ANNEXES¹

1. DRAWINGS OF 12.8 M FERROCEMENT STERN TRAWLER
2. OUTLINE SPECIFICATION OF 12.8 M FERROCEMENT TRAWLER
3. 12.8 M FERROCEMENT TRAWLER COSTS
4. COLLATING LABOUR AND MATERIAL DATA FOR FERROCEMENT BOAT CONSTRUCTION

¹ N.B. All prices quoted in sections 3 and 4 of the Annex are in Indian Rupees and relate to the time when the trawler was built, i.e., 1985-87. The exchange rate prevailing at that time was US$ 1 = 25 Rs.

1. DRAWINGS OF 12.8 M FERROCEMENT STERN TRAWLER

The drawings represent a design of 12.8 m ferrocement trawler built in 1985-87 by the Central Institute of Fisheries, Nautical and Engineering Training in Cochin, Kerala State, India, with the technical assistance of the Food and Agriculture Organization of the United Nations (FAO design IND-101).

LIST OF DRAWINGS
Lines Plan	IND-101	P1
Hull Construction	IND-101	P2
General Arrangement	IND-101	P3
Frame Sections	IND-101	P4a
	IND-101	P4b
	IND-101	P4c
Superstructure and Sections	IND-101	P5

LINES PLAN - P1

HULL CONSTRUCTION - P2

GENERAL ARRANGEMENT - P3

FRAME SECTIONS - P4a

FRAME SECTIONS - P4b

FRAME SECTIONS - P4c

SUPERSTRUCTURE AND SECTIONS - P5

2. OUTLINE SPECIFICATION OF 12.8 M FERROCEMENT TRAWLER

The design of the trawler was prepared for the specific fishing conditions prevailing in Veraval, a fishing centre in the State of Gujarat, and is appropriate for the illustration of specific features of a ferrocement craft. The main features are as follows:

Length overall	12.80 m
water line	12.00 m
Beam moulded	4.28 m
Depth moulded midships	1.99 m
Max draft to DWL	1.80 m
Engine	Ashok Leyland ALM 680
Power	128 BHP at 1500 RPM 148 BHP at 1825 RPM
Gearbox	Hydraulically operated forward/reverse 3.83:1 reduction gearbox
Speed	8 knots at 1500 RPM
Fuel tank capacity	1433 litres
Water tank capacity	420 litres
Duration	65 hours at 1500 RPM
Accommodation	6 berths
Fish hold capacity	13 m3.

Compared with traditional wooden trawlers of similar size, the ferrocement craft is more stable, has higher freeboard, greater endurance, a more powerful winch, a bigger, insulated fish hold, a larger engine and a more efficient deck arrangement for fishing operations. Furthermore, the vessel has some novel features, described below.

The hull construction is shown in Drawing No. IND-101 P2. Details of the frame and hull shell construction are provided in Fig. 10, showing the 16 mm diameter cold-worked high yield frame rod, the double layup of 6 mm diameter semi-bright hard draw rod, and the three layers of 13 mm x 13 mm x 19 g square welded wire mesh which are applied to each side (i.e., 6 layers in total) of the rod reinforcement. The hull is divided into 5 compartments by 4 wooden bulkheads (see General Arrangement IND-101 P3).

The deck is made of timber with 30 mm planking laid on 110 x 80 mm deck beams; Drawing IND-101 P5 shows typical ferrocement to wood interfaces. The vessel has a large working deck aft, with a gantry carrying an overhead net frum, rope driven off the trawl winch. The cod end is raised by the trawl winch warping head via a fixed roller on top of the gantry. Thus the catch may be dumped onto a totally clear deck and then sorted in the fish pounds before stowing below. The 3 drum trawl winch is mechanically driven off the main engine via a clutch and layshaft arrangement. The winch is provided with mechanical self spooling and has a pull of 1 tonne at mid drum. The drum capacity is 800 m of 12 mm wire.

The fish hold is insulated with a 4 inch thick polystyrene foam enabling the catch to be preserved in ice for up to 6 days. The hold can be subdivided for carrying ice to the grounds and for sorting sorted fish of various species if so desired. The stern gland can be inspected and repacked by removing a section of insulation at the bottom of the fish hold.

The Ashok Leyland ALM 680 drives a 3 blade 1.17 m diameter x 0.761 pitch Kaplan propeller mounted in Kort nozzle giving a trawling speed of 3.7 knots at 1600 RPM and maximum free running of 8.8 knots.

