Wednesday, September 29th Seminars
8:30 a.m. to 10:00 a.m.
Session 301
Wing Sail Technology
BMW Oracle’s victory in this year’s America’s Cup drew much attention to its 223′ (68m) wing sail, said to have given the 90′ (27m) multihull a decided advantage over its adversary’s soft fabric sails. Wing, or solid, sails have been around for many years, but light, stiff composite construction is opening the door to new and innovative applications, including commercial ferries and freighters, recreational boats, high-performance racing yachts, and autonomous unmanned craft. Our panel of experts is at the leading edge of this technology—no pun intended.
Speakers: David Hubbard (Harbor Wing Technologies Inc.); Pete Melvin (Morrelli & Melvin Design); Mark Ott (Harbor Wing Technologies Inc.)
Session 302
Planing Hull Efficiency
Going fast on the water is inherently inefficient. Most recreational powerboats are, however, planing craft, and speed is an attribute that’s key to sales. Here, we’ll review the basic planing-hull parameters and characteristics that lead to minimizing resistance. Designers who understand this information can develop low-resistance hullforms without sacrificing performance qualities such as seakeeping, maneuverability, and dynamic stability. Building on everyday analysis techniques, we’ll show you how to analyze performance data both from naval architects and propulsion-system vendors. We’ll also teach you how to interpret the often-misunderstood language of characterizing efficiency. After we illustrate comparative modes of performance analysis, we’ll present a new approach based on the venerated Savitsky method; and, finally, we’ll outline dynamic instability root causes and talk about common tools that identify when and where these problems may occur, both during the design stage and in existing craft.
Speakers: Jeffrey Bowles (Donald L. Blount and Associates); Additional speaker to be announced
Session 303
CNC Milling of Plugs and Direct-Machined Mold Tools
During the past 20 years, a number of key technologies have converged to provide the composites industry with a high-performance means of manufacturing plug and mold tooling. Given existing computer technology, 3D CAD design software, CNC milling equipment, and dedicated materials, you can now receive precision tooling to support your rapidly changing market needs. This precision tooling can be in the form of a plug and/or limited-production mold. Here, we’ll review the advantages that both CNC tooling types offer the boat manufacturer. We’ll cover what you need to start your project and what you should expect when you receive the tool. Your expectations will include: the general tool structure for moving/lifting the tool in-house (steel or wood framing), materials of construction, final surface finish, and chemistry. In addition, we’ll discuss typical fabrication- and lead-time for tools, what further work you may have to perform to the tooling, and how much flexibility you’ll have with these tools. Finally, we’ll remove the “mystique” of CNC-manufactured plugs and limited-production molds by asking you to join us in discussing the current state of CNC composite tooling relative to your own experience.
Speakers: Doug Blount (DLBA Robotics Ltd.); J.P. Schroeder (ATC Formulated Polymers)
Session 304
Best Practices for Sanding
With so many competing abrasives on the market today—and new ones being introduced regularly—you may be confused when it comes to deciding what grits and compounds to choose to achieve the best finish. When you deal with molds, your dilemma is further complicated by the fact that tooling gel is much different from production gel. In this session, you’ll hear from two major manufacturers who will present the systems they have developed for bringing a part or mold to a perfect finish. We’ll also give you an overview of additional manufacturers and their products, as well as case studies of production builders and what sanding materials work best for them. We’ll cover the practice of mixing different kinds of sandpaper, incorporating different manufacturers’ papers within your own system, and managing cost concerns. Attend this session to improve your understanding of the variety of products available from abrasives manufacturers. We’ll explain what those products are intended to do, and how to ensure stellar performance in the different scenarios that you may face. We’ll also deal with how power tools may affect the performance of the abrasive, and what kind and specification performs most efficiently.
