BahanKuliah_AKPI_MerancangKapal

8/4/2019 BahanKuliah_AKPI_MerancangKapal

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Merancang Kapal

(Boat Plans)


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KAPAL KAYU

(WOODEN CRAFT)


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Tentukan Ukuran Utama Kapal


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Buat Desain Lengkap Rangka Kapal


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FERROCEMENT CRAFT


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Boat Plan Components

A complete set of plans for the construction of a fishing boat willprobably vary from one designer to another, but should include atleast the following drawings for a ferrocement fishing boat:

1. Lines plan and offset table2. Hull construction profile and plan3. Hull section/frame detail4. General ferrocement reinforcement details5. General arrangement profile and plan6. Sterngear and liner tube details7. Ruddergearand liner tube details8. Fuel tank(s) construction details9. Watertank(s) construction details

10. Deck construction11. Superstructure profile plan and details12. Fish hold construction details13. Hydrostatics and Stability curves


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Lines Plan


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SiteThere are therefore various considerations to take into account prior tosite acquisition:

A. Budget allocated: Is it sufficient for outright purchase or for rent? Howare these costs to be viewed, eg as an investment, recoverable onoverheads, etc.

B. Vessels: Type, quantity, and size of vessels to be constructed at anyone time.

C. Fitting out: Whether completion or part completion, hulls only, or a

combination of these is envisaged.D. Size of site: Allowing for construction, machinery, material storage,offices, transport and/or launching, consideration of productionexpansion at a later date.

E. Location: To river, sea or lake.

F. Moving: Launching and/or transport facilities.

G. Amenities available: Electricity, water, etc.

H. Availability of materials: Local and/or distant.

J. Access: Road, rail, river, sea, air.

K. Product marketing: Area of access, range of product needed to fulfilrequired volume of sales.

L. Classification Society: Surveyor easily available.


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Workshop Layout Flooring

A reinforced concrete floor, incorporating suitable drains to remove excesscuring water (if this method of curing is to be utilized). The floor should bedesigned to withstand the local loads applied when jacking and moving thesize of vessel to be constructed. It is advisable at this stage to incorporatesuitably located dead-men in the floor, to facilitate easy movement of theboats around the workshop.

Building framework

The building framework should ideally be designed to allow for the use ofhanging tie rods to support the boat's reinforcement both prior to and duringcasting and curing, if this method of construction is adopted. As well asindifferent use whilst lifting engines, deck equipment, etc.

Building height

The height of the eaves of the building should be sufficient for ease ofworking on the sizes of vessels to be built. This may vary from the

ferrocement workshop to the fitting out workshop if composite constructionis envisaged. Also, free air ventilation in hot climates must be allowed forwhilst being able to nullify the affect of wind or draughts during the castingstage. In cold climates extractor fans for removal of welding fumes, etc. willbe required


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Roof trusses

In the ferrocement workshop, it is convenient if the trusses are designed so thatadjustable longitudinal RSJ's may be located to suit hanging tie rods for theconstruction phase of the hulls.

Building cladding

Suitable cladding and construction materials, and insulation to offset the effects ofheat or cold, should be incorporated in the building. This may be one of the requisitesof a classification society.

Material storage

Suitable covered storage for materials should be allowed for, including the properracking and storage of steel, mesh, cement and sand, as well as followingmanufacturers' recommendations regarding storage and treatment of materials to be

held in stock. Access

Adequate access should be provided for receiving materials and for allowing freemovement of personnel around the working areas (fire and safety precautions).

Movement

Adequate access and space for moving the craft to water, whether by slipway, road,or other means, should be allowed for.

Machinery and equipmentDue consideration should be paid to space for machinery and equipment required notonly during the ferrocement phase of construction, but also for fitting out where avariety of different materials may be considered for use including perhaps timber,steel and fibreglass.

Covered space

Sufficient covered space including adequate structures for offices, toilet facilities,lofting and frame making, should be taken into account.


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Services Electricity

Although ferrocement craft can be constructed without electricity, itwill normally be a requirement to have sufficient power available forthe use of welders, grinders, drills, lights, vibrating equipment, as wellas for machinery required for fitting out, including in-houseengineering. This may mean, dependent on equipment, 3-phase aswell as single phase electricity supply being available in 120/240/440volts as applicable.

WaterGood clean and potable quality water should be available. Ice

If possible in hot climates, a local supply of ice made from potablequality water would be advantageous in the casting process.

Gas

Availability of gas for use in oxyacetylene equipment. Hire/Rent/Lease

Some items of service and/or equipment may be hired, rented, orleased if outright purchase is not appropriate


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Teknologi VMS Merupakan Bentuk Fasilitas Service Kapal


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MATERIALS USED IN FERROCEMENTCONSTRUCTION

4.1 Frame rods4.2 Rod reinforcement4.3 Mesh reinforcement4.4 Staples and lacing wire

4.5 Welding rods4.6 Cement4.7 Sand4.8 Admixtures

4.9 Jointing compounds4.10 Water
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4.1 Frame rods

The ideal rod to use is a cold worked high yield(CWHY) rod to British Standard (B.S) 4461although both plain bars and deformed bars maybe used. The latter may be more difficult to usewhen welded by inexperienced people.

