Operating an inflatable floor vessel (BBV) often causes discomfort when crossing long distances or fishing in cool weather, water seeps through the fabric, and the uneven topography of the cylinders tires the legs and back, and the solution is to install a rigid decking system that dramatically changes the cockpit's ergonomics, making it safe and comfortable to move inside the boat.
Use of use polystyrene, known in the household as penplexIt combines low weight, high compressive strength and, critically for water, absolute water resistance, unlike plywood, it does not absorb moisture, rot, and requires complex varnishing, remaining light even after hours of contact with water.
Creating such a floor yourself allows you to ideally adapt the decking geometry to a specific model PVCThe process does not require expensive carpentry equipment or deep technical knowledge, but requires careful attention to detail in calculating the thickness and density of the material. Properly assembled floor turns a soft inflatable boat into a full-fledged vessel with a rigid bottom, while maintaining the ability to quickly disassemble.
Advantages and disadvantages of foam for shipbuilding
The choice of building insulation as a material for floating decking may seem unobvious, but the technical specifications of extruded polystyrene foam make it an ideal candidate. The main value of the material is its closed-mesh structure, which completely eliminates moisture absorption. hygroscopicity The material remains close to zero, which prevents the gain of excess weight and loss of buoyancy characteristic of wood or conventional plywood.
The second argument is thermal insulation: When fishing in early spring or late autumn, the cold from the water does not pass through the bottom of the boat, allowing you to maintain a comfortable body temperature longer without the use of additional mats, and the material is chemically inert, not exposed to salt water, oils, gasoline and most solvents, which is often found in small-sized vessels.
⚠️ Warning: Despite its high strength, the foam is afraid of open fire and some aggressive solvents (such as acetone or toluene) that can melt its structure.
But there are limitations to the material, and the main disadvantage is that it's not very resistant to sharp hits, and if you drop a heavy anchor or step on a heel with a rock, you can get a dent on the surface. cover It's a necessary design element, without which the life of the flooring will be drastically reduced, and it also tends to fade under the influence of ultraviolet light, although this only affects aesthetics, not functionality.
- 🌊 Total water resistance and zero water absorption even with prolonged immersion.
- 🛡️ High compressive strength, allowing you to withstand the weight of several people and equipment.
- ❄️ Excellent thermal insulation properties that keep the heat in the cockpit of the boat.
- ⚖️ Minimum weight of the structure, which is important for the transportation and carrying capacity of PVC boats.
Material calculation and density selection
The first step in creating a quality flooring is to match the density of the material. penplex It's presented in various modifications, which are 31, 35, 45 and so on, and it's a figure that indicates the density of the material in kilograms per cubic meter. 35 kg/m3However, for greater reliability and durability, it is recommended to use plates with a density of 45 kg / m3 and above.
The thickness of the layer directly affects the rigidity of the structure and its buoyancy. Standard insulation sheets are usually 20, 30, 40, 50 or 100 mm thick. For single boats or as the top layer of the composite floor, 30-40 mm are often used. If you plan to create a full-fledged hard bottom to replace inflatable tubes, or if the crew weight is large, optimally apply sandwich-structure It's two layers of 20 to 30 mm, glued together, and it increases the hardness on the kink without critically increasing the thickness.
When calculating the amount of material, you need to take into account not only the area of the bottom of the cockpit, but also possible tolerances for trimming. foamplex For a standard two-seater boat with a length of 280-320 cm, 2-3 sheets are usually enough, depending on the chosen thickness and layout scheme. Be sure to purchase glue for docking elements in advance if you plan a multi-layer structure, and material for finishing.
It is also important to determine the type of protective coating in advance, which can be rubberized fabric, linoleum, carpet or special anti-slip coatings for yachts. The choice of "cladding" depends on the final weight and the coupling properties of the floor. Light options are preferable, since each extra kilogram reduces the payload on the boat.
| Parameter | Meaning/Recommendation | Impact on operation |
|---|---|---|
| Density | 35-45 kg/m3 | Determines the ability to withstand weight without a miscarriage |
| Thickness of layer | 30-50 mm | Affects rigidity and heat insulation |
| Water absorption | 0.2-0.4% for 24 hours | Guarantees unsinkability and lack of weight gain |
| Temperature conditions | -50°C to +75°C | Allows the boat to be used in any climatic zones |
Tools and training required
The process of making the floor from polystyrene foam is simple and does not require a professional workshop. All work can be done in the garage or even on the balcony. The basic toolkit is minimal, but should be on hand before cutting, so as not to interrupt the process.
For cutting the material, it is best to use an electric jigsaw with a saw for wood (with a small tooth) or a special thermoknife. A conventional stationery knife is only suitable for thin sheets (up to 20 mm), they cut thick slabs for a long time and the edge is uneven. If a jigsaw is used, it is important to set the minimum speed of the pendulum so as not to melt the edges of the friction cut.
- 📏 Roulette and metal ruler for accurate contours marking.
- 🖊️ Marker or construction pencil for applying cutting lines.
- 🪚 An electrolobzik or thermoknife for cutting sheets of foam.
- 🧴 Glue (polyurethane or special for polystyrene foam) for gluing layers.
- 🔪 Scissors and glue for mounting the finishing coating.
