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.

[@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 🙂

[@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]

[@Bob-t9w]

Hdpe is slightly harder than warm butter.

[@Formation_Plastics-Bradford-UK]

@@Bob-t9w Some sea going vessels are made of this material.

[@michiganengineer8621]

@@Bob-t9w It's used as the "running surface" for mini-jetboats, admittedly in that application it's designed to shield the actual aluminum hull from rocks that the boats tend to bounce off.

[@shaunmoir9403]

@@Bob-t9w Thank you for your comment. However, I'd like to clarify that HDPE (High-Density Polyethylene) is widely used in the construction of lifeboats, workboats, emergency boats, and similar vessels. Describing it as "as hard as warm butter" is a bit of a misrepresentation. Let me explain the benefits of HDPE as you may not be aware Durability: HDPE is highly resistant to impact and wear, making it an excellent material for boats that need to withstand harsh marine environments. Buoyancy: HDPE is inherently buoyant, contributing to the safety of the vessel. Corrosion Resistance: Unlike metals, HDPE does not rust or corrode, which is crucial for longevity in saltwater conditions. Maintenance: HDPE boats require minimal maintenance compared to traditional materials, reducing overall upkeep costs. Environmental Resistance: HDPE can withstand extreme temperatures and UV radiation without degrading, ensuring reliability in various climates. Lightweight: This material is lighter than many alternatives, improving fuel efficiency and ease of handling. These characteristics make HDPE an ideal material for marine applications where safety, durability, and low maintenance are paramount.

[@ariannycanepa5617]

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

[@luimackjohnson302]

Amazing! Thank you for sharing this very informative video. I need a few of those in my country right away. Greetings from Madang, Papua New Guinea.

[@uwerasche6119]

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

[@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.

[@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?

[@saltaireorangebicyclechopp8555]

I saw this moored up at Rodley (Leeds) last week, a plastic barge, l nearly fell off my bike! It looked superb to me and l wish the company all the best. I cycle Leeds to Skipton several times a week, l am not a boater but what strikes me is the high % of barges on the canal that look like they are falling apart such is the need for steel maintenance.

[@Formation_Plastics-Bradford-UK]

thank you for your kind words🙂

[@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 😁

[@JamaicanSureFishing]

Awesome how much would something like this cost to make ?

[@darmannayyer]

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

[@lancecluster]

How was the steel stringers attached to the plastic?

[@1nvisible1]

*Adhesive.*

[@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*…

[@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]

[@ThePopypete]

What a " BRILLIANT " Idea .😉😁

[@Formation_Plastics-Bradford-UK]

😊

[@plasmaDave]

Looks awesome a great job, my worry would be other canal "users" they can be very rough. Seen some very hard hits. Certainly needs testing.

[@zopEnglandzip]

Fascinating. Its going to change shape over time.

[@shaunmoir9403]

Thank you for your comment! We have over 30 years of experience working with plastic fabrication , and HDPE has been successfully used in workboats and even lifeboats for many years. We've thoroughly addressed the issue of expansion, so concerns about the material changing shape over time are unfounded. We appreciate your input!

[@phil6506]

I had a HDPE barge and over time it turned into an ocean liner.

[@rahmatsyahnusfi6946]

Fantastic Idea GOOOOOOD

[@Formation_Plastics-Bradford-UK]

Thanks very much! 😊

[@markgc65]

I cant imagine it has the strength. But that might be just me being dumb and not underatanding the materials, but in 55 yrs on canals i have seen steel boats hit and smash into nearly everthing imaginable, i dont see plastic taking that kind of punishment. ?? looks very impressive though and hopefully much stronger than i imagine it to be.

[@Formation_Plastics-Bradford-UK]

thank you for this , hope this helps 🙂 HDPE (High-Density Polyethylene) is a highly durable and resilient material, making it an excellent choice for various marine applications. Its resistance to impact and abrasion ensures that it can withstand damage from boat walls, locks, and other potential sources of wear and tear. showcasing its structural integrity and load-bearing capacity. The use of HDPE in boat construction is well-established, with successful applications in workboats, small fishing vessels, lifeboats, and emergency boats worldwide. This proven track record underlines the material's reliability and effectiveness in marine environments. Although no canal boats have been constructed with HDPE yet, the material's resistance to erosion and its enduring performance in other boat types suggest it will be an innovative and sustainable choice for this new application

[@joshlower1]

It'll sink inside of the month

[@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.

[@tomcoryell]

@@matiaswilson4768 What a problem to have, a boat that floats too well! I do understand though. I had to place a hdpe sump pump basin in standing water and getting that thing to sink was difficult even with big holes in it.

[@keithjurena9319]

Excellent construction for severe environments like hypersaline lakes. Now if the hull can be formed in hydrodynamic efficient shapes, this could revolutionize boating.

