We made a barge out of HDPE!

Timelapse of a barge we made from High Density PolyEthylene.
The whole process didn't take half as long as we thought it would, hence only a 5 minute video.
hope you enjoy watching how we made it.

[@uwerasche6119]

Ein unglaublich schönes Projekt. Ich bin total begeistert von der Auswahl der Materialien 👍👍👍👍👍

[@davidgormley4419]

So many boaters would be interested in this. To do away with needing to black a boat every 2 to 3yrs and eradicate erosion is what every boater yearns for. Obviously im sure this is exactly why you did this build. My dream is to own and live on a boat like this, so I’ve subscribed in the hope we hear more about this project and its pros and cons. Tbh I don’t see many cons.

[@Formation_Plastics-Bradford-UK]

Hi, thanks for the great comment 😊 If you would like more information, please feel free to email us at… [e-mail]

[@motosmitty1543]

I've been looking and waiting for someone to make this over a year now. after seeing some speedboats and the rescue boats being used. Love this

[@Formation_Plastics-Bradford-UK]

Thank you 😊

[@shaunmoir9403]

@motosmithy thank you for your comments this barge was actually the brainstorm idea from our directors who had seen some speed boats and ambulance boats made out of HDPE So, they had a thought. can you make a canal boat out of HDPE, why not? can it be done? and can we, do it? so, after speaking with a professional boat builder (we have actually based our design on an old canal boat), we got to work with the entire process the size is 40ft x 12ft and we are looking to build more especially more environmentally friendly ones our plan is to show this in future boat shows and get the word out that they are other options in building that can also better for the environment, We also found out that HDPE is what is used for a lot of lifeboat builds even fishing boats, especially in turkey and holland due to its strength, we knew that this would be a perfect choice for a canal boat as it will be able to take the unpredictable weather of a canal We used a process called extrusion welding, I would love the chance to have a chat with you about all this my email address is [e-mail] and the telephone number is 01274-299055 thank you 🙂

[@JamaicanSureFishing]

Awesome how much would something like this cost to make ?

[@Milkybar3320011]

Clever idea, but the sides would fold in if you bump into another boat, hence the steel frame in the base. Keep working on it though, your onto something.

[@Formation_Plastics-Bradford-UK]

Thank you! Given the speed limits on canals is (I think) 5mph, it would just bounce off 😁

[@JoeWalsh-oi1xu]

What gun did you use to weld it? Also did you have to fair the bow to make it so smooth and how did you do it? What size rod?

[@ariannycanepa5617]

I am very curious about this build. Would love to know the price and if I could see it in person!

[@Anne6621]

if i was going to live in the UK on a Narrowboat and it has been a dream of mine it would be built from this material , i imagine they can build up to 70 feet , this is brilliant !!

[@Formation_Plastics-Bradford-UK]

What a great comment, thank you! ☺️. We would love to build a 70 foot one.

[@rahmatsyahnusfi6946]

Fantastic Idea GOOOOOOD

[@Formation_Plastics-Bradford-UK]

Thanks very much! 😊

[@felixcat9318]

This is particularly interesting and has great potential, especially in the canal boat sector where the constant battle against corrosion of steel hulls is hugely expensive, time consuming and inconvenient. I assume that the joints become as strong as the panels, if not stronger. I had no idea that this material was used in marine applications other than in kayak bulkheads. With an outer and inner hull, could marine two part closed cell foam be poured between the hulls? This would add immense strength into the structure as the panels and foam become bonded together, it would also act as insulation and add buoyancy. Presumably it would depend on whether the marine foam is chemically compatible with HDPE! Thank you for your video, I wonder if this material may find its way into self built boats, which is a very popular activity worldwide. I may consider using it in a very unique, compact build which I originally considered constructing in marine plywood or marine grade aluminium.

