated in the application for Type Approval. The objective of Type Tests is to verify the ability of the product to meet specified requirements by subjecting the test sample to physical, chemical, environmental or operational stresses.

2.8 Application for renewal after four (4) years

Application for renewal should be submitted to DNV not later than three (3) months before expiry date of the Type Approval Certificate. The application shall include updated Type Approval documentation as specified in section 3, item 1 to 6. Items 7 to 10 shall be submitted if changes have been implemented since last issuance of the Type Approval. Upon receipt of the application, DNV will perform a Renewal

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Survey with objective to verify that the product design, material composition and the product marking are not altered since issuance of the Type Approval Certificate. Renewal Survey is to be carried out not later than four (4) years after issuance of the Type Approval Certificate. The main elements of a Renewal Survey are the same as specified for the Certificate Retention Survey in section 2.7. If there, since last issuance of the Type Approval Certificate, has been any change in the relevant standards or in DNV Rules, new assessment of product and Type Tests may be required. The Renewal Survey report will constitute part of the basis for renewal of the Type Approval Certificate.

DNV Rules for Classification of High Speed, Light Craft and Naval Surface Craft, Pt.2 Ch.4 Sec.2. Standard for Certification No. 2.20 - Lifeboats and Rescue Boats, section 12 Standard for Certification No. 2.21 - Craft, Ch.3 Sec.3 The requirements in this section comply with the requirements in ISO/DIS 12215-1 (Small Craft- Hull construction-Scantlings-Part 1: Thermosetting resins, glass fibre reinforcement, reference laminate), grade A and grade B.

4.2 Scope of Type Approval

This Type Approval programme for polyester and vinylester, gelcoat and topcoat includes requirements for: structural laminates fire retardant laminates for use in lifeboats.

3. Documents to be submitted
The following Type Approval documentation is to be submitted by the manufacturer at Initial Type Approval and updated, at renewal. The documentation shall be in triplicate, one copy will be returned to the manufacturer with the Type Approval Certificate and one to the local DNV station/surveyor. The documentation shall be in English, if not otherwise agreed. (Please number documentation according to below list to facilitate review): 1) Type designation, i.e. product name with list of variants that are to be included in the Type Approval and stated on the Type Approval Certificate. 2) Name and address of manufacturer, to be listed on Type Approval Certificate. Additionally, the following shall be specified, if applicable: person in charge phone and fax numbers e-mail and web address 3) Basis for approval. A reference to applicable Rules and Standards, ref. section 4.1, which the product is to comply with. 4) Product description (type of base resin, etc.). 5) Field of Application and special limitations of the product (curing procedure, laminating procedure, shelf life, compatibility /non-compatibility with other materials, etc.) 6) Product specification, data sheet for all variants (mechanical properties, health data sheets, etc.), including at least those properties for which requirements are given in section 4: nominal value for all properties tolerances, as specified in section 4.3. 7) Type Test results for all variants including a summary in the enclosed table, Appendix A, and survey report from DNV local unit. *) 8) Description of production processes. *) 9) Description of quality control arrangement. *) 10) Information regarding marking of the product or packaging. *)
*) To be verified by Initial Survey prior to the issuance of the Type Approval Certificate.

The approval of polyester and vinylester is divided into two different quality grades. Grade 1 and grade 2 are respectively in compliance with the requirements in ISO 12215-1 grade A and grade B: Grade 1: Quality with good water resistance. Grade 2: Quality with normal water resistance. One DNV Type Approval Certificate will be valid for one quality of the actual product with the possibility to include variants. For polyester and vinylester this means: Grade: one base resin. Variants: different additives such as accelerators and thixotropic agents to modify the resin properties. All variants shall fulfil the requirement to the same grade. Modification to reduce styrene emission is considered as a new Grade. The following properties will be printed in the certificate: fracture elongation tensile strength water absorption HDT Barcol hardness density curing procedure used for Type Testing.

Deviation from the requirements will be stated in the certificate.

4.3 General requirements

4.3.1 Resin properties The manufacturer's description of product shall contain information about which manufacturing methods the resin is suitable for; i.e.: lamination by hand lay-up, spraying, resin transfer moulding, vacuum bagging method etc. The resin is to have good wetting properties and is to cure satisfactory at normal room temperature, or at other specified curing condition. 4.3.2 Requirements to production and quality control arrangement The manufacturer should have a quality system that meets ISO 9000 standards, or equivalent. If this quality standard is not fulfilled, the extent of testing and surveys will be specially considered. Quality control arrangement, including requirements in Table 4-1, are to be checked with respect to the following at Initial, Retention and at Renewal Surveys: control on incoming material. test equipment, test methods, test samples, and references to standards used. system for identification. production test reports from delivery testing.

