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MARK III System: Hull and Deck Components for Marine Vessels

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The Mark III system presents a comprehensive suite of components designed for efficient and versatile construction. This innovative system offers a range of features that enhance the overall durability and functionality of structures. From insulated panels to structural supports, the Mark III system showcases an array of elements that work in harmony to deliver reliable and adaptable building solutions.

By understanding the capabilities and advantages of each element, we can unlock the full potential of this dynamic system, enabling us to create resilient and versatile structures that meet the demands of modern building practices.

MARK III System Components

The main components of the MARK III system are:

1 Studs.

2 Load bearing mastic.

3 Insulation panels:

  • Flat panels.
  • Corner panels (90°, 135°, three way corner panel).
  • Top bridge pads.

4 Foam boards.

5 Triplex (secondary barrier).

6 Primary membrane:

  • Membrane sheets.
  • Corner pieces, dog-legs, end caps.
  • Steel corners.

Studs

Studs are generally in AISI 1010 steel or, alternatively, stainless steel. Studs are only used for fitting and position adjustment in position of the insulation panels. See Figure 1.

Studs
Fig. 1 Steel Studs

Load Bearing Mastic

The load bearing mastic is used both to provide support for the insulation panels and to bond them to the inner hull and, at the same time, to compensate for the irregularities of the inner hull. See Figure 2.

Bearing Mastic
Fig. 2 Load Bearing Mastic

Mastic is an epoxy made of resin and hardener mixed in proportion specified by the supplier. Figure 3 shows the check of preparation of the mastic.

Mastic Prep Check
Fig. 3 Verification of Mastic Preparation

Figure 4 shows mastic samples.

Mastic Samples
Fig. 4 Specimens of Mastic

The main physical properties: of mastic are as follows:

1 VOLUMETRIC EXPANSION

After complete curing at 20 °C should not vary by more than 1 % of its initial volume.

2 COEFFICIENT OF THERMAL CONTRACTION of the cured mastic between – 30 °C and 50 °C should not exceed 60 10-6 mm/mm/°C.

3 SHEARING PROPERTIES

From 20 ° C to – 25 °C Shearing strength > 12 MPa

4 TENSILE PROPERTIES

From 20 °C to – 25 °C
Modulus of Elasticity 1 000 < ET < 5 000 MPa
Elongation at rupture A % > 0,9 %

5 COMPRESSION PROPERTIES

Form 20 °C to – 25 °C
Compressive Modulus Ec > 1 000 MPa compressive strength at proportional limit Rc > 15 MPa

Pot life and curing time also play very important role s in quality of the resin.

Flat Panels

A typical flat wall panel is made mainly of:

1 The sandwich panel (lower part of the panel) includes:

Sandwich Panel
Fig. 5 Lower Part of the Panel

2 The “pad-on-panel” (upper part of the panel) includes:

This layer is divided in modules with a square pitch cut of 340 m (normal case) in line with Key Characteristics of Membrane Tanks Systemsmembrane corrugations. This pad has machined areas for in lay of several stainless steel anchor strips. Anchor strips are attached with push through expansion rivets. Pads also have numerous “riv-nut” style metallic inserts, which are used to temporary attach tools necessary for handling the panels and for the erection of the insulation.(See Figure 6.)

Pad-on-Panel
Fig. 6 Upper Part of the Panel

The different layers (plywood, foam boards, secondary barrier, foam blocks and top plywood) are affixed by proprietary adhesives.

Materials are the following:

1 PLYWOOD: birch plywood or combination of other woods may be used according to the location in the panel.

2 RIGID CLOSED CELL FOAM: reinforced polyurethane foam. Reinforcement is provided by fiberglass fiber in two directions, perpendicular to the expansion.

3 ADHESIVES: for panel manufacturing, polyurethane adhesives (two-components type) are used. Epoxy adhesives may be also used for some particular assemblies.

4 COMPOSITE MATERIAL FOR SECONDARY BARRIER triplex.

5 ANCHORING STRIPS: stainless steel AISI 304.

6 RIVETS securing the anchor strips on the top plywood: aluminum.

7 METALLIC INSERTS: carbon steel.

The critical parameters are:

The main dimensional tolerances are as follows:

  1. Sandwich panel thickness: +/- 1,0 mm.
  2. Pad-on-panel” thickness: +/- 0,5 mm.
  3. Length: +/- 3 mm.
  4. Width: +/- 2 mm.
  5. Squareness: The difference between two diagonals not to exceed 1,0 mm by meter of length.
  6. Flatness: 2,0 mm by meter of length; the rise is measured with a ruler in all direction.