[@shaunmoir9403]

@felixcat thank you for these comments, this material is used especially overseas, in holland, turkey, and the USA we have even found a lot of HDPE small fishing vessels made in parts of Scotland we have currently put our engine in this, and we will be getting this ready for going into water end of this year / early next year all going well we will then be showing this at boat shows and hopefully showing the canal boat sector that there are other options rather than the traditional steel boats, Why use HDPE? HDPE hulls are specifically designed to be maintenance-free and do not require painting or anodes for protection. Made from 100% recyclable HDPE and built to last a lifetime. Light, strong, and very tough, HDPE hulls do not require painting or antifouling as the very low friction coefficient of the material prevents marine growth from adhering to the material. The properties of HDPE also mean that it is corrosion, chemical, and UV resistant and has 0% water absorption. How do we help the environment? HDPE has the lowest carbon footprint of all modern boat-building materials. We can manufacture all-electric boats for environments with sensitive marine ecosystems.

[@FamilyNewman-yn2zz]

What an absolutely brilliant idea! I can see so many advantages to this material. It’ll be interesting to see how it fares through the seasons. Superb engineering… where do I sign? Good luck with trials.

[@Formation_Plastics-Bradford-UK]

Thank you very much for your great comment 😎 *Watch this space*…

[@davidgormley4419]

Would it be more costly than steel?

[@matiaswilson4768]

Very intriguing. Please put it to a water test. I’m so curious to see how it will handle the differential stress of cool water on the bottom and a hot summer sun beaming on the deck. Also, how it will handle stresses from waves in warm and cold conditions. Did you all do any stress modeling before construction or is this a pure experimental build? Awesome idea, but the steel beams could be the Achilles’ Heel. The steel beams and HDPE have very different thermal expansion rates. Even if it’s not a factor, the beams corrosion susceptibility will negate the advantage of using HDPE. In future designs looking into using fiberglass beams would probably be he way to go. Wishing you great success!

[@matiaswilson4768]

Rather than using ribs and beams for the bottom hull. A honeycomb stiffener arrangement could stiffen the base significantly and eliminate the need for beams. Last thought, the hull design looks proportional for a steel barge. However this thing will be so light in comparison. Not sure what all is going in it but I would be amazed if it drafted more than 12 inches. It’s going to be top heavy without ballast.

[@Formation_Plastics-Bradford-UK]

@@matiaswilson4768 Firstly, thank you for your comments, questions,and suggestions. I keep asking when it will be tested in the water, no one seems to know (Not the best reply but…). This was built more of a proof of concept more than anything. We used steel beams to add weight, and we’re going to add more ballast, as and when. I like the idea of the honeycomb sections though, that’s a great idea. I’m sorry I can’t be of more help right now. If it ever gets into the water, I will be there filming it, and I’ll post the footage.

[@secondguest6298]

This is fantastic. If I ask nicely, could you make me two long thin hulls for a catamaran?

[@Formation_Plastics-Bradford-UK]

Thank you! Go on then, ask nicely 😂😂😂

[@Q_Channel1]

Great stuff! How did you anchor the I-beams to the HDPE? Also, how did the water test go??

[@Formation_Plastics-Bradford-UK]

Thank you! As in the video, all the I-beams were welded to the beams that run widthways, and then HDPE partitions were welded in place to keep everything secure. Water testing… it still hasn’t been in the water yet 😂😂😂

[@mizzow1740]

Could you post how many HDPE panels you used, their sizes and thicknesses? It's a very good effort, and it looks good too, but I'd like some more info on its fittings and propusion if you could put up the specs please?

[@Formation_Plastics-Bradford-UK]

Hi there. If you would care to email us at the address below, we’ll be happy to help. Many thanks. [e-mail]

[@darmannayyer]

Wonderful! The team are the Children of Noah(PBUH)!

[@Savanna_12]

What is the largest size? Passengers wise if I need to order a touring bus? With full intertainments, small rest & cafe, bathroom..etc

[@Formation_Plastics-Bradford-UK]

I really don’t know tbh. It’s pretty much a standard size, though I couldn’t even tell you how long it is. I was just recording it being built, in case we needed to ever make another one of a similar build. That way we could refer back to this video. Sorry I can’t be of much more help.

