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BONDSHIP Résumé de rapport

Project ID: G3RD-CT-2000-00101
Financé au titre de: FP5-GROWTH
Pays: Germany

Experiences gained from the definition of application cases as well as design, production, testing and repair of bonded joints specific

The aim of WP5 was to develop design and production techniques as well as repair schemes for bonded joints in large passenger and cruise ships.

MONTHS 1-6 (04/2000 - 10/200): During the first six months of the project, a total of ten application cases for bonded joints were defined and described in detail:
AC1 load bearing secondary structures with large dimensions
AC2 foundations on decks
AC3 fixturing profiles for internal outfitting walls
AC4 lightweight sandwich structures (in cooperation with the SANDWICH project)
AC5 cargo lashing devices on RoRo-decks
AC6 doors, windows and hatches
AC7 gutterways on decks
AC8 joints of large external structures into load-carrying primary structures
AC9 new modular structures for balconies
AC10 attachements below decks

Based on existing mostly welded solutions, detailed requirement sheets were proposed by IFAM and filled by Meyer Werft and IFAM. These sheets are detailing loads, environmental conditions, production requirements etc. for all application cases.

After defining the AC's, the principal design of a large prototype structure was started. This structure (sized 7.5m x 4.2m x 2.5m) was designed to be as close as possible to a real ship structure and to accommodate all application cases. The principal design of the prototype was discussed with the partners and the details of the application cases were given to the experts within BONDSHIP, which made recommendations for the design of joint details. The main partners involved in this activities were Meyer Werft, IFAM, R&R and SiKa. Results of joint designs and calculations have already shown, that a rethinking is required by the shipyard towards a Design for Bonding.

This however could decrease the economic benefits obtained from using adhesive bonding techniques and will limit the applicability for onboard changes which is one of the main goals of the shipyard.

Result of these activities was an official report (Deliverable):
Deliverable Nr. 5-51-D-2001-01-0: Basic specification of application cases

MONTHS 7-18 (10/2000? 09/2001): After the applications were defined the planning of the prototype began. The prototype consists of a loadbearing welded ship steel structure (L=7m; B=4,2m; H=2,5m), in which the applications for bonding are accommodated. We got with it both experience in production & repair of bonding components and knowledge regarding stiffness, fire safety, resistance to environmental conditions etc. by tests. Planning comprises also strength calculations for each of the 10 applications by finite element analysis (FEA) at the institute Ifam in Bremen. Additionally Ifam in Bremen and Sika in Zurich made screening tests with materials, which were used on Meyer ships. This was made, in order to determine suitable material/adhesive combinations and to assign these suitable surface pretreatments.

Official report deliverable NR. 5-51-D-2001-01-0: Detailed Design OF Meyer throwing prototype

MONTHS 19-23 (10/2001? 02/2002): In the middle of year 2 planning could be finished and it began the building of the prototype.

Application case 4 in WP5 comprises a number of solutions based on the application of sandwich panels, which are being investigated in close cooperation with the SANDWICH project. A cooperation agreement between the two projects were obtained allowing both projects to use the results in their consortia. Tests have clearly shown the need to further improve the adhesive bonding techniques, the results of first strength tests within the SANDWICH project have been encouraging showing clear increases in the stiffness of sandwich panels due to the implemented filling materials in the range of 30% transverse to the stiffeners. The production of the prototype joints and improvements towards a high quality bonding process will be the main tasks for the second project year.

Official report at DNV in Høvik: Deliverable NR. 5-52-D-2002-02-0: Prototype - JLM

MONTHS 24-30 (03-09/2002) to the end Year 2 (03/02) production was finished and it began with the bonding of the components. For this preliminary manufacturing processes on basis of the screening tests were designed and the steps of bonding were stipulated. Deviating steps were taken up during the bonding and the bonding steps were accordingly corrected. The bonding was realized with support of Ifam and Sika. Planning for testing began from this moment. Testing of the components began in 08/02. Stiffness -, creeping- and load-tests were carried out. In addition repair trials at two applications were accomplished, in order to be able to develop repair guidelines.

Official reports:
Deliverable NR. 5-52-D-2001-01-0: First draft of production procedure
Deliverable NR. 5-52-D-2002-01-0: Final production procedures
Deliverable NR. 5-53-D-2002-01-0: Final repair guidelines.


Thomas REINERT, (Designing engineer)