Speakers: Jim Christianson (3-M); Dan Naugle (Grady-White Boats)
Session 305
Gelcoat Restoration
Success with gelcoat repairs and refinishing is as much about your technical skills as it is about achieving your customer’s expectations. In this session, we’ll look at the multiple challenges of gelcoat restoration. For example: Gelcoat that’s chalked and faded can be polished and waxed, and may look fine for one season—but then what happens? If it chalks and fades again, you’ll have a very unhappy customer. Will a global gelcoat respray/sanding/polishing be sufficient? Or should you recommend an LPU paint job? Will color matches on local repairs look fine after more than a few months of UV exposure? Join us to discuss these very practical questions—and many more—in a session dedicated to gelcoat troubleshooting, materials selection, and technique.
Speakers: Bob Lacovara (Convergent Composites); Bruce Pfund (Bruce Pfund/Special Projects LLC)
Session 306
Cold-Molding Primer
Cold-molding is a proven build method frequently employed to create new boats large and small. In its simplest form, you sheathe a curved shape using wood veneer and, typically, an epoxy adhesive; the result is a strong, lightweight, stiff monocoque structure. In this session, we’ll examine vacuum-bagging for cold-molded hulls, and we’ll offer tips and techniques for making the process efficient. We’ll cover guidelines for selecting veneer, adhesives, vacuum-bagging supplies, and related equipment. We’ll then turn to two case studies: how to glue up, in a single operation, three layers of veneer on a 26′ (7.9m) sailboat; and, six layers of veneer on a 38′ (11.6m) powerboat.
Speakers: Tom Pawlak (Gougeon Brothers Inc.); Brion Rieff (Brion Rieff Boat Builder)
[ABYC] Session 307
Non-Traditional Galvanic Isolator Applications
Here, we’ll describe a methodology that addresses how to protect against the corrosion of expensive underwater components—such as aluminum sail drives—working with existing technology, including galvanic isolators. Our discussion will focus on nontraditional fail-safe galvanic isolator applications. Presenting a real-world case study, we’ll detail a process for incorporating an additional galvanic isolator into the boat’s grounding and bonding system, reviewing both the advantages and potential pitfalls associated with this type of installation. If you’re a boatbuilder, a technician, a marine surveyor, or a manufacturer of marine electrical equipment, you will find this session to be of value. To gain the most benefit from it, though, we recommend you already have a basic knowledge of general corrosion and electrical fundamentals.
Speakers: Dwight Escalera (Executive Marine Services LCC); David Rifkin (Quality Marine Services LLC)
[ABYC] Session 308
Propeller and Shaft Sizing
If you need detailed practical information about selecting and sizing propellers, attend this session, which is a follow-up to Session 208, Drivetrain Design and Specification. We’ll begin with a detailed review of basic prop-sizing equations (propeller geometry, diameter, number of blades, hand, pitch, blade area and DAR); understanding and calculating slip; geometry refinements (skew, rake, blade section shape); geometry tweaks (cup, progress pitch, pitch relief); and propeller function and induced drag. Next, we’ll explain how to calculate and specify a propeller for a single-screw displacement boat. This will include estimating boat speed; speed/length ratio and Froude number; maximum hull speed; determining blade area and diameter; tip clearance; speed of advance (Va); wake factor; blade area and blade loading; apparent slip; optimum pitch ratios; and propeller efficiency. We’ll also define important variables such as reduction gear versus power versus diameter, and the diameter/power/rpm calculation; determine the reduction gear; determine pitch; and convert diameter to pitch and vice versa. After describing the final propeller spec, we’ll look at two common problems: working with an existing gear ratio, and insufficient reduction ratio. Finally, we’ll review the propeller selection for a twin-screw planing boat; this will include estimating speed, planing-hull wake factor, and cup.
Speaker: Dave Gerr (Westlawn Institute of Marine Technology)
[ABBRA] Session 309
Communicating, Collaborating, and Networking: An ABBRA Roundtable Session
In this open forum, we’ll encourage small groups of individuals from boatyards, marinas, dealerships, and manufacturing companies to discuss solutions to their common problems within the marine industry. A frank conversation among business professionals will provide an excellent networking opportunity, and be extremely valuable in helping you find answers for business questions shared among you. Come prepared to offer your own concerns as appropriate subjects for discussion. In past ABBRA roundtables, topics have included everything from boatyard economics to managing seasonal schedules to employee training, technological advances, and new environmental policies and procedures.
