MID GlassFibre Supplies Ltd Ph: +353 1 466 3786

Fibreglass Hand Lay-up

Hand lay-up is the most widely used fabrication technique employed in the reinforced plastic industry. It is normally
used for relatively short runs, but it has also been adapted successfully for series production. It is a production
method which takes full advantage of the two most important characteristics of Polyester resin i.e. that it cures
without heat and without pressure.

Briefly the mould surface is prepared by polishing to whatever degree of surface finish is require, then a Release
Agent is applied. The next step is to apply a resin rich surface (Gelcoat). After this has cured sufficiently liquid
Polyester Resin is brushed onto the gelcoat surface, Glassfibre Mat is placed on the top and each layer is then
impregnated with resin. The laminate is then allowed to cure at room temperature and dependant on conditions and
the type of the resin used, the cure time can vary from 1 hour to 4 hours – see Catalyst Mixing Chart.

1. The first step is to prepare a suitable mould.

2. Apply a film of Release wax polish (silicone free) to the mould surface, keeping the quantity to a minimum.
This is then polished out with a fine cloth to a high polish. Some types of wax used to be left to harden but all
waxes must be used to manufacturer’s recommendations.

3. A film of polyvinyl alcohol solution (PVA) is applied evenly, by spray or sponge, over the whole of the mould
surface and allowed dry at room temperature. Because of its low viscosity, a PVA solution will drain from
vertical sections and accumulate in sharp corners where it may that a long time to dry. If this is not
prevented and the moulding is laid up too soon, it will almost certainly stick and some damage may be done
to the mould.

4. The durability of GRP moulding is mainly dependant on the quality of its exposed surface. Every possible
precaution must be taken to prevent fibres from coming too near the surface where they be liable to be
attacked by moisture. This is achieved by providing a resin rich area on the working surface of the laminate.

5. The next step in the process is the layup of the glass fibre reinforcement (Chopped Strand Mat) with the
Polyester resin. Laying up can be started as soon as the gelcoat has hardened sufficiently to withstand
solvent attack from the laminating resin. The simplest way of checking this is to touch the back of the
Gelcoat lightly with a clean finger. If the Gelcoat feels slightly tacky, but the finger comes away perfectly
clean, then the gelcoat is just at the right stage for laminating. Sometimes a Glass Tissue may be laminated
next to the gelcoat in anti-corrosion applications. This also helps to cut down the risks of the glass fibre
pattern showing on the Gelcoat surface.

6. Chopped strand fibre glass mat is the most usual reinforcement although Woven Roving can be used. Woven
Roving however should have at least 2 layers of the reinforcement mat between them and the gelcoat
otherwise the ‘chequered’ pattern of the rovings will show through. Woven rovings should not be used
adjacent to one another because they have poor inter laminar adhesion. Consequently at least one layer of
the reinforcement mat between the layers of woven rovings is recommended. The reinforcement should be
prepared before the laminating begins. It can be cut to size and tailored if necessary with a scissors or a
sharp knife. The amount of resin required can be calculated by weighting the glass fibre to be used for the
moulding. For chopped strand mat the resin: gloss ratio is usually between 3:1 and 2:1 by weight. (25-33%
glass by weight) – see Material Calculator.
 Cont.:

7. At this stage Pigment is added to the resin (if desired). A quantity of pigment paste is mixed into the resin
preferably with a mechanical mixer to achieve even dispersion. The majority of resins used are pre-
accelerated and only require the addition of Catalyst to activate them before use. The quantity of Pigment,
will have been obtained from information supplied with the resin, which will give quantity of catalyst for a
given working temperature to achieve the desired pot life.

8. A liberal coat of resin is brushed over the gelcoat as evenly as possible and the first layer of the glass is
pressed firmly into place and consolidated with a Brush or Paddle Roller. The resin will impregnate the gloss
mat quite rapidly and dissolve the binder which holds the fibres together. The mat will thus conform readily
to the contours of the resin should be applied on top of the mat until it is fully impregnated because this
may lead to air bubbles being trapped. When the laminate contains air bubbles it is a milky colour (this is
true only of course if the laminate is made using unpigmented resin). As the air is being released the colour
of the laminate will change to the natural colour of the resin. When a Brush is used, or impregnated it should
be worked with a stippling action not moved sideways across the surface. The normal brushing action will
displace the fibres and distribute them unevenly. Consolidation of the laminate is quicker with a Paddle
Roller that a brush. Adjacent pieces of Chopped Strand Mat should be overlapped by tearing rather than
cutting.

9. Subsequently layers of resin and glass mat are applied until the requires thickness has been built up (see
Material Calculator), taking care that overlaps are staggered to prevent local excessive thickening, causing
uneven cure and shrinkage. Each layer must be worked until it is completely impregnated. Where a thick
layer of laminate is required no more than four layers of the resin and glass mat should be applied without
allowing the resin to reach the state of gelation and most of the exotherm to take place. This is to avoid a
build-up of exotherm which may result in either cracking on the surface of the gelcoat, pre-release of the
moulding due to excess shrinkage or discolouration of the pigmented resin.

10. During the layup operation, it is possible to incorporate wood and metal straighteners, also fitting and
sandwich materials such as paper honeycomb, Polyurethane Foam or balsa wood. This lamination should not
take place until the main laminate has passed the ‘green stage’ i.e. cured to a certain degree, otherwise the
addition of ribs etc. will cause localised excess shrinkage and on mould release there will be found to be a
‘ripple’ on the gelcoat opposite the fitting.

11. When a smooth finish is required on the reverse side of the moulding i.e. the working side, a suitable Glass
Tissue can be used as the final layer of reinforcement. This will give a finish which is not as coarse as
Chopped Strand Mat and can look attractive when painted.

12. After the resin, has gelled it is in a soft rubbery state and green for a limited period. In this condition the
laminate can be quickly trimmed by hand with a sharp knife to the dimensions of the mould and suitable
trim edges can be built into the mould for this purpose.

13. The moulding is allowed to cure either at normal room temperature (20˚C) or in a warm room (30-40˚C).

14. After removal from the mould the moulding should be allowed to mature for a few days or given a post cure,
after 24 hours at ambient, at approximately 60-100˚C from 1-4 hours dependant on the final environment of
the finished moulding. In many cases, it is advisable to post cure in a jig to avoid distortion.

15. The polyvinyl alcohol film (PVA) is finally removed by washing from the surface of the moulding using soap
water.