Building ‘Greener' Boats

December 2002 - January 2003

This is an article from WaveLength Magazine, available in print in North America and globally on the web.
To download a pdf copy of the magazine click here: > DOWNLOAD

by Jamer Buote

When the idea of submitting an article on kayak and canoe construction was first proposed to me, my coworkers and I had just completed a major project using the latest vacuum infusion technology.

Since building boats is as much a passion of mine as paddling them, I appreciate the opportunity to share some insights on the benefits of new construction techniques with fellow paddlers.

Although there is a wide variety of materials to build paddlecraft from, it seems fiberglass holds an edge in the minds and choices of most paddlers. Fiberglass is a great medium for kayaks and canoes since it's possible to mold it into the flowing, complex shapes of modern kayaks and canoes.

It's also very durable, when used properly, and stands up well to years of heavy use. My old fiberglass canoe has logged more than a few miles over the last 20 years and still looks surprisingly good with only minimal maintenance and upkeep.

A major downside to fiberglass construction is the negative impact on our environment. It can be fairly noxious stuff, as anyone who has worked with it or been close by when it is being used, will attest.

Fortunately, awareness is gaining momentum and tougher restrictions are being imposed on the fiberglass industry to reduce both airborne emissions and solid wastes. Although there are some in the industry that feel these new regulations are too costly to implement, many others are working hard to develop technologies that meet or surpass these new regulations and guidelines.

With vacuum infusion, and other closed molding techniques, the harmful gasses associated with fiberglass manufacturing are contained under a vacuum bag or between the two-part molds. The off-gas normally associated with fiberglass construction is all but eliminated by using these techniques since the gas can be filtered both before and after the vacuum pump.

These new techniques also use less material than the traditional open or "hand laid" methods, so reduce the amount of solid waste that eventually ends up in landfill sites. Even vacuum bagging, which is quite different than vacuum infusion, can contribute to excessive solid waste if con-ventional bagging materials are used.

Although reusable silicone bags and two-part molds may seem expensive initially, they allow very impressive production runs making them cost effective over the long term.

Another area that benefits from closed molding techniques is the manufacturing workplace. With greatly reduced emissions, the shop floor is certainly a much healthier and friendly atmosphere for those using these newer methods. In the past, laminators looked more like alien life forms than boat builders after donning the suits and breathing apparatus required to work with chemicals used in fiberglass construction.

All this is obviously good news for the environment and for those of us who work within the manufacturing industry but there are also significant benefits to those who paddle the boats made this way. Not only are closed molded kayaks and canoes "greener", they are also stronger and lighter than boats made using older methods.

With traditional hand laid or open molded boats, the resin is applied to dry fiberglass cloth material then rolled or scraped to distribute the liquid evenly through the cloth. A skilled laminator can attain a glass to resin ratio of close to 60% but a 55 to 45% ratio is more often the norm.

Vacuum bagging has the resin added to a dry laminate, then the bag is added and the resin is then spread through the laminate with rubber or hard plastic squeegees. The glass fabric or cloth to resin ratio is only slightly higher than the best hand laminate but the reduction of resin does decrease the finished product's weight somewhat.

Modern materials definitely have their their advantages but our friend Doug has identified at least one potential downside..."Guess I parked 'er a little too close to the camp fire."

With vacuum infusion, the dry cloth laminate is bagged under very high pressure, normally 14.5 pounds per square inch, which translates to a ton of force per square foot. Under this pressure, all moisture and air is removed from the dry laminate before the resin is introduced. The vacuum pressure is then used to draw the liquid resin through the laminate and is maintained until the part solidifies.

The result is a finished product that uses less resin and yields a glass to resin ratio of 70 to 30%. Since there is no excess resin in the material laminate, we see an increase in strength and a reduction in overall weight.

Many paddlers opt for carbon or carbonkevlar to gain extra strength, and to drop a few pounds of weight, but that comes with a price tag that is hard to justify for some of us. Generally speaking, the cost of these materials ends up averaging $100 per pound of weight saved.

With infusion we can gain the strength and lose some weight without the extra cost associated with exotic materials like carbon and kevlar. Because the infusion process lends itself so well to production manufacturing, these advantages need not come at the higher costs attached to these exotic materials. Ironically, even the exotics like carbon and kevlar gain from the infusion process and yield the same advantages enjoyed by the more conventional materials, again without adding to the cost.

Although some companies are slow to embrace these new techniques, it is obvious that environmental concerns and the added advantages of closed molding will set the demand for stronger, lighter and "greener" kayaks and canoes.

Since paddlers in general are a very environmentally aware group I'm confident that we will soon have the choice of our favorite designs constructed with the latest technology - if we ask we will receive. Here's to "greener" boats.

© Jamer Buote is President of Inukshuk Adventure Group on Vancouver Island. He has 31 years in the marine manufacturing industry and 25 years experience in composite manufacturing. He's an avid paddler, sailor, hiker and dog musher.