Lamination of Volvo Penta IPS hull mold plugs - Haisma Scheeps

Lamination instructions 

Volvo Penta IPS * Twin, Triple & Quadruple installation, 

using Volvo Penta IPS hull mold plug 

General information 

* IPS350/400/450/500/550G/600 

1 

Lamination policy 

Why use Volvo Penta hull requirements 

The purpose of this lamination poster is to guide the design and integration of the Volvo Penta IPS system into the hull structure. These requirements emphasize the stringer design and 

hull construction requirements established by Volvo Penta to minimize the risk of water intrusion in the event of groundings. 

Normal scantling rules (e.g., ISO 12215) focus on variables such as propeller thrust, steering forces, mass of machinery, etc. The Volvo Penta IPS hull requirements focus on ensuring an 

adequate structure to keep the hull intact in a hard grounding where the drives are designed to shear off under certain conditions. Extensive full scale testing and calculations conducted 

by Volvo Penta show that forces generated in an underwater collision or grounding are more than 10 times higher than protection afforded by following traditional scantling rules. 

IMPORTANT! 

The Volvo Penta IPS is designed to function as an integrated part of the hull and laminate structure. The strength of the entire system is dependant on the integrated strength of the IPS 

and the hull and laminate structure. The strength of the hull structure is dependant upon a number of factors including shape, fiberglass quality and strength, type and quality of resin, 

lamination conditions, laminator skill, etc. The ultimate responsibility to ensure that all Volvo Penta IPS hull are produced consistently with these requirements rests exclusively with the 

boat builder. 

IMPORTANT! This instruction replace prevoius lamination instructions found in drawing no. 3591073 

2 

E-LTM 

Glass information 

E-BXM 

E = E-Glass 

L = Longitudinal direction (0°) 

T = Transverse direction (90°) 

LT = 0°/90° Biaxial 

BX = +45°/-45° Biaxial or Double Bias 

M = Chopped strand mat (CSM) 

Placement of Volvo Penta IPS hull mold plugs 

Core information 

IMPORTANT! Core material must be off balsa, plywood or plastic foam material 

with hardness ≥ 60 kg/m 3 (3.8 lb/ft 3 ) (also known as 60H) or similar 

IMPORTANT! The use of general hull core material does not yield any deviations 

from the instructions regarding Volvo Penta IPS reinforcements 

3 

See separate poster; Installation Reference, Volvo Penta IPS Hull Plug and 

Engine Foundation or Installation Manual for placing of Volvo Penta IPS 

hull mold plugs 

47700596 - 1(6) 09-2009

Lamination of Volvo Penta IPS hull mold plugs 

Lamination layers 

4 5 

NOTE! All pictures in this poster show a standard 2 degree toe-in installation 

NOTE! Pictures do not 

show correct scale 

IMPORTANT! If narrower mats are used a mat overlap of minimum 50 mm (2”) on the hull mold plug must be 

applied 

Cross sections 

Mat contour fit 

IMPORTANT! Alternative directed fiber mats 

(not CSM) of density less than 1500 g/m 2 

(44.3 oz/yd 2 ) may be used from layer # 4 as 

long as minimum requirements for number of 

layers, total density and total mat thickness 

are met. All mats must be of both type +45°/- 

45° and 0°/90°. These mats should be altered 

in similar way as in recommended layup (see 

table above). 

IMPORTANT! If vacuum infusion is used a 

total thickness of minimum 21 mm (0.8”) must 

still be met 

IMPORTANT! Secondary bondings must be 

avoided for the lamination 

NOTE! Ensure good mat contour fit. Extend mats up 

to at least 35 mm (1.4”) from top off hull mold plug 

6 

Result in hull mold 

NOTE! Mats should be extended at least 150 

mm (6”) up on the aft bulkhead (transom) 

IMPORTANT! The mat lengths must be 

extended for every layer to ensure proper 

slope, see cross section figures. First layer 

must extend minimum 100 mm (4”) from the 

hull mold plug. 

Placement of reinforcement rings 

Sectional view 

7 8 

IMPORTANT! Putty must be high glass fiber 

content mix 

IMPORTANT! Putty must not be used in the v- 

groove before glass fiber layout is completed 

Top view 

NOTE! The reinforcement ring core 

can be made of several segments 


IMPORTANT! Core material 

must be off balsa, plywood 

or plastic foam material with 

density ≥60 kg/m 3 (3.8 lb/ft 3 ) 

or similar 

Final measurement requirements 

IMPORTANT! 

