Structural Adhesive – The Conservation of HMS Victory

Preserving the World’s Oldest Commissioned Warship

HMS Victory is the world’s oldest commissioned warship and an internationally important part of Britain’s maritime heritage. Her ongoing conservation brings together traditional shipbuilding skills, specialist timber engineering and modern adhesive technology.

As part of HMS Victory: The Big Repair, the conservation team required a structural timber adhesive capable of bonding laminated components used within the ship’s load-bearing framework, external cladding and decking.

Following extensive bonded sample trials, Aerodux 185 resin with Aerodux 155 powder hardener was selected for the project.

Overcoming the Structural Timber Challenge

HMS Victory’s original construction relied heavily on large, naturally curved oak timbers secured using traditional joints and mechanical fastenings.

Finding replacement timbers with the maturity, dimensions and natural curvature needed to reproduce these components is extremely difficult. To overcome this challenge, the project team is manufacturing engineered timber sections by bonding multiple layers of hardwood together.

These sections can be laminated in a flat form before being precisely machined into the complex profiles required for the ship.

The chosen adhesive needed to withstand:

• Long-term exposure to demanding marine conditions.

• Changing temperatures and moisture levels at Portsmouth Historic Dockyard.

• Significant loads within critical structural components.

• Severe mechanical forces during post-cure machining.

• A required service life of at least 50 years.

Selecting Aerodux 185/155

Following careful assessment and sample testing, Aerodux 185/155 was selected as the structural bonding solution.

Aerodux 185 is a phenol resorcinol formaldehyde (PRF) adhesive system designed to produce exceptionally strong, durable and weather-resistant bonds. It is particularly suited to load-bearing timber structures and applications exposed to demanding external or marine environments.

The system comprises Aerodux 185 liquid resin and Aerodux 155 powder hardener, mixed at a ratio of five parts resin to one part hardener by weight.

Its combination of structural strength, water resistance and long-term durability made it an ideal structural timber adhesive for the demanding requirements of the HMS Victory conservation programme.

Supporting Multiple Structural Timber Applications

Aerodux 185/155 is being used across four principal areas of timber lamination.

Rib and Frame Components

Iroko is laminated into heavy, flat blocks before being machined into the curved knees and futtocks that form part of the ship’s structural framework.

These components must withstand substantial loads while accurately replicating the shape and lines of the original vessel.

External Cladding

Multiple layers of iroko are bonded to create weather-exposed cladding components for the exterior of the ship.

The marine timber adhesive must maintain its integrity despite prolonged exposure to moisture and changing environmental conditions.

Laminated Decking

Oak sections are laminated to manufacture durable deck planks capable of withstanding foot traffic, structural movement and environmental exposure.

Decking Scarf Joints

High-strength angled scarf joints are used to join standard lengths of oak, creating the long, continuous sections needed for the ship’s decking.

Controlled Application and Quality Assurance

Bonding dense hardwoods requires careful surface preparation and tightly controlled workshop conditions. The production team follows a strict application process to achieve consistent bond performance.

The timbers are first acclimatised to the workshop environment, with their moisture content checked and recorded. The bonding surfaces are then planed and sanded to expose fresh wood fibres and promote effective adhesive penetration.

Aerodux 185 resin and Aerodux 155 hardener are mixed at a ratio of 5:1 by weight. The mixed adhesive is applied to both bonding surfaces at approximately 150 g/m² per face.

Following a short open assembly period, the laminated components are transferred to a beam press, where full and even pressure is maintained throughout the closed assembly and curing period.

The bonded sections are cured at an ambient temperature of approximately 20°C before being conditioned for 48 hours to develop their final strength. They can then be machined using a combination of precision CNC equipment and traditional woodworking techniques.

Strength Beyond the Bond Line

One of the most demanding stages of the process is machining the flat-laminated sections into their final curved profiles.

Removing significant quantities of timber after bonding introduces considerable mechanical stress into each component. The successful machining of these sections demonstrates the exceptional shear strength and integrity of the cured Aerodux 185 bond line.

The completed bond allows the laminated layers to perform together as a single structural section, providing the strength and stability needed for the ship’s critical timber components.

Meeting Demanding Structural and Marine Standards

Aerodux 185/155 combines high structural performance with recognised certification for demanding timber applications.

The system conforms to BS EN 301:2023, Adhesive Type I, covering phenolic and aminoplastic adhesives used in load-bearing timber structures exposed to external conditions.

It is also accepted by Lloyd’s Register EMEA for the structural bonding of wooden members used in the construction of marine vessels and small craft.

Once cured, the PRF adhesive provides excellent resistance to:

• Boiling water.

• Long-term weather exposure.

• Solvents.

• Acids.

• Weak alkalis.

• Elevated temperatures.

These properties provide the durability required for structural components expected to remain in service for decades.

Combining Historic Craftsmanship with Modern Adhesive Technology

The use of Aerodux 185/155 allows the HMS Victory conservation team to manufacture large and complex timber components while preserving the ship’s historic form.

By combining laminated hardwood construction with a high-performance structural timber adhesive, the project can achieve the strength, dimensional stability and weather resistance required without compromising the vessel’s iconic appearance.

This project demonstrates how traditional craftsmanship and modern structural adhesive technology can work together to protect one of Britain’s most important historic landmarks.

At Ureka, we are proud to contribute our technical adhesive expertise to HMS Victory: The Big Repair and help secure the future of this internationally significant ship for generations to come.