The wheelhouse is extended to the port bulwark to maximise accommodation space. The sole of the wheelhouse is set on a hardwood frame and is insulated with a fire retardant material; it incorporates a flush hatch to facilitate the removal of the engine.

Accommodation is provided for 6 people with 4 berths in the fo'c'sle and 2 berths in the wheelhouse; there is a separate toilet with entrance from the deck. A good view of the working deck is provided through two windows at the aft end of the wheelhouse.

The electrical system is 12 volt, with two, 180 Ah batteries; one for engine starting only, and the other for lighting systems. All circuits are suitably wired, switched and fused. The battery boxes are lead lined and vented.

Safety gear is fitted in accordance with the requirements of the Mercantile Marine Department and Local Port Authority. The gear consists of the following:

One 6-man life raft
Two life buoys (one having an 18 m buoyant heaving line)
Six lifejackets
12 parachute distress rocket signals
Fire fighting appliances.

3. 12.8 M FERROCEMENT TRAWLER COSTS

3.1 Cost of jigs and patterns
3.2 Hull costs (including engine beds, floors, webs, bilge keels, rudder and stern tube liners)
3.3 Fitting out costs
3.4 Analysis of costs

This section covers the costs of producing the 12.8 m ferrocement trawler. The first hull was constructed between May and August 1985, with the fitting out of the craft being carried out between March 1986 and March 1987, the period suiting the overall requirements of the project undertaken.

The costs are split into four groups:

1. Capital cost for jigs and patterns required to build the hull from scratch and considered to be a reusable item the cost of which is left out of the final boat costings (although it could be amortized over a number of boats). This item is included for information as to the likely setting up cost incurred in building the first ferrocement boat undertaken.

2. The breakdown of costs to produce the ferrocement element of the boat.

3. The breakdown into sections of the fitting out costs.

4. A general analysis of the costs presented.

Whilst the costs shown are country specific and out-of-date, they are of interest in identifying the distribution and magnitude of expenditure using one particular vessel as an example for which detailed cost records were maintained.

3.1 Cost of jigs and patterns

a) Materials
Quantity	Description		Use	Value: Rs
239 kg	150 x 75 x 6 m/s channel		Keel Jig	1664.15
18.5 kg	100 x 6 m/s flat		Keel Jig	138.38
24	40 x 12 m/s Hex bolts n & w		Keel Jig	64.56
15 kg	150 x 75 x 6 m/s channel		Plummer blocks	104.45
119 kg	50 x 50 x 6 m/s angle		Keel Jig stands	774.60
76.5 kg	40 x 40 x 5 m/s angle		Keel Jig	567.63
18 kg	40 x 40 x 3 m/s angle		Keel Jig	119.23
10 kg	30 x 30 x 3 m/s angle		Keel Jig	65.61
5 kg	40 x 3 m/s flat		Keel Jig	34.00
14 kg	50 x 50 x 6 m/s angle		Tie rod brackets	103.88
12 kg	40 x 40 x 3 m/s angle		Tie rod saddles	79.49
3.5 kg	40 x 3 m/s flat		Tie rod saddles	23.80
70 m	25 x 25 x 12 g SHS		Tie bars	2312.76
79 m	30 x 30 x 12 g SHS		Tie bars	4281.01
19 m	M10 studding		Tie bars	570.19
98	45 x 10 Hex bolts		Tie bars	212.78
		120 washers 150 nuts
15 kg	50 x 50 x 6 m/s angle		'A' brkts	97.65
40 kg	40 x 40 x 3 m/s angle		'A' brkts	264.96
64 kg	35 x 35 x 6 m/s angle		General bracing	446.34
8 pkts	10 swg welding rods		Spacers
			Keel Jig
			'A' frames
			Tie bars	617.36
2.5 lt	red oxide primer		General	74.45
8 shts	6' x 3' x 6 mm comm ply		Patterns	933.04
1 sht	6' x 3' x 3 mm comm ply		Deck camber pattern	171.63
17 shts	8' x 4' x 3 mm hardboard		Body plan	1929.50
1 sht	8' x 4' x 9 mm marine ply		Patterns	525.10
15 kg	oil bound distemper		Lofting	307.65
3.25 kg	wire nails		General	37.43
13	12" x ½" hacksaw blades		General	103.93
4 ft3	Teak		STR edges	1000.00
6 m	oxygen + 3 m3 D/acetylene		General	253.35
	Total material cost (inclusive of delivery and taxes)		Rs 17878.91
b) Labour	To provide all Jigs and Patterns		Rs 17248.87
	Total Material and Labour Cost		Rs 35127.78