Adjust core dimensions to 

meet final ring measurement 

requirements (see figure) 

9 


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Lamination of reinforcement rings 

10 


IMPORTANT! Alternative directed fiber mats (not CSM) 

of density less than 1500 g/m2 (44.3 oz/yd2) may be 

used as long as minimum requirements for number of 

layers, mat density and total mat thickness are met 

11 Sectional view 

IMPORTANT! Secondary bondings must be avoided 

for the lamination 

IMPORTANT! Putty must be high 

glass fiber content mix 

12 

Cross section 

13 


IMPORTANT! Minimum 50 mm (2”) 

overlap must be applied between the 

mats. This yields even if narrower 

mats are used 

NOTE! In order to avoid thicker areas 

each layer should be rotated 

Mat contour fit 

NOTE! Mats should be extended up on the 

aft bulkhead (transom) when applicable 

NOTE! Ensure good mat contour fit. Extend 

mats up to at least 35 mm (1.4”) from top off 

Volvo Penta IPS hull mold plug 

IMPORTANT! The mat lengths must be 

extended for every layer to ensure proper 

slope, see cross section figure. First layer 

must extend minimum 100 mm (4”) from the 

ring core 

Placement of reinforcement beams 


14 15 


IMPORTANT! The aft beam must be 

placed aft of the reinforcement ring and in 

line with the centerline of the hull plug 

IMPORTANT! Beams must be long enough 

to meet both reinforcement ring and inner 

transom bulkhead or compartment sides 

IMPORTANT! Core material must be off balsa, 

plywood or plastic foam material with density 

≥60 kg/m3 (3.8 lb/ft3) or similar 

IMPORTANT! 

Drainage holes in any reinforcement beam must not have a 

diameter larger than 25 mm (1”). For the aft reinforcement 

beam the hole should be placed in the center of the beam 

IMPORTANT! Dimension the core 

so that final ring measurement 

requirements are met, see 

8 

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Lamination of reinforcement beams 

16 


17 

IMPORTANT! Fill transition first with putty of high fiber 

content mix to ease the mat layup 

IMPORTANT! If lamination mats are divided into several 

segments a minimum overlap of 50 mm (2”) must be applied 

IMPORTANT! Alternative directed fiber mats (not CSM) 

of density less than 1500 g/m2 (44.3 oz/yd2) may be 

used as long as minimum requirements for number of 

layers, mat density and total mat thickness are met 

Attachment of engine bed 

IMPORTANT! Secondary bondings must be avoided for the lamination 

IMPORTANT! Mat length must be extended for each layer. There must be is a minimum 

extension of 50 mm (2”) for every layer to ensure a proper slope. First layer must extend 

minimum 100 mm (4”) from the beam core (see figure to the right) 

Construction of engine bed 

18 

W2 ≈ W1 

IMPORTANT! Attachment of the engine bed 

stringers must be made to the forward part of 

the reinforcement ring and approximately at a 

90 degree angle from the ring 

IMPORTANT! Maintain the width of the 

engine bed stringers all the way up to the 

reinforcement ring 

19 

See Installation Manual and drawings for engine bed construction 

and dimensions 

Final result after lamination 

Final geometry 

20 21 

Zones of requirements 

IMPORTANT! Within zone A, both Volvo Penta requirements found in 

"Lamination of Volvo Penta IPS hull mould plugs" ( 4 - 6 ) and 

general scantling rules applies. Minimum required hull bottom thickness 

within this zone is given by the thickest requirement of these. 

IMPORTANT! Zone B refers to the lamination of the 

reinforcement rings and the reinforcement beams. 

See requirements in 10 - 13 and 18 - 19 

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Triple and Quadruple installations 

NOTE! The lamination geometry may vary in a Triple Volvo Penta IPS 

installation depending on the tunnel design 

Placement of Volvo Penta IPS hull mold plugs 

22 

See separate poster; Installation Reference, Volvo Penta IPS Hull Plug and Engine 

Foundation or Installation Manual for placing of Volvo Penta IPS hull mold plugs 

Lamination of Volvo Penta IPS hull mold plugs 

23 

See procedure as for Twin Volvo Penta IPS installation; ⇒ 4 - 6 

24 

Result in hull mold - Triple 

Result in hull mold - Quadruple 

Placement of reinforcement rings 

25 


Lamination of reinforcement rings 

26 


27 



Placement of reinforcement beams 

28 


29 



Triple 

Quadruple 

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NOTE! The lamination geometry may vary in a Triple Volvo Penta IPS 

installation depending on the tunnel design 

Lamination of reinforcement beams 

Triple and Quadruple installations 

30 

See procedure as for Twin Volvo Penta IPS installation; ⇒ 16 17 31 

- 



Attachment of engine bed 

Construction of engine bed 

See procedure as for Twin Volvo Penta IPS installation; ⇒ 18 

32 33 See Installation Manual for engine bed construction and dimensions 

Final result 

34 

Final geometry 

35 

Zones of requirements 

Triple 

IMPORTANT! Within zone A, both Volvo Penta requirements found in 

"Lamination of Volvo Penta IPS hull mould plugs" ( 4 - 6 ) and 

general scantling rules applies. Minimum required hull bottom thickness 

within this zone is given by the thickest requirement of these. 

Triple 

IMPORTANT! Zone B refers to the lamination of the 

reinforcement rings and the reinforcement beams. 

See requirements in 10 - 13 and 18 - 19 

Quadruple 

Quadruple 

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Lamination of Volvo Penta IPS hull mold plugs - Haisma Scheeps

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