Speakers: Mark Amaral (American Boat Builders & Repairers Association); Doug Domenie (Brewer Dauntless Shipyard)
[MITEC] Session 310
Connections: Marine Educators and the Marine Industry
When the economy started to crash, a number of people blamed not just business and financial managers, but the way they’d been taught. “Business schools have to change,’ they said. Well, if business schools have to change, what about marine-industry schools? We have a different world now, too, and employers may not be looking for the same skills and attitudes they did a decade ago. In this seminar, you’ll discover how marine technology education stays connected to the industry as a whole. We’ll also look at how technology and the marketplace influence our schools as they prepare their students to work effectively in today’s boatyards, boat plants, and service centers. Our panel of educators welcomes your questions and comments on this topic.
Speakers: Ann Avary (Center of Excellence for Marine Manufacturing & Technology); Susan Daly (International Yacht Restoration School); Roger Hellyar-Brook (The Landing School)
[NMMA] Session 311
Managing and Improving Your Boat Plant Safety Program
There is no such thing as an accidental injury; having an employee get injured is far more disturbing than facing an OSHA citation for not complying with regulations. Fortunately, many boatbuilders have highly effective programs in place to prevent accidents. In this session, we’ll focus on the safety issues that OSHA is currently emphasizing, specifically: combustible dust and boat plant fire-protection standards. You’ll also learn how OSHA views the boatbuilding industry when comparing it to similar industries. Most importantly, though, you’ll hear directly from two marine-industry professionals who run successful safety programs and are willing to share how they do it. We’ll present our information in a workshop setting, so be sure to bring your safety questions and your business cards. We want you to take full advantage of this opportunity to network with colleagues and discover how fellow boatbuilders are facing safety challenges and managing risk.
Speakers: Randy Clunie (Sea Ray Boats); John McKnight (National Marine Manufacturers Association); David Selig (Brunswick Corporation); Erik Wiborg (Regulator Marine)
[IBEX] Session 312
Hiring, and Employee Retention
The most vital element of your business is your staff. Part science and part art, finding and retaining the right people is always a challenge for managers. Here, we’ll tell you what to look for as you establish ”behavior profiles’ for specific job performances to ensure that each employee is the right fit for a given set of tasks, which increases your employees’ overall job satisfaction. We’ll help you better understand the factors and costs behind employee turnover; and we’ll share best practices to keep your shop’s attrition rate low. Finally, we’ll describe how to most effectively orient new employees in your workplace.
Speaker: Rich Guthrie (Five Star Solutions LLC)
3:30 p.m. to 5:00 p.m.
Session 401
Incorporating Hybrid Power Into Yacht Design
Hybrid power comes in a variety of different forms with significant impact for yacht design, particularly with regard to how major equipment is placed, interior volume is used, noise is managed, and weight is distributed. Less obvious are the implications for propeller apertures and installations, especially when it comes to pod, pivoting, and rotating drives. Pushed to extremes, hybrid power offers the ability to depart radically from conventional wisdom. In our seminar, we’ll explore the effects of this emerging technology on yacht design, and we’ll introduce some of the ways in which yacht designers have already exploited hybrid power.
Speaker: Nigel Calder (Calder Enterprises)
Session 402
Design and Architecture of Maxi Multihulls
Big cats and tris have come to dominate high-speed sailing—from America’s Cup competition (Alinghi, BMW Oracle) and the world sailing speed record (Hydroptere), to multiple ocean races and competition for the Jules Verne Trophy (Groupama 3). These exotic, and expensive, boats are pictures of wind-powered efficiency made possible by advances in composite materials, fabrication technology, and design capacity. Join us to consider the current state of the multihull art as we focus on what limiting factors are likely to be pushed in new designs. We’ll also cover regulatory issues, as well as system design challenges and solution options. We’ll close with a consideration of how recent advances on these very specialized craft may be applicable to the rest of the boatbuilding industry.
