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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). 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. 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.
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 fish hold is insulated with a 4 inch thick polystyrene foam enabling the catch to be preserved in ice for up to 6 days. 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. The electrical system is 12 volt, with two, 180 Ah batteries; one for engine starting only, and the other for lighting systems. Safety gear is fitted in accordance with the requirements of the Mercantile Marine Department and Local Port Authority. The hull was built according to the method of construction set out in the earlier sections of this document.
Whilst the costs shown are country specific and out-of-date, they are of interest in identifying the distribution and magnitude of expenditure using one particular vessel as an example for which detailed cost records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. 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.
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 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. The easiest way to keep an analysis of labour for ferrocement construction is to have an appropriate breakdown of jobs.


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.
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. 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. Each section in the job file can readily identify the area being costed, ie jig work, hull fabrication, etc.
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.
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. It is essential therefore to know the capabilities of one's own workforce to be able to estimate costs accurately. I can see that you may have some issues with the joining of the vacuformed parts if you want to get rid of non-scale seams and joints, but whether you go all out to bring it up to today's techniques or build it fairly stock, it should be very impressive. Chuck Hollinger was a well known model builder and designer in the late 40's through 60's. I chose to build mine stock but it lends itself to all the scratch built details you could ever desire It's about the ideal size for a boat of that type.
The vessel has a large working deck aft, with a gantry carrying an overhead net frum, rope driven off the trawl winch.
The hold can be subdivided for carrying ice to the grounds and for sorting sorted fish of various species if so desired.
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. A good view of the working deck is provided through two windows at the aft end of the wheelhouse.


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. 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). It must be borne in mind that all labour used was new to ferrocement construction, and used to working for a government institute. However, a list providing a breakdown of working areas within the fitting out work would be of more practical use.
Obviously if there is more than one boat being constructed at a time then the former method is the best to use.
It is all the better for estimation if the cost exercise is over several different types of craft.
The cod end is raised by the trawl winch warping head via a fixed roller on top of the gantry. The stern gland can be inspected and repacked by removing a section of insulation at the bottom of the fish hold. This item is included for information as to the likely setting up cost incurred in building the first ferrocement boat undertaken.
The labour cost figure would be reduced considerably if the hull was constructed in the private sector. Thus the catch may be dumped onto a totally clear deck and then sorted in the fish pounds before stowing below. The hull is divided into 5 compartments by 4 wooden bulkheads (see General Arrangement IND-101 P3). The 3 drum trawl winch is mechanically driven off the main engine via a clutch and layshaft arrangement.




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