3.2 Hull costs (including engine beds, floors, webs, bilge keels, rudder and stern tube liners)

a) Materials

Quantity	Description	Use	Value: Rs
79 kg	25 x 3 m/s flat	Frames	527.25
45 kg	25 x 25 x 3 m/s angle	Frames	293.58
28	Lengths ^A" med black tube	Frames	3593.53
192 kg	12 mm m/s rod	Frames
		E. beds etc	1436.54
556 kg	16 mm m/s rod	Frames, Keel
		Stem, Transom	4075.48
2 m	M10 studding	Keel	60.02
600	25 x 8 m/s Hex set bolts	Frames	186.00
140	25 x 8 m/s Hex set bolts	Gunwale	43.40
110	25 x 8 m/s Hex set bolts	Beamshelf	34.10
70	25 x 8 m/s Hex set bolts	Transom webs	21.70
90	25 x 8 m/s Hex set bolts	Drain holes	27.90
130	25 x 8 m/s Hex set bolts	16 no.
		Scuppers	40.30
2280	8 mm m/s Hex nuts	Scuppers	410.40
2280	8 mm S/coil spring washers	Scuppers	196.08
14 kg	40 x 40 x 3 m/s angle	Setting up	92.74
7 kg	40 x 40 x 3 m/s angle	Transom stiffeners	46.37
13 kg	25 x 3 m/s flat	Limber holes	86.76
45 kg	30 x 30 x 3 m/s angle	Gunwale	315.00
35 kg	30 x 30 x 3 m/s angle	Beamshelf	245.00
6 kg	30 x 30 x 3 m/s angle	Transom stiffeners	42.00
9 kg	30 x 30 x 3 m/s angle	Gen'l bracing	63.00
13 kg	30 x 3 m/s flat	Beamshelf
		and Scuppers	90.01
36 kg	30 x 6 m/s flat	Gunwale	247.00
33 kg	30 x 6 m/s flat	Engine beds	226.41
58 kg	50 x 6 m/s flat	Set up frames	374.74
5 kg	75 x 6 m/s flat	Stem pattern	37.40
55 kg	12 x 12 m/s square	Beamshelf	364.32
82 kg	(6.5 m) 100 x 15 m/s flat	Engine beds	615.00
6 m	M20/^A" studding	Engine beds	520.62
36	M20/^A" Hex full nuts	Engine beds	53.64
1 m	20 mm/^A" studding	Plummer b'cks	86.77
8	M20/^A" Hex full nuts	Plummer b'cks	11.92
81 kg	1.6 mm annealed lacing wire	Staples	805.64
1047 kg	6 mm SBHD rod	All	11710.53
280 kg	8 mm SBHD rod	All	3132.06
22 rls	30 m x 1 m x ½" x ½" x 19 g
	Galvanised mesh	All 660 m2	24538.80
		Carried forward	54652.01
		Brought forward	54652.01
6½ rls	30 m x 1.4 m x ½" x ½" x 19 g
	Galvanised mesh	All 273 m2	10133.21
25 pkt	10 Swg welding rods	All	1929.25
1 lt	red oxide primer	Gunwale
		Frames, B/S	29.78
6 m	110 x 50 Aini (0.41 ft3)	Engine beds	86.60
1.22	Lorry load sand	Casting	319.64
1 ton	Ice	Casting	153.60
110 bags	O/P cement	Casting	6894.80
2 box	white chalk	General	11.26
30	12" x ½" hacksaw blades	General	244.44
1	18" x 1" hacksaw blade	General	47.44
9	14" x 1" hacksaw blades	General	390.24
10 kg	White oil distemper	Body plan	205.10
200	Mudi (coir rope)	Curing	80.00
6 m3	oxygen + 3 m3 D/acetylene	General	242.31
	Hire charge 10 Kw Generator	Casting stand by	2550.00
	Hire 2 x 40 mm Vibrator shaft/needles	Casting stand by	150.00
2 no.	Rental 15' x 12' Tarpaulin	Casting stand by	24.00
13 kg	Polyester filler	Web, Floor	748.02
3 kg	Marine grade filler	Filling	301.68
1	1252 F/F 1021 D m/s
	Liner Tube	Stern gear	1500.00
1	220 F/F 1021 D m/s
	Liner Tube	Rudder gear	944.00
1	m/s Heel shoe C/W bearing, assembly and s/s button	Rudder gear	1740.50
	Total material cost (including delivery and taxes)		Rs 83377.88

b) Labour

Labour cost to construct the hull, including the subcontract cost of Rs 4887.00 for plasterers:

