HULL, STEEL & ALUMINIUM STRUCTURES

Project Manager control of structural inspection, repair and refit work

Structural work on a yacht must be planned around the vessel’s original construction, material type, Class requirements, survey findings and the intended scope of repair or modification.

The Project Manager is not expected to replace the naval architect, structural engineer or Class surveyor. The PM’s role is to coordinate the inspection, technical decisions, approved repair methods, subcontractors, documentation, programme and quality control.

The objective of this module is to help the Project Manager recognise structural risks, understand the information required before work begins and maintain traceability from initial defect through repair, inspection and final acceptance.

Key responsibilities

• Identify whether the structure is steel, aluminium, composite or mixed construction.
• Obtain relevant structural drawings and previous repair history.
• Confirm Class involvement and survey requirements.
• Establish the areas requiring inspection, access or opening-up.
• Coordinate thickness measurements and NDT where required.
• Record corrosion, deformation, cracking, wastage and previous repairs.
• Ensure structural defects are photographed and referenced before repair.
• Establish whether naval-architect or Class-approved repair drawings are required.
• Confirm material grade and certification before fabrication begins.
• Ensure replacement plate thickness and material specification are correct.
• Control removal of damaged material so adjacent structure is not unnecessarily compromised.
• Coordinate hot-work permits, fire watch and surrounding-area protection.
• Monitor distortion risk during cutting and welding.
• Confirm welding procedures and welder qualifications where required.
• Ensure repair stages are inspected before areas become inaccessible.
• Maintain traceability of photographs, measurements, material certificates, NDT and survey reports.
• Confirm final acceptance by the appropriate technical authority.

PROJECT MANAGER COMPETENCY TEST

Scenario 1 — Plate Wastage

Ultrasonic thickness measurements identify significant wastage in part of a steel shell plate. The subcontractor proposes welding a doubler plate over the affected area.

Question:
What should the Project Manager do?

A. Approve the doubler because it is faster
B. Confirm the repair method with the relevant technical authority and Class where applicable before proceeding
C. Allow the welder to decide
D. Paint the area and monitor it later

Correct answer: B

Why:
The appropriate repair depends on structural condition, location, Class requirements and approved engineering practice. The PM should ensure the repair method is technically accepted before work proceeds.

Scenario 2 — Aluminium Repair

An aluminium hull plate requires replacement. A subcontractor proposes using aluminium plate available in stock but cannot immediately provide its material certification.

Question:
What is the correct action?

A. Use the plate because all marine aluminium is equivalent
B. Confirm the correct alloy, temper and certification before fabrication
C. Use thicker material to compensate
D. Ask the paint supplier

Correct answer: B

Why:
Aluminium alloys and tempers have specific mechanical and welding characteristics. Material traceability should be confirmed before structural fabrication.

Scenario 3 — Hidden Structure

A repair area will be closed permanently after a new plate is installed, but the internal stiffeners and welds have not yet been inspected.

Question:
What should happen?

A. Close the area to maintain programme
B. Stop and arrange the required inspection before the structure becomes inaccessible
C. Photograph only the outside after welding
D. Ask the owner after completion

Correct answer: B

Why:
Inspection hold points must occur before structural areas become inaccessible. Otherwise important evidence and verification may be lost.

Scenario 4 — Welding Distortion

During replacement of a large plate, visible distortion begins developing in the surrounding structure.

Question:
What should the Project Manager do?

A. Continue until the plate is fully welded
B. Pause the work and review the welding sequence, heat input, restraint and technical repair plan
C. Grind the distorted area flat afterwards
D. Apply additional paint

Correct answer: B

Why:
Structural welding can introduce significant heat and distortion. The operation should be reassessed before further damage develops.

MODULE COMPLETION

Before completing this module, the Project Manager should be able to:

• distinguish the principal structural materials used in yacht construction
• identify the structural information required before repair work
• understand the purpose of thickness measurements and NDT
• recognise corrosion, wastage, cracking and deformation as structural concerns
• understand the importance of approved repair methods
• confirm material specification and certification
• understand welding and distortion-control considerations
• identify inspection hold points
• maintain structural repair traceability
• coordinate subcontractor, Class, surveyor and naval-architect involvement
• ensure evidence is retained before repaired areas become inaccessible

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