4. Requirements
4.1 Basis for Type Approval
The DNV Type Approval may be issued based on compliance with one or more of the following Rules/Standards:

DET NORSKE VERITAS

Standard for Certification - No. 2.9, October 2009 Type Approval Programme No. 1-501.9 Page 6

The extent of the manufacturer's quality control during production shall as a minimum be as listed in Table 4-1 to ensure even product quality. The manufacturer shall carry out delivery testing of each consignment and measured values shall be filed and be made available to the surveyor. 4.3.3 Description of Type Testing The extent of Type Testing covers both the liquid resin properties in Table 4-1, or on an equivalent level, and the cured resin properties in sections 4.4 and 4.5. These tests are to ensure that the product properties are as stated by the manufacturer. Type Testing results from all variants are to be submitted to the Society for evaluation, including a summary of the type tests results in the enclosed table, Appendix A. If there are several similar variants a less extensive test program can be agreed upon with the Society. Other standardised test methods than those given for the respective materials may be used upon agreement. Liquid properties of resins will be checked according to product specification at DNV Survey.

Resin in solid condition shall be tested according to Table 4-2 at initial approval and at change of specification. 4.4.2 Requirements to Low Styrene Emission resins (LSE) Resins containing waxes or other substances (like DCPD resins or blends of DCPD), which might lower external adhesive capacity shall be subjected to the delamination test according to Table 4-3: Production of test piece: 1) A laminate consisting of five (5) layers of 450 g/m2 emulsion/powder bounded mat with excess polyester in the upper surface. Curing procedure: 48 h at 23C. 2) A new laminate consisting of five (5) layers of 450 g/m2 emulsion/powder bounded mat is built on the first without any form of upper surface treatment. 3) Curing procedure as selected in section 4.4.1. Fibre weight fraction to be 50% 5. Production of reference piece: 4) A laminate consisting of ten (10) layers of 450 g/m2 emulsion/powder bounded mat. Curing procedure as selected in section 4.4.1. Fibre weight fraction to be 50% 5.

4.4 Requirements to resins for structural laminates

4.4.1 Resin in solid condition For preparation of test samples the curing system shall be specified with type of activator and initiator and% of each. Use of standard MEKP (active oxygen 9.0-9.2%) is preferable. The test samples for each variant shall be made of the finished resin product and cured with one of the following curing procedures: a) Normal curing: 24 hours at 23C. Post curing: 24 hours at 50C. b) Post curing for materials with H.D.T. higher than 85C: 24 hours at 60C. c) Curing systems requiring high temperature cure can be approved after special consideration.

4.4.3 Fire retardant resin for use in lifeboats The finished resin including all fillers shall fulfil the requirements for liquid resin in Table 4-1, or on an equivalent level, and cured resin in Table 4-2, grade 2 and the requirements to combustibility in Table 4-4. A finished resin with water absorption of 100-150 mg per test sample may be approved with a comment in the certificate: The water absorption is outside the requirements. Area of application will be evaluated during approval of classified objects.

Table 4-1 Manufacturer's Quality Control for Polyester and Vinylester in liquid condition. Specify tolerances for base resin and each variant Control on: Test standard 1) Acceptance Criteria Minimum level of verifi- Frequency of control cation Viscosity ISO 2555 (1989) 2) msv 250 mPas Production log available Each batch (Brookfield) or at survey ISO 2884 (1974) (Cone/plate) Monomer content ISO 3251(1993) msv 2% Production log available Each batch at survey Gel time 3) ISO 2535 (1997) for curing time at room temp.: Production log available Each batch of vari< 60 min.: msv 5 min at survey ants. 120-60 min.: msv 10 min Initial DNV survey > 120 min: msv 15 min
For notes and legends see end of Table 4-3

Table 4-2 Testing of mechanical properties of the cured end product Property Test standard Number of Acceptance criteria/Data format parallels Grade 1 Grade 2 Density ISO 1675 (1985) min. 3 msv msv g/cm3 Volumetric curing shrinkage ISO 3521 (1997) min. 3 * msv msv % Ultimate tensile strength 4) ISO 527-1(1993) min. 5 msmv msmv MPa min. 55 min. 45 Tensile modulus ISO 527-1,2(1993) min. 5 msv msv MPa min. 3000 min. 3000 Fracture elongation ISO 527-1,2(1993) min. 5 * msmv msmv % min. 2.5 min. 1.5 Ultimate flexural strength ISO 178 (1993) min. 5 msmv msmv MPa min. 100 min. 80
For notes and legends see end of Table 4-3

Minimum level of verification DNV survey DNV survey DNV survey DNV survey DNV survey -

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Standard for Certification - No. 2.9, October 2009 Type Approval Programme No. 1-501.9 Page 7

Table 4-2 Testing of mechanical properties of the cured end product (Continued) Flexural modulus ISO 178 (1993) min. 5 msv msv min. 2700 min. 2700 Barcol hardness 5) EN 59 (1990) Measured on msv msv ASTM D 2583 (1995) all test speci- min. 35 min. 35 mens Heat deflection temperature ISO 75-2 (1993) min. 5 * msmv msmv min. 70 min. 60 Water absorption 6) ISO 62 (1980) min. 5 * msmv msmv max. 80 max. 100
1) 2) 3) 4) 5) 6) Other standards may be agreed upon with the Society prior to testing.

