JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 44

FEATURE “Marine” Earthrace breaks world record thanks to composite industry support Earthrace is an incredible 78ft wave-piercing trimaran powerboat that runs as a carbonneutral project, exclusively on 100% biodiesel. T he boat left Sagunto, Spain, where she was undergoing a full pre-record refit, on 27 April in an attempt to break the round-the-world speed record. The full record route was as follows: Sagunto (Spain), Azores, Puerto Rico, Panama Canal, Manzanillo (Mexico), San Diego (USA), Hawaii, Majuro (Marshall Islands), Koror (Palau), Singapore, Cochin (India), Salalah (Oman), Suez Canal, Sagunto (Spain). The boat crossed the finish line in Sagunto at 13.42 GMT on Friday 27 June, having taken 60 days 23 hours and 49 minutes to travel about 24,000 nautical miles fuelled by biodiesel to demonstrate the efficiency of alternative fuel sources while drawing global attention to their potential. Earthrace, the world’s fastest eco-boat, smashed the world speed record for a powerboat to circumnavigate the globe, knocking almost 14 days off the previous record.“This fantastic team of people and our astonishing boat have broken the record by a massive margin”, said Pete Bethune, New Zealand skipper and owner of Earthrace. Composites on board With the support of major players in the composite industry, Earthrace was completely re-fitted before starting her world record attempt. Whilst DIAB provided Divinycell structural cores, Sigmatex and Formax provided the carbon fibre that was desperately needed for this non-profit venture. DIAB products were already used on the current recordholding boat, Britain’s Cable and Wireless Adventurer, who set the record of 75 days ten years ago in 1998. Since then, there have been five other attempts, including the first by Earthrace which took place in 2007 but was stopped after storm damage caused by bad weather in the Mediterranean. DIAB & the Earthrace project A key element of the record-breaking strategy was to run the boat continuously at high speed (up to 40 knots) in high-sea states. It was essential that the chosen core provide high levels of both shear strength and shear strain, in order to withstand the cyclical loading conditions that were experienced for more than 60 days. And since the vessel features a metallic silver paint finish, the core also needed to offer good high-temperature performance when the boat was in tropical climes. An interesting aside is that the previous record-holder – “Cable & Wireless” – was also a DIAB-cored vessel. The boat, 24 metres (78 ft.) long, was built at the Auckland, New Zealand yard of Calibre Boatbuilders using a “mouldless” strip plank method where the DIAB core is applied in the form of planks to temporary frames to create the hull shape. Earthrace vessel), because it dispenses with the need for a mould. In principle, it involves setting up a series of transverse frames and/or bulkheads and attaching core “planks” to the frames to create the hull shape. After fairing, the outer skin reinforcements are laminated into place. The hull is then rotated 180°, any temporary frames are removed, and the inner skin reinforcements are applied. In the case of the Earthrace, a somewhat different methodology was used, since the hull was produced as two half mouldings. Basically, a “female mould” approach was taken. Again, frames were set up and the DIAB core “planks” were applied. Then, the inner skin carbon reinforcements were laminated into place. The half hulls were joined together longitudinally, the boat was rotated, and the outer skin laminates were applied. To speed the planking process and reduce filling and fairing, the foam core “planks” were supplied with a convex profile on one long edge and a concave profile on the other. No mould needed The strip plank technique is a fast and very cost-effective way to produce a one-off boat (as is the case with the JEC Composites Magazine / No43 September 2008

JEC COMPOSITES MAGAZINE - Issue #43 - September 2008

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #43 - September 2008

Cover
Editorial
Market Place
Advertisers
CONTENTS
NEWS WORLDWIDE
- Companies
 - Agenda of events
 - Innovations
 - Equipment: Rapid prototyping
BUSINESS
 - Market survey
 - Niche market
 - Human capital
FEATURE - MARINE
 - Design
 - Modelling
 - Core materials
 - Prepreg
 - Natural fibre core
 - Sandwich structure
 - Gelcoat
 - Infusion
 - Application
USERS' PLATFORM
 - Composites in the world
 - Applications
KNOW-HOW
 - Materials
 - Manufacturing
Special JEC Composite Asia
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - Cover
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 2
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - Editorial
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - Market Place
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - CONTENTS
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 7
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - - Companies
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 9
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 10
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 11
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 12
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 13
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 15
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Innovations
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 17
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Equipment: Rapid prototyping
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - BUSINESS
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Market survey
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 21
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 22
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Human capital
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 24
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - FEATURE - MARINE
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Design
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 27
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 28
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 29
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Modelling
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 31
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 32
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Core materials
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 34
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Prepreg
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Natural fibre core
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Sandwich structure
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 38
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Gelcoat
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 40
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Infusion
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 42
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 43
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Application
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 45
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 46
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - USERS' PLATFORM
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Composites in the world
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 49
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Applications
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 51
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 52
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 53
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 54
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - KNOW-HOW
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Materials
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 57
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 58
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 59
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 60
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 61
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 -  - Manufacturing
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 63
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 64
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - Special JEC Composite Asia
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - II
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - III
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - IV
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - V
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - VI
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - VII
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - VIII
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - IX
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - X
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 75
JEC COMPOSITES MAGAZINE - Issue #43 - September 2008 - 76
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