Workplace preparation is also important: Styrofoam, when cut, forms static electricity and small crumbs that stick strongly to clothing and surfaces, it is recommended to cover the floor with film or paper, and the material is light and can fly out of draft, so large sheets are better held or cut on a stable table.
For a perfectly smooth cut without a crash, you can use a nichrome string connected to the transformer, but this method requires compliance with safety due to the high voltage.
Step-by-step instructions for the manufacture of flooring
You start by creating a precise template. Because the bottom of the boat has a complex geometry with rounding and narrowing to the nose, it would be a mistake to simply cut a rectangle by the size of the cockpit. Take a dense paper, cardboard or cheap substrate under the laminate and spread them out on the bottom of the inflated boat. Carefully circle the contours, given the places of the cylinders and the location of the transom cans.
After the template is ready and checked in the boat, transfer the contours to the sheet foamplexWhen marking, it is important to take into account technological gaps. The material should not rest on the cylinders in a strained state, otherwise, when pumping the boat or changing the air temperature (when the pressure in the cylinders increases), the floor may deform or damage the inner surface of PVC. The optimal clearance is 5-10 mm around the perimeter.
If a multilayer scheme is chosen (for example, two layers of 25 mm to obtain 50 mm thickness), then the bottom layer can be made whole, and the top layer can be made composite, cut into 2-3 parts for ease of transportation. The layers are glued together with polyurethane glue. The glue should be applied evenly, avoiding aggressive solvents that can eat the foam. After gluing, it is desirable to put the structure under the press for 12-24 hours until complete polymerization of the glue.
⚠️ Attention: When assembling multilayer floor, make sure that the joints of the upper and lower layers do not coincide. Separation of the seams (as in bricklaying) significantly increases the overall rigidity of the structure and prevents the formation of through cracks.
The final step is to skin, and the resulting foam workpiece needs to be put in a strong "clothing," and you can use linoleum that is glued to the same polyurethane glue, or rubberized fabric, and the edges of the coating are wrapped on the ends and glued to the bottom of the floor, creating a sealed casing, which will protect the soft material from mechanical damage and ultraviolet light.
☑️ Checklist of floor assembly
Installation and operation in the boat
Installing the finished floor in a PVC boat is usually easy, thanks to the light weight of the structure. Unlike plywood decks, which can weigh 15-20 kg or more, the foam floor weighs 3-4 times less, which makes it easy to lay it even one person without tilting the boat or putting extra load on the transom during installation.
The floor is simply placed on top of or on top of the normal inflatable floor, if the boat design permits, and because of its thermal insulation properties, it is often used as a standalone bottom, removing the regular NDNDM to reduce weight, although it depends on the specific boat model and the swimming conditions. It is important to make sure that the floor is flat and has no stress points that could wipe the fabric of the cylinders when moving.
And in the operating environment, it's stable. It doesn't creak like wood, it doesn't thunder like aluminum. It's easy to take it out, rinse it with fresh water, and dry it out. Because it doesn't absorb water, it takes a minimum of time to dry -- just wipe the surface with rags, and this is especially true when you go from salty seawater to fresh water, to avoid corrosion of other equipment.
The main advantage of the foam floor is the ability to use it all year round without the risk of swelling, rotting or loss of properties, making it ideal for winter fishing.
Care, storage and durability
Despite its high strength, polystyrene The main enemy of the material is mechanical exposure to sharp objects and prolonged direct ultraviolet radiation. If the protective coating (linoleum or fabric) is damaged, it must be restored as quickly as possible to prevent direct contact of the sun with foam.
Store the floor in a rolled-up or large rolled-up form, avoiding breaking. Although the material has a certain elasticity, a constant fracture at the same point can lead to a crack, it is optimal to store the flooring in a boat case or in a spacious box protected from rodents, who, alas, are very fond of biting foam.
The life of this floor is virtually unlimited if the whole protective shell is intact. The material does not age over time, does not lose its thermal insulation properties and does not change the geometry. In the case of serious damage to the foam sheet itself (for example, a deep hole), it is easy to replace by cutting a new piece according to the old pattern, which makes the structure repairable in the field.
- 🧼 Wash the floor regularly with fresh water after use in salt water.
- ☀️ Try not to leave the boat with the floor open in direct sunlight for a long time.
- 🐀 When storing in the garage, use rodent repellents or sealed covers.
- 🔍 Periodically check the integrity of the protective coating and the integrity of the seams.
Can I paint the floor from a foamplex?
Ordinary solvent-based paints (nitropaint, enamel) can melt polystyrene foam. For staining, use only water-based paints (acrylic, latex) or special formulations that are specified "compatible with polystyrene/foam". However, painting only makes sense if you do not use an external skin (linoleum/fabric).
Will this floor withstand a motorboat with a jet ski?
For high-power boats (more than 5-6 hp), pure foam may not be rigid enough, especially in choppy conditions. In such cases, it is recommended to use a combined scheme: a lightweight aluminum frame or plywood filled with foam inserts for buoyancy and heat, or increase the density and thickness of the material to values close to structural.
How much does this increase the load capacity of the boat?
The floor itself is a positive buoyancy floor, and it doesn't reduce the load capacity, it adds a few dozen liters of buoyancy, but when you add anything to the boat, you take up a useful volume, and the floor itself is a tiny 2-4 kg, so its effect on the sludge can be neglected.