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Page ii
VOLUME I
INTRODUCTION
INTRODUCTION
This volume deals with the construction in
ferro-cement of a 65-foot (19.5 m) power boat
hull for twin engines. The construction method
demonstrated is the upright, welded framework
method in suspension from an overhead
structure.

The contents of this volume treat in proper
sequence with all the construction stages from
lofting through to a hull ready to be plastered.
Inevitably, for the purposes of illustrating the
construction work in detail, one single design
of hull had to be chosen. Prospective builders
of other designs of boats within this category
need not be deterred, however. The techniques
demonstrated here may be safely imitated to
produce other hulls of equal proven quality.

Construction Costs:
Costs of construction are what immediately
interest the prospective builder. Following the
reproduction of the set of drawings from which
this hull was built, a comprehensive catalogue
has been included. The catalogue lists all the
equipment and materials used in the yard and
in the construction of the demonstration hull.
It will be noted that some of the equipment
and most of the tools were purchased. In those
instances where equipment was required only
for a short period of time it was, where possible,
rented. In cases of either rental or purchase
the prices are recorded as they stood in
Seattle, Washington, USA, in the spring of 1972.

The costs of overheads: management, yard
material, electricity, insurance, social security,
etc., have been omitted because of the wide dif-
ferences in these costs from one place to another.

Labor Costs:
Labor costs also differ widely from one
region to another. For this reason estimates
are given of the number of man-hours required
to perform a given task by a given trade classi-
fication. This information will be found in the
Construction Schedule, a valuable guide which
is placed immediately after the Catalogue in
this Section. From these man-hour estimates
(in fact, an actual record of man-hours utilized

in the construction of the demonstration hull),
the prospective builder can calculate total labor
costs according to the rates prevailing in his
area.

The Manager's Check-List:
The Construction Schedule has purposes
other than a guide to labor requirements and its
principal function is to serve as a form of check-
list for management. Here, in condensed form,
the manager has set down before him all the essen-
tial information required for building the hull
efficiently. For precise details on certain jobs
the manager refers, by numbers of Stage, Job
and Task, to the corresponding section in the
text, for both text and Construction Schedule
follow the same titles and sequence.

The Construction Schedule reminds the
manager when to consult the Catalogue for deliv-
eries of materials and equipment. It informs him,
as has been mentioned, on what types of trades-
men will be required for a certain job, also, how
long the job should take.

Because of printing space requirements only
a skeleton Construction Schedule is included
here but, in expanded form, more space would
be given for the manager's own annotations. In

the case of series production of one design of
hull the Construction Schedule would be con-
stantly revised according to the performance of
the work force as it gained efficiency. The basic
information contained in the Construction
Schedule would be submitted to an over-all,
Master Construction Schedule which would pro-
ject, on one sheet of paper at any one time the
varying stages of production of all the boats in
the yard. This was the system employed in the
Bahamas in 1971 when a new boat yard was
developed, men trained and ten ferro-cement
vessels of one design were successfully built and
launched within a five-month period. (See
Volume III.) If a crisis should arise where a fleet
is required in a hurry, a production schedule of
this type could be effectively used on a protected
beach to produce one boat complete through
trials every working day. Providing space, mate-
rials, labor and money were available. Details of
the production method would alter but this
tried and proven principle would remain the
same.

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