big news, New pontoon lifetime floor at lower cost

[luckyjr]

 

[EGlideRider]

Re: big news, New pontoon lifetime floor at lower cost

Pretty neat. What are you gonna cover it with?

 

[luckyjr]

Re: big news, New pontoon lifetime floor at lower cost

I'm putting carpet down. 8'6" x 26'. New floor weighs 595lbs made of light gauge galvanized steel. It will last longer than the boat. I love never having to replace the floor again. Came in 26' length. Real fast to put down. Cost around $700.

 

[EGlideRider]

Re: big news, New pontoon lifetime floor at lower cost

I don't think I've ever heard of using galvanized steel as a deck. And the weight is near that of plywood.
Keep us posted with pictures.

 

[jessp]

Re: big news, New pontoon lifetime floor at lower cost

View attachment 106440

can you provide a link for it? Will be replacing my decking this year.

 

[5150abf]

Re: big news, New pontoon lifetime floor at lower cost

Marine ply is 80lbs per and for 26' you would need 6 1/2 sheets or 520lbs so it is a bit heavier.

I don't see any fastners showing, how did you fasten it to the crossmembers?

Just remember that the deck is a major strutural part of the boat and will take quite a load so fasten the crap out of so it doesn't come loose.

 

[luckyjr]

Re: big news, New pontoon lifetime floor at lower cost

I think I am the first. I owned a couple ASME fabrication plants in my working career. Each piece is tied together with self tappers and then j bolted underneath with a rod system to the frame. You can also weld it to the frame since it should be on there for the life of the boat. The boat feels much more solid than it did before with the strength of the steel member. The decking will be used on the roof the cabin because it can be set up leak and water proof.

 

[luckyjr]

Re: big news, New pontoon lifetime floor at lower cost

In response to the weight. I agree plywood weigh 80lbs per sheet dry. But when it is wet it weighs much more. The steel weighs the same wet or dry.

 

[luckyjr]

Re: big news, New pontoon lifetime floor at lower cost

can you provide a link for it? Will be replacing my decking this year.

This something I came up with. Let me test it and make some changes. I am learning what would be best and trying to find some bugs. When I can recommend it, I will. So far looking good.

 

[Bamaman1]

Re: big news, New pontoon lifetime floor at lower cost

Pontoon boats just have marginal structural rigidity, as they're really just bastardized, understressed designs--to save money and weight. They really weren't designed to run 50 mph, with pontoons flexing independently due to relatively weak frames.

What you're missing is that the plywood adds a great deal of strength and rigidity to the whole pontoon boat. With a thin metal decking, you will be able to see the difference when you go over a wave from 45 degrees of left or right of center, and the whole pontoon structure flexes 6" or more.

Aluminum floors used on pontoon boats in past years have bends in them to provide some strength. Plywood is still stronger--and relatively cheap. Thin galvanized sheets simply won't give you proper strength you need.

 

[luckyjr]

Re: big news, New pontoon lifetime floor at lower cost


This is a custom design that would be about 100 time stronger than plywood. I am going to weld each intersection to the riser cross members which are also steel. The riser were the weak section until I overlayed them with steel.
This pontoon had 3/4 and 1/2 for a total of 1@ 1/4" inch of plywood and it was still flexy. That is why I went to this. Very strong design, you can see each section is screwed together forming little I beams on each side.

 

[Mr Crabbs]

Re: big news, New pontoon lifetime floor at lower cost

100x stronger than plywood? Has this been tested or just a guess? I agree that wet plywood weighs more but it has to be soaked and stay that way.

 

[jeeperman]

Re: big news, New pontoon lifetime floor at lower cost

Are those commercial building galvanized steel studs?
I do not think the galvanizing is designed to be exposed to the elements.
Welding them to anything will burn off the galvanizing so you will want to protect those areas for sure.
I would question how much sag your going to get in the web of those studs. Especially if some one is jumping on the web.

A single layer of plywood sheets loose 100% their ability to prevent flex every 8 feet and 4 feet.
I think you will have more rigidity than with the plywood deck.

 

[luckyjr]

Re: big news, New pontoon lifetime floor at lower cost

Are those commercial building galvanized steel studs?
I do not think the galvanizing is designed to be exposed to the elements.
Welding them to anything will burn off the galvanizing so you will want to protect those areas for sure.
I would question how much sag your going to get in the web of those studs. Especially if some one is jumping on the web.

A single layer of plywood sheets loose 100% their ability to prevent flex every 8 feet and 4 feet.
I think you will have more rigidity than with the plywood deck.

Your good jeeperman, you are right about non structural steel studs but this structural channel has heavy galvanized and carry big loads. The I's are 5/32 thick and are very rigid. The pic shows the 3ft span in the front between cross members. That deck is caterleving over the 3' span with no probelm with traffic. This gives you some idea how strong this decking is. This web is fine but that was a concern but holds my 250 lbs good. Cold galv will handle the burn or I could just use flat head bolts and nuts. The risers are weak point structurally. So no matter how strong your floor is,you are limited by the riser design but it looks good. I did beef them up with steel. You can see the reinforcement sticking out in the pic.