Speakers: Pete Melvin (Morrelli & Melvin Design); Mike Taylor (Taylor Marine Services); Additional Speaker to be Announced
Session 403
FEA for Structural Composites Optimization
From custom carbon/epoxy pre-pregs to production E-glass vinyl ester infusion, laminates are increasingly optimized to reduce weight, reduce cost, and improve performance. Whether applied to custom racing yachts or high-quality production yachts, engineering these laminates has become more challenging in order to realize the benefits of advanced-composite construction techniques. To accurately assess the performance of composite laminates and provide further optimization, traditional engineering methods and scantling rules have increasingly been augmented with Finite Element Analysis. Here, we’ll provide an overview of FEA, including how and when it can be applied, as well as the potential benefits. We’ll discuss model construction, load case definition, material properties, analysis methods, and results interpretation. We’ll provide case studies to illustrate the concepts of FEA and to highlight the benefits of its application to the structural optimization process.
Speaker: Dave Fornaro (Ariston Technologies)
Session 404
Manufacturing Defects—and Their Engineering Consequences
In this session for boatbuilders, repair facilities, surveyors, and engineers/designers, we’ll discuss some of the manufacturing errors frequently seen in our industry, and their effects on the quality and strength of the finished product. We’ll analyze very specific building decisions, including—but not limited to—framing fit, tabbing sizes, inside corner fillets, beveled vs. square core-edge terminations, and frame attachments to decks. A few of the questions we’ll consider are: Does a 1/4″ (6.35mm) gap under a bulkhead really matter? If it does, would a putty fillet make it better? Can delamination be triggered by “line bubbles” in tabbing to poorly fitted framing? We hope you’ll bring your own questions—as well as your observations and experiences—to share with the group.
Speakers: Steve Burke (Burke Design LLC); Bruce Pfund (Bruce Pfund/Special Projects LLC)
Session 405
Writing the Damage-Survey Report
Claims handlers are busy people. They want their surveyors to answer just three magic questions, then stop. Brevity is key (Just the facts, ma’am). So what are those three magic questions? Learn from a marine surveyor who specializes in damage survey. In this session, you’ll discover how to answer the three questions, and along the way, you’ll find out how to write a proper damage-survey report. We’ll also explain how good photos can help tell the story, and we’ll describe both the joint survey and the field survey report. Most importantly, we’ll teach you what not to say—and why—in your reports. In the event the claim goes south, we’ll help you imagine what one of your reports might look like in court, blown up to poster size, with key phrases highlighted. What would the jury think?
Speaker: Steve Knox (Knox Marine Consultants Inc.)
Session 406
Metal Kit Construction
The capacity for design and engineering data files to be delivered electronically--and almost instantaneously--anywhere in the world has increased the appeal and practicality of detailed building kits for metal boats. Designers can deliver completely kitted plans whether large or small, commercial/military or recreational, steel or aluminum to shops with CNC cutting machines for assembly on site or at nearby building facilities. Two experienced designers working in aluminum and steel will share their new, highly efficient approaches to kitting metal boats in a range of sizes for builders in different parts of the world, explaining what they call “boatbuilding kits 2.0,” and describing the benefits you can gain from this practice, while avoiding common errors.
Speakers: Marnix Hoekstra (Vripak); Albert Nazarov (Albatross Marine Design Co. Ltd.)
[ABYC] Session 407
High-Current DC-Circuit Protection
High-current DC-circuit protection affects a number of aspects in a boat’s electrical system. For example, circuit protection for starter-motor circuits is becoming increasingly common, even though it is not required by either the U.S. Coast Guard or the American Boat & Yacht Council. In this seminar, we’ll explain how to provide this type of protection correctly, and we’ll discuss those situations when it’s just not feasible economically. We’ll also explain why repairers are seeing increased incidents of overheated bow and stern thruster over-current protection devices, and we’ll describe how to deal with that problem. On gasoline-fueled boats, the requirements for ignition protection are well known, but many fuses installed on board are not adequately rated, so we’ll suggest some new strategies for overcoming that issue. Can you remedy a fault in over-current protection on a high-energy battery system? Here, you’ll learn how to protect systems with potentially high fault currents in excess of 5,000 amps AIC (ampere interrupting capacity). Finally, we’ll explore procedures for paralleling fuses to achieve higher capacity in special circumstances, and we’ll critique the specialty fuses that are now coming available.