[@weldonfrazier6453]

How did you join the panels together in the beginning part?

[@Formation_Plastics-Bradford-UK]

We used a ‘Munsch gun’. It’s like a normal welding gun, but floods the joint with weld. You can see the gun at around 6-7 seconds in during the video.

[@abyssalblue3089]

I've been researching various materials for a Catamaran build, I hadn't seriously considered plastics till watching this video. Would you mind sharing the approx cost of the HDPE panels/ box? I'm also curious as to how robust the joints between panels are, was there any sheering/stress testing? I'm assuming some type of spray expansion foam would be applied to the lower hull?

[@shaunmoir9403]

good morning and thank you for your comment, would you be kind enough to send an email to [e-mail] with a telephone number and we can have a chat and go over everything that you would like to know, thank you 🙂

[@Formation_Plastics-Bradford-UK]

Material costs keep changing month by month unfortunately. Because of the manufacturing process,all the welded joints are as strong as the sheet material. R.E expansion foam, no. We needed to add ballast to help it lay lower in the water.

[@abyssalblue3089]

@@Formation_Plastics-Bradford-UK Thank you so much for your reply.

[@Formation_Plastics-Bradford-UK]

@@abyssalblue3089 Our pleasure. If you have any other questions, please feel free to ask, and we will do our best to answer them.

[@abyssalblue3089]

@@Formation_Plastics-Bradford-UK what is the thickness of the HDPE sheets on your project?

[@pankaj399]

What was the thickness of the sheet used ( different gauges)

[@Formation_Plastics-Bradford-UK]

Hi there. I think the floor was 20mm sheets, and the sides were 10mm.

[@goproracertv]

How do the production costs compare with steel… and how strong is the hull

[@Formation_Plastics-Bradford-UK]

Unfortunately, no one seems to know the true end cost. It was built during quiet periods, so we don’t have accurate labour times, only very rough estimates.

[@shaunmoir9403]

HPDE (high-density polyethylene) is a strong and robust material deviated from petrol. Unlike other polyethylenes, HDPE is heavy and firm. Approximately, 1.75 kg petrol is used to produce 1 kg HDPE raw material. HDPE is lighter than water and together with its durability, it becomes a preferred material for marine purposes. HDPE boats can be shaped by molding and extrusion methods. It can be processed in workshops and can be welded with special methods. It is difficult to combine with adhesives. HDPE is a very strong material with a density between 150000 - 400000. Its resistant to water and chemicals. HDPE’s mechanical composition is extremely strong on impact and tension. Normally the tension resistance is like 225-350 kgf/cm2 and heat resistance is above 100 OC. HDPE is widely used in pressure pipes, gas distribution pipes, liquid containers, machine and home appliance parts, and in insulation. Lately, because of its resistance to water, it is also used in tank and boat manufacturing. Rather than looking at this as being a cheaper option in plastic, I think it should be viewed as a much better option to traditional steel boats and therefore comes with a premium cost

[@adean4146]

does it crack? what happens if a big heavy steal boat smashes into it?

[@Formation_Plastics-Bradford-UK]

Given there’s usually a 4mph speed limit on most canals. If it were bump into another vessel, it would only be a maximum 8mph ‘crash’. So our barge would most likely just bounce off, with very little to no consequence.

[@kylefarmer4340]

Can I ask whare yous sourced the plastic sheets I’m trying to do a project atm but can’t seem to find a company to supply them at a reasonable price. Thanks

[@Formation_Plastics-Bradford-UK]

Materials like HDPE, and polypropylene, we usually get from Oadby Plastics. Bear in mind, we buy in bulk, so we may get it a little cheaper than buying one or two sheets.

[@kylefarmer4340]

@@Formation_Plastics-Bradford-UK thanks il give them a try it is about 40 sheets I’d be after

[@Formation_Plastics-Bradford-UK]

@@kylefarmer4340 You should be ok with an order like that 👍🏻. Good luck with your project.