If the toons and riser were made of steel, you could have very rigid structure now. The weight could be close to aluminum. They woul be good for off shore with some design changes or hold these big motors.

 

[luckyjr]

Re: big news, New pontoon lifetime floor at lower cost

100x stronger than plywood? Has this been tested or just a guess? I agree that wet plywood weighs more but it has to be soaked and stay that way.

Guess, I had a plywood floor and its lot work getting it off . A job I want ever have to do again and neither will my grand kids.

 

[Mr Crabbs]

Re: big news, New pontoon lifetime floor at lower cost

Are those commercial building galvanized steel studs?
I do not think the galvanizing is designed to be exposed to the elements.
Welding them to anything will burn off the galvanizing so you will want to protect those areas for sure.
I would question how much sag your going to get in the web of those studs. Especially if some one is jumping on the web.

I noticed that too. If he drills through them they will need to be sealed up also.

I'm guessing that the pontoons themselves take up any flexing between the plywood sheets since they are perpendicular to the butt joints.

Is flexing plywood an issue? I've never read about it here.

 

[luckyjr]

Re: big news, New pontoon lifetime floor at lower cost

Thanks Mario for your help.
Cold Galv has been used for decades in the industrial business to patch areas welded on. I am just doing tac welds with stainless flux core wire. Not a problem. The 6" plank are 26' foot long and tied together with self tappers down the 26'. Postioned in a different direction than plywood runs. Once connected to the cross members in what ever fashion, you have a superior way of building a pontoon floor no matter what you use. All forms of Steel are stronger, better, and lower cost, inmo of 45 years in business.
It goes down quick and I am just trying find a way to make better. I think the size and thickness is right on to handle the deflection.

The people over at Pontoon Stuff kick me off their forum awhile back because as they said it" if there was anything better on the market to build floors with, the manufactures would have already done it".

You ask what's wrong with america. That the new attitude of the younger generation. They never question the status quo. American was built on a better way to do something. I guess old dogs can't do new tricks either.

 

[Mr Crabbs]

Re: big news, New pontoon lifetime floor at lower cost

Lucky, I really hope this new deck works well for you. It would be exciting to see a cheaper, longer lasting alternative to plywood, however......

I worked 14 years in commercial industrial construction and manufacturing and know galvanized studs well. IF you damage the gal AND introduce moisture you'll start corrosion, the gal will blister and it spreads.

Having said that I do think it would be great if the pontoon manufacturers considered testing decks like this welded first, cut their penetrations install their duct runs and then galvanized or coated. Could be a great idea.

I'd also not knock these kids coming up. They have plenty of good ideas. Their generation didn't coin the phrase 'Nobody got fired for buying IBM'.

 

[luckyjr]

Re: big news, New pontoon lifetime floor at lower cost


Little humor, I was working on the boat and caught this pic

Lucky, I really hope this new deck works well for you. It would be exciting to see a cheaper, longer lasting alternative to plywood, however......

I worked 14 years in commercial industrial construction and manufacturing and know galvanized studs well. IF you damage the gal AND introduce moisture you'll start corrosion, the gal will blister and it spreads.

Having said that I do think it would be great if the pontoon manufacturers considered testing decks like this welded first, cut their penetrations install their duct runs and then galvanized or coated. Could be a great idea.

I'd also not knock these kids coming up. They have plenty of good ideas. Their generation didn't coin the phrase 'Nobody got fired for buying IBM'.

Thanks for the comments, maybe I was a little harsh. My son 35, is International Director of Product developement for FMC, no one is questioning their ability or intelligence. I am talking about keeping an open mind and always look for the better mouse trap. I was amazed by the teatment I received from Pontoon Stuff adm staff. I know they were protecting the products they sell but I don't sell this stuff, I was sharing info. What ever pontooners want to use on their floors is up to them. I am working the bugs out, if there are any, for my benefit.

The type of fabrication plants I owned were Code Stamp Plant U R S N to the American Society of Mechanical Engineers standards. National certified. The kind of stuff that can blow up a rifinery if you don't do your job right. I did that for 45 years. My clients were the companies that own refineries and chemical plants. In their specs it stated when welding on galvanized areas, apply COLD GALV to repair to the effective area. This sructural heavy galvanized channel I am using will be fine for years and years to come. You are right, if opening a hole could be avoided, that would be best situation. It could be done easily if this became a standard product. IMO, this is a better mouse trap for me. But the interest doesn't seem that great. There seems to be more interest how to get your toons clean and shiney with chems that will give you cancer or kill you.

Anyone can do this themselves at a reasonable cost. I am not welding the floor to the frame. I have came up with a "J" bolt design that will work really well.

 

[jeeperman]

Re: big news, New pontoon lifetime floor at lower cost

The higher end pontoon companies are using decks made of long lasting, no rotting materials.
Aluminum decks, etc.
Although a galvanized steel deck might be cost effective, it would be a marketing nighmare to get the public to buy into the idea of using any type of steel in a pleasure boat of anykind.