Speakers: Wayne Kelsoe (Blue Sea Systems Inc.); Ed Sherman (American Boat & Yacht Council)
[ABYC] Session 408
Exhaust-System Design and Testing
If you’re not current with the latest changes in marine exhaust systems, you should attend this session to find out how new developments in exhaust are impacting the rest of the boat. You’ll hear a comprehensive review of the state of boat-exhaust design and applications. You’ll also learn how the ABYC standard P1: Installation of Exhaust Systems for Propulsion and Auxiliary Engines applies to modern vessels. Finally, we’ll explain how to take into account critical considerations such as available space, engine specifications, back-pressure limitations, and desired noise attenuation when designing exhaust systems.
Speakers: Bert Browning (Centec Industries); Eric Johnson (American Boat & Yacht Council)
[ABBRA] Session 409
Proper Winterization for Onboard Systems
If you live in a place that never experiences sub-freezing temperatures, or snow, or ice, then you don’t need to worry about winterization. For the rest of us, it’s a deadline that looms every fall. There’s more to winterization than merely running antifreeze through engines and water systems. In many cases, winterization is also an opportunity to inspect vessels for service and repairs. In short, offering good winterization service work can help you develop orders for the winter storage period. In this presentation, you’ll learn techniques and processes for thoroughly winterizing and inspecting a variety of onboard systems, ranging from engines and potable water, to batteries and sanitation systems. The processes we outline will not just preserve your customer’s vessel; they’ll also ensure quicker and more reliable commissioning in the spring.
Speaker: Steve D’Antonio (Steve D’Antonio Marine Consulting)
[NMMA] Session 411
A Different View: Systems-Level Look at Lean
Many production builders have some experience with lean systems, and have made substantial progress implementing a few lean tools such as 5S, kanban, and work cells. At the same time, many builders are unaware that lean production is most effective, encompassing, and engaging when it is implemented company-wide. By changing your organization end to end, lean can help make it action oriented—and more competitive. In this presentation, you’ll learn why lean means a total system transformation. Join us to discover how to leverage your existing progress in lean systems to gain immediate and substantial results. We’ll explain how you can draw on your current resources to reach new and higher levels of productivity and profitability through continuous improvement.
Speaker: David Veech (Institute for Lean Systems)
[IBEX] Session 412
Telephone/Internet Selling Skills
A positive approach to selling starts with a plan that you can implement each morning. Join us in this session to learn how to improve your selling skills online or over the phone. We’ll start by explaining the importance of answering incoming calls within three rings, as well as responding to online inquiries within eight minutes. We’ll teach you the four key components of a friendly and professional personal greeting, and we’ll describe specific customer-service strategies for all your phone and online communications. Finally, we’ll offer techniques for polite and acceptable communications when you must place a caller on hold or transfer a call.
Speaker: Rich Guthrie (Five Star Solutions LLC)
[SPECIAL SESSION] 6:15 p.m. to 7:45 p.m.
[PBB] Session 413
Navigating the Global Marketplace
Today’s economy is international. It’s now common to source materials and labor from one country, assemble in another, and export to a third. There also are tremendous opportunities to provide professional services in other countries, but you need to know how to navigate the regulations in there as well as here in the U.S. If your business is entirely domestic, you may be missing out on opportunities to grow your company. For this open session our distinguished panelists are all veterans of offshore boatbuilding, from China to Poland to Dubai. They bring a wealth of experience, and expert advice to the table. Join us for a lively discussion on the pitfalls and potential rewards of looking beyond your own town, state, and country to save money and improve profits.
Speakers: Rob Kaidy (Ocean5 Naval Architects Inc.), Vic Duppenthaler (OneWorld Consulting); Additional Speakers to be Announced
