Axsail
FINDINGS LIBRARY · HULL AND STRUCTURE

Gelcoat stress cracks: star cracks, parallel cracks and what surveyors make of them

UPDATED 6 NOVEMBER 2026 · 3 EXAMPLE FINDINGS · 1 SOURCES

What star cracks and parallel gelcoat cracks say about a fibreglass boat, how a surveyor tells crazing from structural cracking, what repair involves and three example findings graded A, B and C.

AT A GLANCE
Gelcoat stress cracks
USUAL GRADE
A for cracks with soft or moving laminate at a loaded area. B for cracks through the gelcoat at a loaded point that need the laminate checked. C for localised crazing on firm laminate
FOUND WITH
Looking along the hull and deck in low light, reading the pattern of each crack, pressing and sounding the laminate round it, and asking what's mounted on the other side
JUDGED AGAINST
Pattern and stiffness. Safe Skipper reads star cracks as impact and linear cracks as bending or flexing, and says cracks right through the gelcoat point to some structural failure beneath
REPAIR COST
Grinding out and filling the gelcoat is a small job. Fixing the cause underneath, if there is one, is priced per boat

Gelcoat is a thin, hard, brittle skin. It doesn't bend like the laminate underneath, so it cracks first and shows where the boat has been hit or where it flexes. Most cracks are only skin deep. Some are the first sign of a laminate that's moving.

Reading the pattern

Safe Skipper's guide gives the patterns. Star or starburst cracks come from impact, with the centre at the point of impact. Linear cracks, often in parallel lines, mean bending or flexing; it names deck edges and the deck to cabin side corner. Stress cracks don't crisscross.

So a star in a cockpit sole is usually a dropped tool. Parallel cracks fanning from a stanchion, a winch or a traveller mean the fitting is working the deck.

How a surveyor checks it

Look in low, raking light along the hull and deck. For each crack, note the pattern and what's nearby, and look at the other side if you can. Press round it and sound it: Safe Skipper separates scratches from cracks that go right through the gelcoat and indicate some structural failure beneath. A dull note or movement means the laminate needs a closer look.

Check the high-load places: round the keel, chainplates, winches, the traveller, the stem and anywhere the boat might have hit something.

What decides the grade

What's under the crack. Moving or soft laminate at a loaded area is an A. Cracks through the gelcoat at a loaded fitting on firm laminate are a B, to find the cause. Local crazing or a small impact star on firm laminate is a C.

Gelcoat stress cracks: example findings

The same defect written up at each grade, the way Axsail writes it from what the surveyor says on board. The grade follows what was found, so use these as wording, then grade what you see.

HULL AND STRUCTUREA
Hull bottom, aft of the keel

Parallel cracks across the hull bottom aft of the keel, with a dull sound and slight movement of the laminate when pressed. Owner reports a grounding.

Recommendation: Do not sail until the laminate and the keel area have been inspected by a composite repairer and repaired.

HULL AND STRUCTUREB
Deck, base of the mainsheet traveller

Parallel cracks running out from each end of the traveller base, through the gelcoat. Laminate firm on sounding.

Recommendation: Check the backing and the deck laminate under the traveller, reinforce as needed and repair the gelcoat within 12 months.

HULL AND STRUCTUREC
Cockpit sole, port side

Star crack about 50 mm across, consistent with a dropped item. Laminate firm and sounds solid.

Recommendation: Grind out and fill the gelcoat at the next maintenance period.

ASafety. Safety or compliance deficiency. Fix before the vessel is next underway.
B12 months. Deficiency that needs timely attention. Fix within about 12 months.
CRoutine. Note or observation, cosmetic or maintenance. Routine maintenance at the owner's convenience.

What repair involves

Job Reported cost
Grind out, fill and fair the gelcoat Small parts and time
Add backing or reinforcement under a fitting Yard labour, priced per job
Laminate repair after impact or grounding Composite repairer, priced per boat

Safe Skipper's repair steps: grind out, clean with acetone, mask, fill with gelcoat filler, sand and polish. Find the cause first.

Photos to take

Each crack close up with something for scale, the wider area showing the fitting or feature nearby, and the inside where you can reach. With Axsail, describe the pattern and the sound as you take the photo and it goes on the hull finding.

Writing it up

Give the location, the pattern, star, parallel or crazing, the size, what's nearby and the result of pressing and sounding. Say whether you think it's cosmetic or structural and why.

Frequently asked

What causes star cracks in gelcoat?

Impact. Safe Skipper says star cracks are caused by external impact, with the centre of the star at the point of impact, such as a dropped winch handle or a knock against a dock.

What do parallel cracks in gelcoat mean?

Bending or flexing. Safe Skipper points to linear cracks along deck edges and where the deck meets the cabin sides. Cracks running out from a fitting suggest the fitting is loading a panel that bends.

Are gelcoat cracks structural or cosmetic?

Safe Skipper separates scratches, which sit in the gelcoat, from cracks that go right through it and point to some level of structural failure beneath. Press and sound the laminate round the crack. Firm and solid is reassuring; soft, dull or moving isn't.

Can I just fill gelcoat cracks?

Only once the cause is known. Safe Skipper says the underlying cause of stress cracks needs to be identified before repair, or they come back.

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