Total Labour cost		Rs 40660.69
Total cost of	(a) Material
	(b) Labour	Rs 124038.57

The average labour cost for the hull was Rs 47.50 per seven-hour working day (1985). It must be borne in mind that all labour used was new to ferrocement construction, and used to working for a government institute. The labour cost figure would be reduced considerably if the hull was constructed in the private sector.

3.3 Fitting out costs

Because what is termed as 'normal practice' for quoting prices for boats varies so much from one boatbuilding area to another, it was felt that to list each and every fitting out item would be unnecessary. However, a list providing a breakdown of working areas within the fitting out work would be of more practical use.

A selection can be made from any number of items on the list to provide the combined cost for the areas required.

It may help to refer to the specification and drawings provided in the Annex to gauge the quality and extent of the work carried out.

A consolidated list of material and labour costs is set out in Table 3 for the 12.8 m fitting out. The cost of the hull is included (item 1) to provide the total cost of the vessel.

The average labour cost for the fitting out period had risen to Rs 56.60 per 7½ hour working day.

3.4 Analysis of costs

When looking at the costs presented, the following points should be taken into account:

a) All material costs shown include delivery and taxes.

b) The total cost is ex overheads or profit.

c) A reduced costing may be seen to be more appropriate for the following reasons:

i) the boat was constructed under an Indian Government/FAO training project

ii) the boat was a new design and had several new features (to the workforce) incorporated

iii) the labour content due to (i) and (ii) would, out of necessity, be higher than its commercial counterpart

iv) material purchasing by government departments is both time consuming and more expensive due to the quotation and payment policy required, than their commercial counterparts.

The above observations are to provide a more realistic picture for those that want to use the figures in helping to assess their own likely costs.

4. COLLATING LABOUR AND MATERIAL DATA FOR FERROCEMENT BOAT CONSTRUCTION

Labour

The easiest way to keep an analysis of labour for ferrocement construction is to have an appropriate breakdown of jobs. Viz for a typical hull construction:-

1. Frame making including stem and transom
2. Frame meshing
3. Setting up keel, frames, stem and transom
4. Fairing hull
5. Installation of stern tube lines
6. Complete engine bed installation
7. Plummer block installation
8. Fitting sheer angle, creating knuckle points
9. Complete beamshelf installation
10. Transom webs
11. Centreline web
12. Hull rods complete
13. Hull mesh complete
14. Bilge keels complete
15. Rudder gear, liner tube and keel shoe installation
16. Skin fitting holes, scupper holes, fairleads
17. Check over hull
18. Casting hull
19. Curing
20. Water test, remove steelwork and fill bolt holes, and hull as required

Table 2
CONSOLIDATED COSTS OF 12.8 METRE FERROCEMENT TRAWLER

DESCRIPTION	MATERIALS	LABOUR	VALUE: TOTAL RS	% OF COST
1. Hull construction	83377.88	40660.69	124038.57	10.68
2. ALM 680 engine c/w hydraulic gear box	222708.50
PTO installation, SW inlet, outlet, exhaust, controls, etc.	6454.17	3283.15	232445.82	20.03
3. Stern gear c/w 3 blade RH Kaplan prop.	42513.63	479.85	42993.48	3.70
4. Ducted nozzle	10446.73	10730.95	21177.68	1.82
5. Rudder gear and steering controls	21509.53	1237.50	22747.03	1.96
6. Bilge and deck wash system	13930.54	1692.09	15622.63	1.35
7. Fuel tanks, system complete	8002.36	3358.91	11361.27	0.98
8. Fresh water tank and system	2394.37	2904.33	5298.70	0.46
9. Engineering miscellaneous	7333.20	-	7333.20	0.63
10. Electrical system	16372.28	2601.27	18973.55	1.63
11. Timber deck, bulkheads, soles, bearers, BS, forepeak, wheelhouse, RS and sheer capping	110498.79	57758.20	168256.99	14.49
12. Fish hold, c/w pound boards	65904.13	14395.36	80299.49	6.91
13. Galley sink, WC	6113.37	1969.89	8083.26	0.70
14. Handrail and bulwark	4340.34	4040.80	8381.14	0.72
15. General deck equipment	39364.64	4545.91	43910.55	3.78
16. Gantry complete	9137.56	5909.67	15047.23	1.30
17. Winch c/w layshaft and control	39159.23	3813.51	42972.74	3.70
18. Hull anode	525.76	404.08	929.84	0.08
19. Complete painting	36263.33	6642.07	42905.40	3.69
20. Fastenings	19099.24	-	19099.24	1.64
21. Launching, trials and final work	39139.20	1161.73	40300.93	3.47
22. Engine/gear box and general spares	28185.31	-	28185.31	2.43
23. Optional equipment	91718.00	1464.80	93182.80	8.02
24. Fishing gear, c/w 6 nets, 2 sets otterboards	61434.71	6293.11	67727.82	5.83
Total costs ex overhead and profit	985926.80	175347.87	1161274.67	100.00