Figure 7 is the photograph of a number of flat panels ready to be installed.

Flat Panels
Fig. 7 Flat Panels Prepared for Installation

Figure 8 is the photograph after installation on the top of a tank.

Tank Top Panels
Fig. 8 Panels Installed on Tank Top

Corner Panels

A typical corner panel is made mainly of a basic panel (or single leg) including:

Two single legs are joined together through the hardwood key and the stainless corner. A joint exists between the two legs: it includes a plywood wedge and glass wool.

The continuity of the secondary barrier between the two legs is insured with a curved joint.

The hardwood keys are bonded on the secondary barrier. The stainless steel corners are fixed in the hardwood keys through studs and nuts. These studs are welded on the stainless steel corners during their prefabrication. The fixation of these corners should be such that they can slide on the hardwood keys (in operating condition).

Material of corner steel is AISI 304. Other materials are the same as for the flat panels. See Figures 9 and 10.

Corner Panel
Fig. 9 Typical 135° Corner Panel
Corner Panel
Fig. 10 Typical Three Ways Corner Panel

The dimension tolerances are:

Top Bridge Pads

These final insulation blocks fill in the open spaces between pad-on-panel areas. These are installed after soft triplex has been glued in place, examined and leak tested.

A typical top bridge pad is made of:

Bridge Pad
Fig. 11 Bridge Pad with Anchoring
Insulating Foam Block
Fig. 12 Closed-Cell Foam Structure

These materials are bonded together. If the location of the top bridge pad in the tank is in the way of a membrane sheet edge, anchor strips are fixed on the top plywood, similar to standard insulation panels. Top plywood is machined, anchor strips are fit and secured with push-in expanding aluminum rivets. Note that aluminum rivet location is kept out of weld attachment path for stainless steel corrugated panels.

The material is same as for the flat panels.

The dimension tolerances are:

Reinforced Polyurethane Foam Boards

The reinforced polyurethane foam is produced in a continuous run, on a laminator, using high-density polyurethane foam together with fiberglass fiber continuous strand mat to increase the resistance at cryogenic temperature to thermal and mechanical stresses induced by the ship’s deflection at sea.

After foaming and temperature stabilization the boards are planed and cut into requested dimensions.

1) MATERIAL USED

High-density polyurethane foam liquid components.
Continuous strand mat.

2) MAIN CHARACTERISTICS OF THE PRODUCT

The finished boards are cut from the produced raw board after curing (2 weeks). The board thickness corresponds to the foam expansion direction and shall be at least 160 mm. The necessity to produce raw foam board of regular shape is a crucial parameter to avoid discarding excessive amount of raw materials.

The thickness may vary with the contract boil off of each vessel. Note that a lower boil off (thicker insulation panel) may be obtained at the expense of the cargo volume. Present accepted trade off value for the boil-off is 0,15 % per day.

3) APPARENT DENSITY AND COMPRESSIVE PROPERTIES

The density should be uniform within the same board with a maximum difference not exceeding 8 kg/m3 (measurement performed on the samples for compressive test).

The apparent density “d” at 20 °C should be (average on five specimens):

117 < d < 130 kg/m3

The compressive requirement is that the compressive strength and modulus are determined at 20 °C in the direction of the foam expansion (average on five test pieces):

4) TENSILE PROPERTIES AT 20 °C AND – 170 °C

The requirement is in the X and Y directions:

a) 20 °C ( average on five test pieces):

b) 170 °C (or –196 °C) ( average on five test pieces) :

The lower limit of Young’s modulus at 20 °C and – 170 °C are given for reference only. Values below these limits are acceptable, provided all the other mechanical properties of this specification are met.

5) THERMAL CONTRACTION COEFFICIENT BETWEEN 20 °C AND MINUS 196 °C

The tests are performed in the main three directions of the panels:

6) SHEARING PROPERTIES AT AMBIENT TEMPERATURE AND AT MINUS 100 °C

The test is performed on five test pieces in each direction:

a) At -100°C the requirements are:

On individual test piece Rs > 0,90 MPa in X and Y direction, Rs > 1,20 MPa in Z direction.

b) At 20°C the requirements are:

On individual test piece Rs > 0,80 MPa in X and Y direction, Rs > 1,00 MPa in Z direction.

7) CLOSED CELL CONTENT

Closed cell content is to be 94 %.

8) DETERMINATION OF THE PERMEABILITY TO MOISTURE

The test conditions correspond to 20 °C and to 0 °C through 85 % relative humidity gradient.