[@Formation_Plastics-Bradford-UK]

@@kylefarmer4340 Hello again. Did you manage to source any info on material? If not, please feel free to email us any enquiries. [e-mail]

[@onomatopejaB]

Hi, great job! (: what thickness of HDPE you used? Some big, flat parts are thermal bended or cut and welded togrther? Cheers! 😁

[@Formation_Plastics-Bradford-UK]

Thank you! The flat base was 20mm. In the video at the beginning, you can see it being welded together. I think the sides were 12mm. We formed shallow curves by pulling the panels into the required shape. Any tight curves, like the corners were heat formed using moulds ( these can also be seen in the video)

[@onomatopejaB]

@@Formation_Plastics-Bradford-UK 20mm?! Wow, it will be ultra strong 😁 HDPE is cool material. Thanks!

[@Formation_Plastics-Bradford-UK]

@@onomatopejaB Yeah, it’s so easy to work with. The best part is that it will absorb any bumps, rather than buckling,like metal.

[@onomatopejaB]

@@Formation_Plastics-Bradford-UK and it’s freezproof ;) I am thinking of using 15m long HDPE (10-12mm, U-shape bended, welded) floats with foam to build a houseboat base :) It would be nice to see the water test video. Cheers!

[@Formation_Plastics-Bradford-UK]

@@onomatopejaB Sounds like an interesting idea 🙂 A year after it being finished, it still hasn’t been near any water ☹️ It’s still awaiting being fitted out with the motor and all conveniences. No one seems to know when it will be completed 🤔

[@johnmathew3389]

How much total cost

[@_onesimpleidea]

What happened when you put it in the water?

[@Formation_Plastics-Bradford-UK]

Sorry for the late reply. Unfortunately, it is still waiting on being kitted out. It still doesn’t have a motor 😂. Needless to say, it’s never seen any water yet 🤣

[@fallen4u248]

are you into S & M then?

[@jimlofts5433]

could that be injection moulded ?? like tesla does with the giga press or even in modules ?

[@Formation_Plastics-Bradford-UK]

I’m not sure tbh. It would need a massive tool to do that, and also the tooling cost would be very prohibited given this was a one-off.

[@jimlofts5433]

@@Formation_Plastics-Bradford-UK agree but gee it would be epic say about 50ft long molded plastic with foam layer then more plastic - inbuilt ribs and keel supports / floor pan / bulkheads with or without carbon fibre inserts - maybe one day for some exotic racing build for a class of boats - thanks for heads up

[@Formation_Plastics-Bradford-UK]

@@jimlofts5433 We built this as proof of concept more than anything. I think if the market was there, then alternative manufacturing methods could/should be looked in to.

[@karleemurphy6391]

There’s definitely gonna be a market ..

[@karleemurphy6391]

I’m asking nicely,, may you send me 12m of this stuff haha

[@davehopkin9502]

Given the inevitabiity of the boat (when it in the water) scrapping along lock walls ect, how will the HDPE stand up to the wear, with steel its just going to scrape the paint/blacking off, but will the HDPE get gouges into in? Great idea though....

[@Formation_Plastics-Bradford-UK]

That’s actually a great question Dave! My honest answer would be that I don’t really know. We built it more of a ‘proof of concept’ idea, and are still awaiting it actually going in the water. Sorry that I can’t be any more help with that.

[@davehopkin9502]

@@Formation_Plastics-Bradford-UK No thats fair enough.... wonder if a steel rubbing strip and edge to the underplate would be a good move

[@Formation_Plastics-Bradford-UK]

@@davehopkin9502 It probably would be better but, that kind of negates the purpose of building it out of ‘plastic’. If, and when it ever gets in the water, we will find out if we wasted our time building it 😂

[@Mad.Man.Marine]

@@Formation_Plastics-Bradford-UK aluminum rail pipes may be a good upgrade? Would last a long long time being isolated and would give you the ability to rub of piers and walls without much damage.

