To
build each hull, Turbotsan’s operators first create a frame of polyethylene
pipe that serves as the skeleton for the boat-much like the “ribs” in a
traditional wooden hull.
Wedged between the
Black and Mediterranean seas, Turkey has been a seafaring nation for millennia.
In this capacity, it has often been at the forefront of shipbuilding
technology, creating seaworthy craft out of everything from reeds to steel.
The tradition continues to this day in a nondescript industrial
building-typical of the more prosperous manufacturing areas in Istanbul-where
the five-year-old shipbuilder Turbotsan builds large, seaworthy vessels
entirely from plastic.
Inspired by the Zodiac line of inflatables, Turbotsan owner Burcin Yaslan
wanted to develop a line of seagoing craft that was larger and sturdier.
However, doing so presented a number of technical challenges, including finding
a way to weld together the various polyethylene parts making up each hull.
Ultimately, Yaslan solved the problem by
implementing a number of handheld Weldplast and Fusion plastic welders and
extruders from plastics assembly equipment manufacturer Leister Process
Technologies (Itasca, IL).
To build each hull, Turbotsan’s operators first create a frame of polyethylene
pipe that serves as the skeleton for the boat-much like the “ribs” in a
traditional wooden hull. Operators then weld on a number of plates using the
Leister extruders. To ensure the remaining hollow spaces won’t take on water in
the event of a leak, they are filled with foamed-expanded polystyrene. The
result is a sturdy, long-lasting, lightweight and agile boat that is
indistinguishable in terms of performance from a conventionally manufactured
boat.
The welded seams between the pipe
frame and the hull plates are made using Leister’s most powerful handheld
extruder, the Weldplast S4, which produces up to four kilograms of extrudate an
hour. The many smaller joints making up the hulls are welded using a Fusion 3C
system or the Weldplast S2. Operators use a compact Fusion 2 to execute welds
in hard-to-reach areas.
Yaslan and his 20-person team now
produce about 40 boats a year. Customers include a number of regional
coastguards that have since proven the boats’ abilities to stand up under even
the harshest operating conditions.
The boats are available in a range of shapes and sizes, from small open-cockpit
vessels to 54-footers with cabins and lower decks. Depending on the customer’s
wishes, the boats can be supplied as either bare hulls or complete with engines
and fittings. The boats have been so successful, the company plans to expand
its production facilities to meet growing demand.
For more on plastics assembly, visitwww.leister.com.