Naturally, for preparation of tie-rods, keel, jig and any miscellaneous jigging items, the cost of these should be kept under a separate heading and amortized over a convenient number of hulls to be built of the same type.

By working the labour under the headings outlined, one can obtain a clear picture over two to three hulls as to the number of hours required for each stage of the work, as well as having an indication if a job such as a 'ferrocement beamshelf' is cost effective as against the installation of a timber shelf.

Material

The only way to keep an accurate record of material used is either by having all the materials properly racked and booked out each day to the job, or by knowing the quantities in stock prior to starting a particular job and doing a stock take at the end of the construction period of the hull. Obviously if there is more than one boat being constructed at a time then the former method is the best to use.

If the materials for all sizes are racked individually, then it is an easy job to keep stocks up to the limit required, as well as the drawing of the materials from the stores is made much simpler.

Booking out can be done on a daily basis to a job number and then transferred to a job file where the cost can be filled in from a stock index which has an up to date price including tax and delivery charges brought down to a cost per kg/m length or quantity basis.

Each section in the job file can readily identify the area being costed, ie jig work, hull fabrication, etc.

Costing and estimation for ferrocement work

Naturally from a costing and estimation purpose it is better if one already has some identification of costs to hand from work previously carried out.

From this knowledge a figure for square m surface area can be calculated for labour and materials. It is all the better for estimation if the cost exercise is over several different types of craft.

For estimation where there has been no previous experience, examples are set out below taken from the Cochin project for first time construction, using some skilled labour unfamiliar with ferrocement construction:

	Material cost including tax	Labour per m2
a) 10.5 m Fishing boat hull	Rs 730/m2	60 hrs/m2
b) 12.8 m Fishing boat hull	Rs 730/m2	53 hrs/m2

These figures are relevant to 1985, on estimating for the present it would be necessary to allow a figure in for inflation, proportionate cost of jigs, overhead charge and profit, to arrive at a current selling price.

The figures above for labour would dramatically change when a comparison is made with actual commercial construction times of similar craft with well trained personnel, and operating under an incentive scheme:

	Labour per m2
a) 10.5 m Fishing boat hull	21.5 hrs/m2
b) 12.8 m Fishing boat hull	19.0 hrs/m2

It is essential therefore to know the capabilities of one's own workforce to be able to estimate costs accurately. Table 4 is set out to help in estimating ferrocement boatbuilding costs.

Table 3
ESTIMATED FERROCEMENT COSTINGS

Hull type: ____________________________________		Job No: _________________
Prepared by: __________________________________		Date: ___________________
Surface area calculations
1. Hull: _________	5. Beamshelf: ________________	9. Coamings: _____________
2. Webs: _______	6. Bulkheads: ________________	10. Bilge keels: ___________
3. Floors: _______	7. Deck: ____________________	11. Longit Webs: __________
4. E/Beds: ______	8. Deck Webs: _______________	12. Block Areas: __________
Total Surface Area = _________ m2

Labour:
Hours at ___ per hour
Overheads at ___ %
Labour Total:-
Materials:
Sq/metres at per m2
Overheads at ___ %
Materials Total:-
Subcontract labour casting cost
Internal moving allowance cost
Classification Society cost
Overheads at ___ %
Miscellaneous Total:-
Works Cost Total:-
Profit Margin ___ %
Additional Items at Cost:-
a) Designers royalty %
b) Lofting
c) Jigs recovery cost ÷
d) Works Cradle cost ÷
e)
Costings Total:-

Selling Price up to 19 (ex delivery, transport & tax)

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