[@Formation_Plastics-Bradford-UK]

@@Mad.Man.Marine I think, with hindsight, as you suggest, we maybe should have done that. Also, if we’d have made some form of bracket to allow the changing of the rail pipes, without having to un-fabricate what we welded in place.

[@spinaway]

Would love to know the cost compared to steel.

[@Formation_Plastics-Bradford-UK]

Tbh, I don’t even think we know the actual cost 😂

[@IgorSchmackow]

Dear Friends, How long did it take to build of the barge?

[@Formation_Plastics-Bradford-UK]

Hi there. We only worked on it when our regular work went a little quiet. I think it took about a year, on and off.

[@IgorSchmackow]

@@Formation_Plastics-Bradford-UK thank you, I meant how long it took to build this barge - 1 week or a month.

[@Formation_Plastics-Bradford-UK]

@@IgorSchmackow Ah right. This was the first one we ever made. We didn’t have any blueprints to work to, so we consulted with a guy that have made one before. Roughly, I would think it took somewhere between 3 to 5 months in total. I hope that helps.

[@lukez4037]

What issues did the vessel have with shrink/expansion? Most vessels I've seen people make fell apart shortly after use due to issues with temperature change and the insane shrinkage rate.@@Formation_Plastics-Bradford-UK

[@Formation_Plastics-Bradford-UK]

@@lukez4037 For more technical info, please email us at [e-mail]

[@eternalfrostandsunshine]

What did you use to weld it together

[@Formation_Plastics-Bradford-UK]

We used a ‘Munsch gun’. It’s like a normal welding gun, but floods the joint with weld. You can see the gun at around 6-7 seconds in during the video.

[@petercurrell9344]

The swim is a bit short and the stern 3 mitres needs to narrow to ease leavig the moorigs.

[@PhuongLe-dk1jl]

What is the thickness of hdpe board ?

[@Formation_Plastics-Bradford-UK]

I think the floor/hull was 20mm HDPE, and the sides were 10 or 12mm.

[@embededfabrication4482]

should have put another strip of material along the outer edge before putting on the sides maybe

[@Formation_Plastics-Bradford-UK]

We consulted with a guy that designs and builds barges. This was the suggested build method. If we ever make another, we may well make some design changes.

[@TROUROCKS]

it was going soooo well .... and then came the steel .. bugga i said

[@Formation_Plastics-Bradford-UK]

The steel was added for two reasons. First, to strengthen the hull. Second, to add some ballast.

[@aggabus]

40 ft??

[@goproracertv]

Why don’t you go into production building and selling these… you could build a very future proof eco barge with much more modern layout than existing traditional boring wide beam designs

[@Formation_Plastics-Bradford-UK]

That was the original intention. This was a proof of concept. It was ‘completed’ around 2 years ago, but hasn’t been touched since. We are now making plans to bring it back, and fit it out ourselves. Hopefully, we’ll have another video of the progress.

[@gunturguntur7387]

Lokasi pembuatan perahu ini d mna ?

[@Formation_Plastics-Bradford-UK]

kami berbasis di Inggris.

[@34136TS]

Ola! Please guys, do you have any contact info? Much obliged

[@Formation_Plastics-Bradford-UK]

We can be contacted via our website below. formationplastics.co.uk/

[@34136TS]

@@Formation_Plastics-Bradford-UK Thanks guys - I've just FB messaged 😇

[@aggabus]

Motor wheel

[@labbo5591]

Really had me interested untill the HDPE turned into steel 'I' beams!!🤔🤔🤔🤔🤔🤔

[@Formation_Plastics-Bradford-UK]

The ‘I’ beams are there to make the hull rigid, and to add ballast, which in turn makes it more stable in the water.

[@shaunmoir9403]

As this was a prototype we were advised to put beams in for the stability while being crained from the hiab knowing what we do now we do not need to use the beams and our next one in production will not have these

[@johnmathew3389]

How much totally cost

[@Formation_Plastics-Bradford-UK]

Sorry, only just got a notification of your reply. If you email Shaun, I’m sure he’ll have more idea than me. Cheers. [e-mail]