Permeability to moisture is to be < 4,0 g/m2/h.

9) THERMAL CONDUCTIVITY COEFFICIENT

The thermal conductivity curve between -160 °C and +20 °C is determined for the approval procedure. This test is performed on at least 4-month-old foam.

10) QUALITY CONTROL

During fabrication, a strict QC/QA has to be applied. Particular attention is to be paid to the following two points:

Secondary Barrier Material: Triplex

There are two kinds of secondary barrier:

The Rigid Secondary Barrier

The rigid composite material used for rigid secondary barrier must:

The product is generally made of a thin aluminum foil inserted and bonded in between two impregnated glass clothes.

The thickness of the aluminum foil has to be 70 +/- 10 %.

1) CHEMICAL COMPATIBILITY OF THE PRODUCT

The raw materials used to manufacture the product shall be compatible with:

2) MECHANICAL CHARACTERISTICS

3) THERMAL CONTRACTION COEFFICIENT

The average coefficient from 20 °C down to -196 °C must be:

< 12 10-6 mm/mm/°C

4) DIMENSIONAL CHARACTERISTICS

The product will be delivered in sheet with following dimension:

The Flexible Secondary Barrier

The flexible secondary barrier must:

The product is generally made of a thin aluminum foil inserted and bonded in between two impregnated glass clothes. The thickness of the aluminum foil has to be 70 +/- 10 %.

Read also: Aluminum Welding Techniques: Advanced Methods

Figure 13 shows a roll of flexible triplex.

Triplex Roll
Fig. 13 Flexible Triplex Roll

1) CHEMICAL COMPATIBILITY OF THE PRODUCT

The raw materials used to manufacture the product shall be compatible with:

2) MECHANICAL CHARACTERISTICS

a) Warp:

at 20 °C > 88 000 N/m
at -170 °C > 190 000 N/m

b) Woof:

at 20 °C > 88 000 N/m
at -170 °C > 190 000 N/m

3) DIMENSIONAL CHARACTERISTICS

In general, the product will be delivered in rolls with following dimension:

Primary Membrane Components

The membrane, which forms the primary barrier of the cargo tanks, is made of standard components including:

All these components are manufactured from 1,2 mm thick stainless steel 304L sheets.

Protective wrap sheeting is kept on throughout the shaping operations and until pieces are fit in the tanks.

Figure 18 is photograph of pallets of membrane sheet ready to be installed.

Installation Ьaterials
Fig. 18 Pallets of Membrane Sheet

Corrugations and knots are cold formed by pure folding without heat, with no stamping effect using tooling specially designed for this purpose.

The tooling for forming the corrugation has been designed in order to obtain corrugations of constant length and separation distance of expanded sheet regardless of the behavior of the sheet after shaping (see Figure 19).

Fluting Tooling
Fig. 20 The Tooling for Forming The Corrugation

This constant length of expanded sheet provides satisfactory fitting and proper overlapping, when overlapping is required, when the sheets are fitted in the tank and tacked before welding.

During the operations for fabricating the standard primary barrier components, very special attention must be given to the cleanliness of the sheets to be used and to that of the tooling for final shaping.

1) CORRUGATED SHEETS

There are sheets for vertical and horizontal sides (see Figure 14).

These sheets bear two mutually perpendicular sets of non continuous, pointed arch-shaped corrugation, which cross over each other and form at their points of intersection, a geometric figure called a knot.

One set is composed of large corrugation.
The other set is composed of small corrugations.

After the corrugations are formed, these sheets are joggled over a part of their perimeter according to their position.

The largest sheets have three large corrugations and nine small corrugations.

Large corrugation pitch: 340 mm
Small corrugation pitch: 340 mm.

2) SHEETS ON CHAMFERED SIDES

Theses sheets bear two sets of mutually perpendicular corrugations (large ones and small ones) with different pitches.

Large corrugation pitch: 340 mm
Small corrugation pitch: 480 mm

After the corrugations are formed, also these sheets are joggled over a part of their perimeter according to their position.

The largest sheets for the chamfered sides have three large corrugations and twelve small corrugations.

3) FORMING OF THE CORRUGATIONS OF A SHEET

The operations for forming the corrugations of a sheet are generally preceded by the precutting of one of the edges of the sheet crosswise in order to obtain suitable perpendicularity of this edge with respect to the two long edges.

The sheet shaping operations involve:

4) DIMENSIONS AND TOLERANCES AFTER SHAPING