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95-14 Assessment of Fire, Smoke, and Toxicity Characteristics
of Composite Materials Proposed for Marine Applications
Objective Determine the flammability, smoke, and toxicity properties of composite
materials and identity promising candidate material systems for ship and offshore
platform structures designed to meet international fire-safety and envirorunental
standards.
Benefit The study wall provide needed understanding of the opportunities and limitations
of the application of composites in compartments subject to fire hazard. It wall provide
the stimulus for encouraging new matenals development and provide the opportunity to
evaluate promising new fire-resistant materials.
SSC National Goals
· Improve the safety and integrity of marine structures.
· Reduce marine environmental risks.
SSC Strategy Prevention research, including damage-tolerant structures, structural
monitonng, and human factors
Background Materials used to construct and outfit commercial ships must meet stringent
requirements for flammability, while still meeting nave] architectural requirements for
light weight and low cost. The International Convention for the Safety of Life at Sea,
1974, as amended, requires the hull, superstructure, structural bulkheads, decks, and
deckhouse to be constructed of steed or other equivalent matenals. "Equivalent
matenals" is further defined in the convention as any noncombustible matena] that by
itself or because of insulation provided, has structural and integrity properties equivalent
to those of steed at the end of standard fire tests. Further requirements are also
established for bulkhead, ceiling, and deck matenals. The lack of generation of smoke
and tome combustion products in a fire is also important for successful fire safety.
Paradigms about the performance of composite matenals in a fire are often inconsistent
with test results. Tests on fberglass/epoxy pipe, for example, have demonstrated the
safety meets of the use of fiberglass pipe in firewater systems on onshore platforms, and
fiberglass/epoxy firemain pipes are now used in most parts of the world, including the
United States, the North Sea, and the Middle East. Me United States, Norway, and the
United Kingdom are highly active in assessing the safety of materials in a fire safety, and
this project should take advantage of U.S. and foreign developments to ensure that the
study does not duplicate prior efforts. The program should concentrate on commercially
available materials. Phenolic resins have shown promise in past studies; however, a host
of new materials have recently become available, including several manufactured in the
United States.
The workshop sponsored by the SSC entitled "Use of Composite Materials in
Load-Beanng Manne Structures" (SR-1331) strongly recommended that work be done on
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the fire characterization of composite materials, including their flammability, smoke, and
toxicity properties.
Recommendations
· Survey the existing data base on fire performance of composite materials,
including data from non-U.S. programs. The contractor should also solicit industry for
promising new fire-resistant materials with low smoke and toxicity charactenstics. This
survey should consider matrix resins as well as insulation materials and include all
possible solutions, including thermoses and thermoplastic resins and phenolic-based
materials.
· Survey and identity appropriate test methods for evaluating the performance of
composite materials for marine structural applications.
· Conduct fire, smoke, and toxicity tests on promising new materials for which
data are not available.
· Identity applications where fire-resistant composite matenais could provide
enhanced safety, structural efficiency, and competitive economical advantage. For
example, a fire-resistant resin might be used to construct pipe that would be sufficiently
fire resistant that it did not require separate fire-protection insulation for dry Remain
pipe application. Other examples might include a composite structural frame or
bulkhead, composite deckhouse, or accommodation module.
· From a human-factors viewpoint and considering fire and smoke standards,
recommend maximum acceptable smoke and toxicity threshold levels for the applications
studied above.
Duration 4,000 labor hours over 2 years
95-15 High Productivity Welding Processes (9413)
Objective Reduce new ship construction costs and improve weld property control
through automation of welding processes.
Benefit The data developed by this project wall provide information to shipyards and
allow them to (~) better develop new processes for higher productivity welding and (2)
assess the improvements inherent In automated processes particularly in weld geometry
control that improve ship integrity. This work will assist shipyards in obtaining code and
Industry acceptance of the new procedures and wall develop methods of using the higher-
quality processes.
SSC National Goal Support the U.S. maritime industry in shipbuilding, maintenance,
and repair.
