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Polymarine Company. Herstel en onderhoud van polyester boten in Lemmer en omstreken

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Polyester or epoxy: which do you use for a boat repair?

Epoxy bonds considerably better to cured polyester than polyester resin does, and it is osmosis-resistant too. But you cannot apply gelcoat over epoxy; it has to be painted. If you want a gelcoat finish, polyester is the obvious choice. So your top coat decides the resin, not the other way round.

Why epoxy bonds better

Polyester resin bonds chemically to polyester as long as that has not fully cured. On a hull of ten or twenty years old that chemical bond is gone; then it is purely mechanical, and that is considerably weaker.

Epoxy does bond both mechanically and chemically to almost any substrate, including old, fully cured laminate. For structural repair on an older boat that is the stronger starting point.

The catch is in the finish

Gelcoat is itself a polyester resin. Over epoxy, gelcoat cures poorly or not at all: it stays tacky or lets go later. So an epoxy repair is finished with paint, not with gelcoat.

For an underwater hull that is rarely a drawback, because primer and antifouling go over it anyway. Above the waterline, where you want the colour and shine of the hull back, it changes the whole job: repairing one scratch with epoxy ends up meaning painting a whole panel.

That is why above the waterline we generally work with polyester and gelcoat, and below it with epoxy.

Cost and handling

Polyester resin is cheaper and cures faster, which is convenient when several layers have to go on top of each other. Epoxy is more expensive, cures more slowly and is more sensitive to the mixing ratio: estimate too generously and it stays soft.

Epoxy smells less than polyester, but it does call for gloves, because skin contact can cause sensitisation - after which you can never work with it again.

In short

Below the waterline, structural repair, or a boat older than fifteen years: epoxy. Above the waterline with a gelcoat finish: polyester. And in both cases the preparation - the tapering - decides more about whether the repair holds than the choice between these two resins.

Frequently asked questions

Can I apply polyester over epoxy?

Not without trouble. Polyester cures poorly on epoxy and the bond is unreliable. The other way round works fine: epoxy over cured polyester is in fact a strong combination.

Is epoxy more watertight than polyester?

Yes. Epoxy takes up considerably less moisture, which is why an epoxy barrier coat is used after an osmosis treatment and as prevention on the underwater hull.

What do you use yourselves?

It depends on the location. Above the waterline, polyester with gelcoat, so the colour and shine come back without painting. Below the waterline, epoxy, to keep moisture uptake as low as possible.

Damage to your boat? Send a photo.

A photo and a short description are enough to assess the damage. Then you hear what is needed and get a quote to suit.