Why choose an alternative to timber?

With the standout benefits being non water absorbing, low-maintenance and an almost infinite service life, composite boards and panels are a valuable alternative to timber for a range of applications across the Marine, Transport, Engineering, Construction and Mining industries just to name a few. With the combination of excellent strength-to-weight properties and impressive load-bearing results, this rot and corrosion free option is perfect for load bearing structural and non-structural requirements that only require the same basic tools and processes as is required to cut or use timber.

 

What Structural composite timber replacement products are available?

FF360 Panel is a very light weight, versatile Australian-made sandwich composite panel constructed using a closed-cell composite core between 2 multidirectional fibreglass laminates consolidated under vacuum, which performs like the web of an I-beam. Find out all the technical details here.

Thermo-lite board is constructed with a high density closed-cell polyurethane foam containing both chopped strand matting and woven roving. Find out more here.

 

What thickness is suitable for my application?

Both FF360 Panel and Thermo-lite board have slightly different thicknesses available, however both have comparable sizes available:

• 5-6.35mm is great for fit-out options, wall coverings, non-weightbearing canopies etc or wherever you require a curve.
• 8-9mm is for more structural fit-out and can handle unsupported span up to 200mm wide.
• 12-12.7mm recommended for unsupported spans up to 450mm for load bearing.
• 15mm recommended for over 450mm unsupported spans up to 600mm for load bearing.
• 19-20mm is ideal for unsupported spans 600mm and above for load bearing.

 

Do I still need to seal or coat these composite boards before use to make them waterproof?

No seal coat is required to either the surfaces or edges of either option with regards to making them not absorb water, as they both are closed-cell, waterproof, corrosion and rot-free.

 

Do I still need to seal or coat these composite boards if using directly as flooring?

If either sheets are used as flooring or a surface that you will have direct contact with, Thermo-lite boards sand/sand option and the FF360 Raw/Raw side option require a coat of paint/ flowcoat on the top surface and vertical edges before they comfortably can be walked on/rubbed against, otherwise they are itchy.

Also these surface finishes are not UV stable and will change colour when exposed to direct sunlight, (not deteriorate, as are UV resistant) so the seal coats also prevent discolouring and makes the edges more hard-wearing. As mentioned above, a seal coat is not required to make them waterproof, as are both closed-cell. These sanded and RAW surface finishes are ideal if you are intending to sand and apply a flowcoat/nonskid finish, or wrap in carpet.

 

Can I fibreglass straight to these composite options?

Thermo-lite boards sand/sand option requires the surface to be keyed with 80 grit sand paper minimum and then wiped over with acetone or a residue free solvent / cleaner. A ‘hot coat’ of resin is then recommended to be applied and allowed to cure prior to applying further fibreglass / resin / lamination etc.

FF360 Raw/Raw options require the nylon fabric with noticeable red lines running length ways to be removed / peeled off from surface you wish to work on and for best results a mild scuff with 80 grit sand paper to the surface of the panel will aid in adhering all common adhesives and or resin types. Ensure all surface contaminants from handling and any dust are removed using a damp acetone wipe over or compressed air before use.

Some more specific info on tips prior to use below.

 

What Finish Options are Available?

FF360 Panel

• Raw / Raw comes with a removable nylon film, allowing minimal preparation required to laminate against and compatible with polyester, vinyl ester and epoxy resins and adhesives. (The Raw side is not UV Stable) Suitable for carpet to be adhered straight to without any further prep, or laminating fibreglass to after scuff & removal of nylon film.
• Tex / Raw comes with a durable UV Resistant Gelcoat textured finish on one side that is ready to use, with easy maintenance and cleaning. Not considered a non-skid surface, but a mild finished texture. Standard Tex Colours: White or Light Grey. Other colours can be custom ordered if lead time suitable. Suitable for Carpet and EVA sheets to adhered straight to. Would need to sand gelcoat layer to apply another flowcoat non-skid layer to, and sand off the gelcoat before laminating to.
• Smooth / Raw is an additional option that is made to order, please send through specs required for a quote. *Like all gloss composite panels, a mild print-through is seen on these panels. Suitable for EVA sheets to adhered straight to, fit-out panels, without any further prep.

Like all sandwich panels, all edges have the core centre exposed, but it doesn't absorb water and won't rot. These edges are recommended to be finished with paint or flowcoat to finish off once cut/exposed reduce the itch, and cosmetics to be hard wearing, while making them UV stable.

 

Thermo-lite Board

• Sand/Sand finish is the only option we stock Suitable for carpet to be adhered straight to without any further prep.
• Natural/ Elephant surface finish (depends on stock availability) we can have access to this finish however require notice to special order in. Comes with a durable finish on one side that is not itchy and requires sanding off if laminating to.