SSC Strategy Development of structures-related producibility technology
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Background In recent years, improvements in utilizing conventional welding processes
have enhanced productivity. While the U.S. industry in the last decade has been
concentrating on Navy ship construction, European and Japanese shipyards have
advanced automation in commercial ship construction, which is more readily adapted to
such methods. It is essential that the domestic shipyards move from the facilities
optimized for high flexibility and di~cult-to-weld materials in Navy construction to
commercial ship construction, which emphasizes highly repetitive producible designs that
use materials that are more readily welded. A rigorous assessment of the state of the art
In foreign shipyards and related industries should add to the high-productiv~ty methods
now used in the U.S. heavy industry. Application of these techniques to domestic
shipyards should improve the productivity of fabrication ~ commercial and military ships.
Automated methods produce more consistent and controlled weld geometries.
This improved eeometn has better fatigue nerfonnance than that produced hv In
. _ ~ ~ 1 ~ r~~~~~~ —J ~
and semiautomatic methods. The automated processes wall also control thermal
parameters better to reduce vanability in weldment properties.
A methodical and quantitative study of the venous improvements in fabrication
and welding processes should provide the domestic shipbuilding Must th a bench-
mark to assist planning for new automated facilities. Me impact of automation on
weldment properties could lead to designs that are more cost-effective.
Recommendations Perform the following tasks:
· Identifier and catalog recent productivity improvements (new electrodes,
procedures, and gas mixtures) in commercial welding processes, and identifier the state of
the art In automation in the foreign shipbuilding industry, such as gantry robotics;
portable robotics; portable mechanized equipment; new high-speed butt-welding
processes; and adaptive controls for seam tracking, fill, and penetration control.
· Based on available data, assess the improvements possible in venous processes
used by the industry for specific welding tasks in ship construction. Define benefits and
trade-offs in terms of deposition rate, operating characteristics, and other welding factors
that affect productivity. Note effects on weld quality (e.g., improved process control and
better control of weldment geometry and properties), and develop sufficient background
information to permit designers to take better advantage of the improved consistency of
automated welds.
· Prepare a quantitative report for use by the marine industry, with the potential
to assess cost savings and code acceptance.
Duration 2,000 labor hours over 2 years
95-16 Evaluation of Marine Structures Education in North America
Objective Provide the knowledge needed for the SSC to wisely and effectively take steps
to improve the structural engineering departments in North American colleges and
universities In support of ship structural design.
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Benefit The project wall result in improved training In ship structural design and
construction and hence improved ship structural designs and international
competitiveness of the U.S. shipbuilding industry.
SSC National Goals
· Improve the safety and integrity of marine structures.
· Reduce marine environmental risks.
· Support the U.S. maritime industry in shipbuilding, maintenance, and repair.
SSC Strategy Sponsoring university research in areas such as design tools development,
Producibility, production Drocesses. reliability design. and dama~e-tolerant structures
O — _ ~
Background In many instances, ship structural designers have either undergraduate or
graduate degrees, or both, in civil engineering. Therefore, all applicable aspects of
structural eng~neenng are included in this discussion of ship structural design. The SSC
has officially recognized in its strategic plan that healthy, capable schools teaching
modern methods of ship structural design and construction are essential to sustaining and
improving the international competitiveness of the U.S. ship design and construction
industry. At the same time, the SSC has recognized that the extent and quality of ship
structural engineering education has apparently declined in recent years and has
indicated a desire to take steps to improve the situation. Reasons for the decline noted
above seem to include the genera] decline of eng~neenng as a career choice of talented
high school students. In addition, the decline of commercial shipbuilding in the U.S. has
had two effects—a decline In the number of students attracted to ship structural design as
a career choice and a decline in the pool of faculty candidates with relevant ship
structural design experience. Furthermore, the reduction in government and industry
support for university research in ship structure research and development has decreased
the number of faculty members who specialize in this area. The SSC must be armed
with facts concerning the current status of and trends in ship structural design and
construction education before it can make proper decisions on how to improve the
situation.
