Building a better boat

Established fully as a polyester resin producing unit in 1997, Scott Bader in Jebel Ali is the Middle East arm of the international composite producing firm, started in the UK in 1921. Now providing the raw materials that make up the largest boat manufacturers’ yachts in the world, its heritage demonstrates a continued process of polyester resin innovation, from designing the first room temperature cure polyester resin in 1941 and the first ‘air drying’ polyesters in 1949, to creating the first marine polyester resin in 1954 that was used to make the GRP hull for Halmatic’s Perpetua, the first sizeable GRP motorboat in the world. Now focussing on servicing the Middle East boat building industry, Sales and Marketing Manager Bob Garner has brought onboard the experience of South African Bruce Penn as Marine Business Development Manager. Here they explain why it is important everyone knows about polyester resins, not just boat builders.

Twelve years securing the market in South Africa; what does Dubai hold?

Scott Bader has long been established in the Middle East market by providing polyester resin for the commercial pipe industry, but it is impossible to ignore the potential of the marine industry that exists here. That is what I am here to do; develop our business. I’m here to demonstrate Scott Bader’s new resin and gelcoat products and processes to the marine industry across the Middle East region.

Do you think more boat builders will set up here?

To fit the future predicted rise in leisure boating, it would certainly make sense for other builders to establish themselves here, be they independents or offshoots of larger companies. It is the only way that supply will really be able to satisfy the expected demand. But it is not just the future that we are interested in; it is the here and now of the industry.

Have you come to preach new practices?

Not exactly. It is about education. There are lots of new products developed by Scott Bader that allow for quicker and more precise building practices, which were not possible previously. It is a question of how a boat builder wishes to invest in their product. We are not just trying to get companies to specify Scott Bader products, but to see how the products we offer can help their design and production processes.

All resins are not the same?

Resins may be separated into categories, but how you mix and apply them in building a boat is critical in ensuring you get the desired finish. Depending on what type of vessel a builder is laying up, we can select and tailor the consistency of the resin to ensure the finished laminate has optimum consistency for the size, type and application of boat.

Do you try to be involved with the design process?

Not at all. That is up to the boatbuilders’ designers, marine architects and specialist builders. We merely supplement the process by offering the builder a variety of different ways that they can use in creating that perfect finish. You cannot just use general purpose resin for all applications; you have to tailor the resin to the laminating and application processes to be used. For example, the resin used to build boats here has to be tailored for the Middle East conditions.

Is this of real value to the average boater?

That depends. Apart from those who dream of having their own boat built, most boat owners may be in the position of either having a gelcoat or paint finish. When it comes to these decisions, it is important to ensure whoever is building the boat is aware of the new gelcoat technologies available to get the best finish possible.

You also sort out the finish?

Of course. The gelcoat finish is an integral part of the laminating process. It’s not all about stringers and pre-preg foam cores. That is what provides the stability for a hull’s structure, but it is the gelcoat finish that will be most visible so it is vital to get that right. Obviously the lay-up is critical in getting a smooth and consistent surface, but we have also developed products such as the Crystic Crestacoat which is brushed or sprayed behind the gelcoat to provide an absorbent flexible layer so that the gelcoat is not affected by the curing of the fibreglass laminate. This will ensure a smooth, mirror-like finish on the gelcoated surface. But this product does not work miracles, so a lot is also dependant on the quality of the moulds.
Could prospective owners specify these on their boats?

That would depend on the boatbuilder, their skill and flexibility to adapt to new products. If owners are looking for the ‘ultimate’ finish then yes, it would be something they should request or specify.

How do you assist builders?

We are not just selling our products, we aim to provide a technical service to help boatbuilders find the right products and applications for their product. For a company building small inexpensive boats, there is no point recommending a Crestacoat product – it would make their product too expensive. We like to sit with a client and establish a working relationship to evaluate how our products can help their product become more competitive – be that structurally, aesthetically or by speeding up production. While most suppliers have concentrated their sales on the end product, Scott Bader realises that the most important part is the first step, the plug. If you get the plug and, by extension, the mould to a superb finish the end product will mirror that. Scott Bader’s focus is on supplying materials from this stage through to completion. We are marketing a total system.

Who have you worked with?

Most notably, the Bahraini powerboat builder Al Dhaen has been working with us over the past two years. And we say worked because not only have we advised them on products and applications, but they also come to us and ask us what we have to help differentiate and promote their new products. This two-way communication is the best way of developing and improving the end product. Every builder has cost restrictions depending on the product and their client’s needs. We can simply help to match their product with their budget to get the desired build.

Will other builders follow?

Its not a question of following. It is about ensuring they have the best product. As many Middle East builders are now competing with European made boats, their products are up against builders who already use new generation products and processes, and so to be competitive will have to ensure their boats offer just as much in terms of design and surface finish. There has been a massive interest locally for our products and service, with sample trials currently underway at many boat builders across the region.

Are you experiencing demand across the board?

You mean apart from marine? We are expanding our production facility by 35 per cent and will soon be the single largest UP Resin producing site in the region. We also supplement our range by importing specialist products from other Scott Bader sites in Europe, and are able to offer a full range of new generation bonding pastes, Crestomer high performance adhesives, tooling systems and mould protection coatings.

Do you see future changes in the marine industry?

Most builders still rely on hand lamination, which is the most basic form of lay-up, though a few have mechanised their processes. As demand grows we may see the major players increasing their investment in mechanisation of their production processes.

Is there a production technique you favour?

Every boat building technique has its benefits and problems. We don’t promote any particular method or type without careful consultation with and understanding of customer needs. We will technically recommend materials to use for the method and finish clients require.

Is this a new service?

The requirement was not there before. Now that local boat builders are raising the quality bar there is a growing demand for new technology polyester resin products and advanced processes, backed by expert know-how and technical support. This is what Scott Bader is bringing to the market. Like any building project, if one gets the right base materials and lays them well, then the end product will succeed. Conversely, if one doesn’t get the basics right, the product will never truly be internationally competitive.
Tel: +971 4 883 5025
www.scottbader.com