MPa

DNV survey

C mg

DNV survey DNV survey

For polyester and vinylester the following parameters should be used; Viscometer type A, rotational frequency 10, temp 23 C. Viscosity can be accepted with msv 20%. Specify activator and initiator and % of each. Test samples for tensile testing ISO 527-2/1A/(2 or 5); test specimen 1A and test speed 2-5 mm/min. Resin may deviate from these values, provided a minimum value of 30 is met and the manufacturer can demonstrate adequate cure. Test sample 50 50 4 mm ( 1 1 0,2). Distilled water. Exposure time 28 days at 23C. Resin may deviate from these values, provided the water ageing properties are documented.

* Barcol hardness should be measured on each specimen and comply with manufacturer's specified value.

msv: manufacturers specified value, verified to be within 10% of mean of Type Test results. msmv: manufacturers specified minimum value, verified to be below m-2sdev (mean - 2 standard deviation) of Type Test results.

Legend:

4.5 Gelcoat and topcoat

The gelcoat and topcoat shall be produced of base polyester that fulfils the requirements in section 4.4 grade 1 and Table 4-5. 4.5.1 Fire retardant gelcoat/topcoat for use in lifeboats Fire retardant gelcoat and topcoat shall be produced of base resin that fulfils the requirements to fire retardant resins in section 4.4.3 and shall be able to withstand long term exposure to weathering without any visible signs of crazing, outwash of matter or dramatic colour change.

least include the following information: manufacturers name or trade mark production plant product name (grade) storage instruction production date.

4.6 Requirements to packaging and marking of product

The product or package is to be marked. The marking shall at

The marking is to be carried out in such a way that it is visible, legible and indelible. The product name shall be the same as stated on the DNV Type Approval Certificate (ref. item 1 in section 3).

Table 4-3 Interlaminar strength of LSE resins, double cantilever beam test. Property Test method Number of paral- Requirements lels Interlaminar fracture toughness, DCB
1)

ASTM D 5528 (1994), Mode 1 1)

min. 5

Minimum lev- Frequency of verel of verifica- ification tion Min. 80% of mean strength in reference DNV survey Initial and piece. change of specifiThe fracture shall not be a typical brittle cation fracture with smooth surfaces.

Double cantilever beam test with high loading rate.

Table 4-4 Combustibility testing of fire retardant resin Property Test method Combustibility ASTM D 2863 (1995)

Requirements Oxygen index min. 23

Minimum level of verification DNV survey

Frequency of verification Initial and change of specification

Table 4-5 Properties of gelcoat/topcoat Property Test method Fracture elongation1) Covering
1) 2)

Requirements min. 2.0%

ISO 527-1,2 (1993) 2)

Minimum level of verification DNV survey DNV survey

Frequency of verification Initial and change of specification Initial and change of specification

Complete covering shall be achieved within a thickness of maximum 400 mm of cured resin.

Test of elongation has to be carried out only for gelcoat/topcoats containing more than 15% minerals and other filling compounds. Test sample shall be made of base resin covered with 400 mm cured gelcoat on each side and cured according to procedure in 4.4.1 (Other standards may be agreed upon with the Society prior to testing.).

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Appendix A Type Approval of Polyester and Vinylester products

Please fill in the table and submit to the Society for evaluation.
Manufacturer's name and address: Property Uncured resin Viscosity Monomer content Gel time Test method Product: name: Renewal of cert. no: Requirement

Manufacturer's Specifica- Type Test results tion Average Std. deviation

ISO 2555 (1989) ISO 2884 (1974) ISO 3251 (1993) ISO 2535 (1997)

msv 250 mPas msv 2% for curing time at room temperature: < 60 min.: msv 5 min 120-60 min.: msv 10 min > 120 min.: msv 15 min Grade 1 Grade 2 msv (g/cm3) msv (g/cm3) msv (%) msv (%) msv min. 35 msmv min. 70C msmv max. 80 mg msmv min. 55 MPa msv min. 3000 MPa msmv min. 2.5% msmv min. 100 MPa msv min. 2700 MPa msv min. 35 msmv min. 60C msmv max. 100 mg msmv min. 45 MPa msv min. 3000 MPa msmv min. 1.5% msmv min. 80 MPa msv min. 2700 MPa

Cured resin Density Volumetric curing shrinkage Barcol hardness H.D.T. Water absorption Ultimate tensile strength Tensile modulus Fracture elongation Ultimate flexural strength Flexural modulus Gelcoats Covering requirement LSE resins: Interlaminar fracture toughness Elongation of gelcoat Lifeboat Combustibility

ISO 1675 (1985) ISO 3521 (1997) ASTM D 2583 (1995) EN 59 (1990) ISO 75-2 (1993) ISO 62 (1980) ISO 527-1,2 (1993) ISO 527-1,2 (1993) ISO 527-1,2 (1993) ISO 178 (1993) ISO 178 (1993)

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Max. 400 mm in cured condition ASTM D 5528 (1994), Mode Minimum 80% of mean strength of reference piece I ISO 527-1,2 (1993) Minimum 2.0% ASTM D 2863 (1995) Oxygen index, minimum 23