Recommendations Perform the following tasks:
· Perform a study to assess the current status of applicable ship structural design
and construction training in North America and trends in the condition of that training.
Address both undergraduate and graduate programs at public and private institutions.
Utilize external resources such as Accreditation Board for Engineering and Technology
and the Education Committee of the Society of Naval Architects and Marine Engineers
as well as direct contact with the institutions themselves.
· Develop a set of questions that can be asked of each institution to gain a
comprehensive understanding of the situation. Examples of topics about which questions
might be asked are
I. the annual number of graduates who have majored in ship structural
design and recent trends;
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2. the annual number of students attending ship structural design courses and
recent trends;
3. courses offered In ship structural design and ship construction;
4. the content of the shin structural design and ship construction courses
offered;
5. the balance between theoretical and practical design courses;
6. design projects required (length, scope, individual versus team efforts, etc.~;
7. practical work experience required;
8. lab work required;
9. industry experience of facula in ship structural design;
10. faculty experience in ship structural design research and development;
Il. industry experience of faculty in ship construction;
12. emphasis given in curriculum to ship production and producibility of
structural designs;
13. emphasis given to economic aspects and cost-effectiveness trade-offs in
ship structural design; and
14. emphasis given to the relationship between ship structural design and
total ship system design.
· Perform an analysis of the survey results to develop a comprehensive picture of
the current status of ship structural design and construction education in North America.
· Identitr major deficiencies and problem areas.
· Develop a set of recommendations for SSC actions that would help to correct
the major problems identified.
Duration 1,000 labor hours over ~ year
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RESEAlRCHRECOMMENDATIONS FOR FYs 1998-1999
SR-1368 Compensation for Openings in Structural Members
Investigator John Hopkinson
Contractor Vibtech, Inc., North Kingstown, Rhode Island
Objective Establish rational methodologies and guidelines for the determination
of appropriate compensation for small and large openings in primary structural
members of ships. Two sets of guidelines are required, one suitable for
oreliminarv and contract design and another for detailed design. The efficiency
and reliability of structural reinforcements around openings In primary structures
should be improved and their design ant! construction should be made less costly.
Project Chair Stephen G. Arntson, Arlington, Virginia
Technical Adviser none assigned
SR-1369 Fleet of the Future Publication Review
I~lYlesti.~llor~.~ohn w Fisher
C`)ntr~.tor Lehigh University, Bethlehem' Pennsylvania
Objective Review the work published by the Center for Advanced Technology
for Large Structural Systems of Lehigh University under the U. S. Navy-
sponsored "Fleet-of-the-Future" program. Summarize the material in a single
volume and publish it as an SSC report.
Project Chair William I. Siekierka, Naval Sea Systems Command, Arlington,
Virginia
Technical Adviser none assigned
SR-1374 A Guide to Damage Tolerance Analysis of Marine Structures
Investigator LalitMalik
Contractor Fleet Technology Tnc., Kanata, Ontario, Canada
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ACTIVE AND PENDING PROJECTS
This section covers current projects funded with FY 1992 (or earlier) funds, those
continued with FY 1993 funds, and those that will be supported with FY 1994 funds.
They constitute the current program. The majority of projects are for one year;
multlyear projects are funded incrementally on an annual basis.
Project descriptions include the project number and title, the name of the
pnncipal investigator and organization (when determined), a brief statement of the
project's objective, and the names of project chairmen and technical advisers (when
assigned).
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TABLE 4 Active and Pending Projects
Number Project Title
SR-1300 Evaluation of a Generalized Onboard Response Monitoring
System (Phase 2)
SR-1335 Interactive Nature of Cathodic Polarization and Fatigue
SR-1338 Uncertainty in Strength Models for Manne Structures
SR-1339 Effect of High-strength Steels on Strength Considerations of Design
and Construction Details of Ships . . . . .. . . . . . . . . . . . . . . . .