4.2 Rod reinforcement

For use in the hull shell, deck floors, bulkheadsand stiffening webs or girders; ideally should bea semi-bright hard-drawn (SBHD) rod of 6 and 8mm diameter for concrete reinforcement to BS

4482. Mild steel rod to BS 15 may also be usedbut in practice will require closer frame spacingor support to prevent being bent out of shapeduring construction and/or distortion by welding.
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4.3 Mesh reinforcement

The ideal mesh is a 13 x 13 mm x 19 gauge (1 mm) welded mesh toBS 4482. Although meshes of 18-22 gauge can be used, 19 gauge

will prove to be the best from a practical point of view. In colder, lesshumid climates, it may be used ungalvanised; in semi-tropical/tropical it will need to be galvanised

4.4 Staples and lacing wire

Staples and lacing wire are best made from 1.6 mm or 16 gaugeplain degreased annealed mild steel lacing wire. This can be

purchased in 25 kg reels and cut on a suitable jig to provide either30 mm or 40 mm length staples to suit single and double rodconstruction, with the legs of the staples set at a width to suit thesize of mesh being used.

4.5 Welding rods

The normal gauge of welding rod required will be 10 swg or 3.25

mm, although small quantities of other gauges will also be used.Welding rods are of general purpose, all angle type, and should becared for in compliance with the manufacturers advice and goodpractice.
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4.6 Cement

The cement to use is usually ordinary Portland. However, a rapid hardeningPortland cement may be used in cold climates. Sometimes a sulphateresistant Portland cement is used, either wholly or in part mixed with

ordinary Portland against sulphate attack, although as most vessels areprotected by marine paints and antifouling, its use is hardly necessary. If thecement is used with admixtures, care should be exercised in compatibility.All cements are to be to BS 12 or equivalent local standard.

Other cements may be considered providing they offer adequate strength,density, and uniform consistency

4.7 Sand

The importance of good, clean, well graded sand, cannot be overemphasized if one is to make the high grade impervious mortar required forboatbuilding.

The sand will be of a silicious nature and conform to the grading envelopeshown in Fig. No. 6. The sand is not to contain sulphates, pyrites, or otherchemically active substances in such amounts that the mix is harmed. If seasand is used, it is to be washed free of any saline compositions. (It is

always preferable to use non-saline river sand.) The sand should notcontain loose clay or clay which adheres or covers the sand grains. Thesand is not to contain humic acid or organic materials in quantities that maybe detrimental. Preferably, the sand should be 'sharp' and not contain non-crystalline minerals.
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4.8 Admixtures

There is such a wide range of admixtures available today that one cannot makerecommendation without first testing those chosen. If they are to be employed, careand discretion should be exercised at all times.

Three main criteria should be considered when applying admixtures:

a) Is the strength of the mortar increased or decreased?b) The effect of the admixture on the steel reinforcement.c) Practicality of use on site and supervision of exact mixing quantities.

4.9 Jointing compounds

With the advent of new methods for joining concrete, far more jointing compounds areavailable for making 'wet' joints in cement structures. It is always best to carry outtests on the potential system before use.

For joints in hull construction and repair, a two component epoxy polysulphide resingives an excellent bond. If this is not obtainable, a cement grout applied judiciouslywill give better results than some PVA glues that are commonly available to thebuilding construction industry.

4.10 Water

Mixing water should comply with the requirements of BS 3148. Water should bepotable, clean, and free from harmful salts or foreign materials which may impair thestrength and resistance of the mortar.

BS 3148 gives details of testing water for concrete by comparing the properties ofconcrete made with any particular sample of water with those of an otherwise similarconcrete made with distilled water; therefore the tests will usually be performed in alaboratory.
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MATERIAL TESTING AND PRACTICE

5.1 Compression test5.2 Slump test

5.3 Taking a sample of cement

5.4 Sand testing and practice

5.5Water:cementratio (weight)5.6Cement:sandratio (weight)

5.7 Additional tests
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CONSTRUCTION OF A FERROCEMENT HULL

6.1 Introduction6.2 Design6.3 Supporting the structure

6.4 Keel, backbone and stem construction6.5 Frame, web and floor construction6.6 Setting up the frames6.7 Sheer or gunwale6.8 Knuckle line6.9 Fairing in the frames6.10Beamshelfconstruction6.11 The hull reinforcement6.12 Liner tubes for stern gear and rudder gear6.13 Plummer block supports6.14 Engine bed construction6.15 Bilge keels6.16 Requirements for fitting a nozzle

6.17 Preparatory work prior to casting6.18 Casting procedure6.19 Curing the hull6.20 Water testing and finishing off
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