SR-1341 Residual Strength Assessment for Damaged Marine Structures
SR-1342 Hydrodynamic Impact on Displacement Ship Hulls ..
SR-1343 Optimized Weld Metal Properties for Ship Structures . . .
SR-1344
SR-1345
Assessment of Reliability of Existing Ship Structures (Phase 2)
Probability-based Design (Phase 3~: Implementation of Design
Guidelines for Ships . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .
SR-1346 Improved Ship Hull Structural Details Relative to Fatigue
SR-1348 Measurement of Ice Loads on Ship Structures . .... . .
SR-1349 Evaluation of Ductile Fracture Models for the Prediction of Fracture
Behavior of Ship Structure Details
SR-1350 Reexamination of Design Criteria for Stiffened Plate Panels . . . . . . .
SR-1351 Hull Structure Concepts for Improved Producibility
SR-1353 The Role of Human Error in the Design, Construction, and Reliability
of Manne Structures
SR-1354 Grounding Protection of Tankers
SR-1355 Inspection of Marine Structures
SR-1356
SR-1357
SR-1358
SR-1359
SR-1360
SR-1362
· · · . —
Strength Assessment of Pitted Plate Panels
Retention of Weld Metal Properties and Hydrogen Cracking
Optimized Design Parameters for Welded TMCP Steels . . . .
U.S.-Russian Cooperative Research Effort .. .... ... . .....
Structural Maintenance Project
Probability Based Design (Phase 4), Synthesis of the Reliability Thrust
Area 72
SR-1363 Symposium and Workshop on the Prevention of Fracture in Ship Structures
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· · · ·
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SR-1364 Guidelines for Evaluation of Finite Element Models and Results
SR-1365 Optimal Strategies for Inspection of Ships for Fatigue and/or Corrosion
Damage
SR-1366 Corrosion Control of Inner-Hull Spaces . . . .
SR-1367 Design Guide for Marine Applications of Composites
SR-1368 Compensation for Openings in Structural Members
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SR-1300 (Phase 2) Evaluation of a Generalized
Onboard Response Monitoring System
Investigator Jack W. Lewis
Contractor ARCHAIC Offshore Corporation, Escondido, California
Objective Evaluate a generalized operations-oriented stress and motion monitoring
system under shipboard operating conditions.
Project Chairman Walter M. Maclean, U.S. Merchant Marine Academy, Kings Point,
New York
Technical Adviser C. B. Walburn, Bethlehem Steel Corporation, Sparrows Point,
Maryland
SR-1335 Interactive Nature of Cathodic Polarization and Fatigue
Investigator Car] E. Jaske
Contractor Cortest Columbus Technologies Inc., Columbus, Ohio
Objective Investigate the effects of cathodic polarization on fatigue of steel in seawater
and how cathodic polanzation is influenced by notch severity, crack size, and material
composition and microstructure (steed strength).
Project Chainnan William Hanzalek, American Bureau of Shipping, Houston, Texas
Technical Adviser William H. Hartt, F1orida Atlantic University, Boca Raton
SR-1338 Uncertainty in Strength Models for Marine Structures
Investigator Owen Hughes
Contractor Ross/McNatt Naval Architects, Stevensv~le, Maryland
Objective Quantify bias and uncertainty in structural strength formulations In order to
evaluate safety margins and derive design criteria.
Project Chairman Rickard Anderson, Military Sealift Command, Washington, D.C.
Technical Adviser Paul H. Wirsching, University of Arizona' Tucson
6s
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SR-1339 Effect of High-strength Steels on Strength Considerations
of Design and Construction Details of Ships
Investigator Peter W. Buermann
Contractor Gibbs & Cox, Inc., New York, New York
Objective Analyze the in-service failures in construction details using high-strength steels,
identifier problem areas, and recommend design and construction details to reduce
problems.
Project Chairman Philip G. Rynn, American Bureau of Shipping, Houston, Texas
Technical Adviser Roger G. Kline, Consultant Ship Structures, New Berlin, Wisconsin
SR-1341 Residual Strength Assessment for Damaged Manne Structures
Investigator Christopher J. Wiernicki
Contractor Designers and Planners, Inc., Arlington, Virginia
Objective Develop approaches to assess the residual strength and life of marine
structures that have sustained damage in service.
Project Chairman John S. Spencer, American Bureau of Shipping, Houston, Texas
Technical Adviser Maria Celia C. Ximenes, Chevron Shipping Company, San Francisco,
California
SR-1342 lIydrodynamic Impact on Displacement Ship EIulis
Investigator John C. Daidola
Contractor M. Rosenblatt & Son, New York, New York
Objective Assess the state of the art in estimating forebody hydrodynamic impacts on
displacement ship hulls, and develop a plan for future research on hydrodynamic impact
loadings on marine structures. The plan must address slamming, wave slap, and
Frontal impacts.
Project Chairman Allen H. Engle, Naval Sea Systems Command, Washington, D.C.
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Technical Adviser Subrata K. Chakrabarti, Chicago Bndge & Iron Co., Plainfield, Illinois
SR-1343 Optimized Weld Metal Properties for Ship Structures
Investigator Robert J. Dexter
Contractor Advanced Technology for Large Structural Systems Engineering Research
Center' Lehigh University' Bethlehem' Pennsylvania
Objective Develop guidelines to improve productivity by optimizing weld-metal
properties for use with high-strength steels.
Project Chairman J. Allen Manuel, Naval Sea Systems Command, Arlington, Virginia
Technical Adviser James M. Sawhill, Jr., Newport News Shipbuilding, Newport News,
Virginia
SR-1344 Assessment of Reliability of Existing Ship Structures (Phase 2)
Investigators Alaa Mansour
Contractor Mansour Engineering, Inc., Berkeley, CalifoInia
Objective Estimate reliability levels associated with important failure modes of existing
ship structures.
Project Chairman Robert A. Sielski, Manne Board, Washington, D.C.
Technical Advisers Keith Hjelmstad, University of lIlinois, Urbana; Solomon C.S. Yim,
Oregon State University, Corvallis
SR-1345 Probability-based Design (Phase 31:
Implementation of Design Guidelines for Ships
Investigator not yet determined
Contractor not yet determined
Objective Develop a prototype probability-based design or safety-checking criteria for
ships.
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Project Chairman Bill Richardson, Carderock Division, Naval Surface Warfare Center,
Carderock, Maryland
Technical Adviser Achintya Haldar, University of Arizona, Tucson
SR-1346 Improved Ship Elull Structural Details Relative to Fatigue
Investigator Karl Stambaugh
Contractor Consulting Naval Architects, Severna Park, Maryland
Objective Develop a series of improved structural details that accounts for the unique
fatigue stress pattern of ship structures.
Project Chairman Chao Lin, U.S. Mantle Administration, Washington, D.C.
Technical Adviser Robert L. Clark, Clark—Cim, Inc., Reston, Virginia
SR-1348 Measurement of Ice Loads on Ship Structures
Investigator J.W. St. John
Contractor Science Technology Corporation, Columbia, Maryland
Objective Develop a data base on ice loads that could be used for probability-based
design approaches. Assess the effects of ship displacement, impact location, and hull
shape on the ice impact loads on icebreakers and other marine structures.
Project Chairman Rubin Sheinberg, U.S. Coast Guard, Washington, D.C.
Technical Adviser none assigned
SR 1349 Evaluation of Ductile Fracture Models for the
Prediction of Fracture Behavior of Ship Structure Details
Investigator Robert J. Dexter
Contractor Lehigh University, Bethlehem, Pennsylvania
Objective Establish the effectiveness of ductile fracture mechanics models for predicting
the fracture behavior of component ship-structure details.
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Representative terms from entire chapter:
structural design