[@shaunmoir9403]

Thank you for your comment. We specialize in plastic fabrication and can manufacture any shape you need, including hydrodynamic efficient designs for hulls. We appreciate your interest!

[@Goldfinger140]

Plastic fantastic! Three cheers for HDPE!

[@Formation_Plastics-Bradford-UK]

🙌🏻🙌🏻🙌🏻

[@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.

[@frasercrone3838]

@@shaunmoir9403 Was the HDPE you used recycled material or virgin product. I would be far more interested in the project if it is recycled material.

[@shaunmoir9403]

@@frasercrone3838 Thank you for the comment we used virgin hdpe for this one as it is a prototype however that is not to say we will not be using recycled hdpe for future projects all our material is reusable which means all offcuts from these are labelled as PIR(post-industrial recycling) once you have a product at the end of its life the product can be recycled this will then be called PCR (Post-consumer recycling) any none structure component ie cabins, benches, consoles etc from the boat can be made from recycled hdpe, not the hull as all suppliers would not recommend making a hull from recycled hdpe

[@human6.045]

That lip (bottom plate/sheet) sticking out all around the bottom could be an Achilles' heel, if it gets snagged going up in locks, or under the sides of canal edging as happens often enough with steel canal boats. Steel and strong welds don't really have issues with this (except for some wear) so, I'm wondering how strong the HDPE welds are and also how it wears rubbing and catching on these things; as mentioned above. I think a decent rubbing strake down on that edge would make a lot of sense. It's a different material, so a different approach than traditional may be the way to go with these sort of things. Good concept and great to see someone give it a go, why not; as good as steel is it's got Many downsides.

[@Formation_Plastics-Bradford-UK]

Thank you for your feedback! This was indeed our prototype, and we've learned a lot from it. You're absolutely right about the potential risk of the bottom lip snagging in locks or against canal edges-a challenge even for steel boats. One of the standout qualities of HDPE in this project has been its impact resistance. HDPE is both durable and flexible, which allows it to absorb impacts effectively. The welds, when done properly, are remarkably strong, We completely agree that adding a rubbing strake along the edge would be a smart improvement. It would provide extra protection and reduce the risk of snags or damage. Since HDPE differs from steel, we're exploring alternative approaches and refining traditional designs accordingly. Thank you again for your input and support! While steel certainly has its benefits, we believe HDPE offers exciting possibilities, and we're eager to keep improving based on these insights.

[@human6.045]

@@Formation_Plastics-Bradford-UK I'll be keeping a lookout for future updates, so definitely worth my time subscribing. All the very best for the future!

[@johnlundquist8855]

Wow. Beautiful

[@Formation_Plastics-Bradford-UK]

Thank you John!

[@deltacx1059]

My main concern with this is impact and scrape resistance, yes HDPE can be welded but that doesn't help you if whatever you hit blows a hole in the hull. I would assume the bottom plate is rather thick compared to the sides but impact is still definitely possible there. I do wonder how effective this could be for a sailboat, extensive framing would be needed for sure.

[@Formation_Plastics-Bradford-UK]

thank you for this I'm not sur if your are aware HDPE (High-Density Polyethylene) is a highly durable and resilient material, making it an excellent choice for various marine applications. Its resistance to impact and abrasion ensures that it can withstand damage from boat walls, locks, and other potential sources of wear and tear. showcasing its structural integrity and load-bearing capacity. The use of HDPE in boat construction is well-established, with successful applications in workboats, small fishing vessels, lifeboats, and emergency boats worldwide. This proven track record underlines the material's reliability and effectiveness in marine environments. Although no canal boats have been constructed with HDPE yet, the material's resistance to erosion and its enduring performance in other boat types suggest it will be an innovative and sustainable choice for this new application 🙂

[@zimpon]

How do you join the seams/joints?? Are they bonded or melted together?

[@Formation_Plastics-Bradford-UK]

Thank you for your comment. These are actually melted together using various equipment, and the process is very similar to MIG welding.

[@MrBillgiles]

That is a great idea and should be much cheaper to manufacture I would imagine. I'm sure it would resist shoulder barges (no pun intended) from heavier steel boats but would you say it would resist point impacts from the bow of another boat?

[@Formation_Plastics-Bradford-UK]

Thanks! Possibly cheaper, but it will certainly last longer than traditional builds. Yes, this will literally bounce back from any bumps it may receive.

[@johnmathew3389]

How much total cost

[@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 😂😂😂

[@frasercrone3838]

I would say they used one of the Urethane products used in the automotive and construction industry when bonding metal to other material but still has flexibility.

[@HenryHobson-uc2bk]

if the barge took a collision hit, would the welds give way easily or will the hdpe material crumple up as steel would ?

[@Formation_Plastics-Bradford-UK]

great question HDPE (High-Density Polyethylene) is a highly durable and resilient material, . Its resistance to impact and abrasion ensures that it can withstand damage from boat walls, locks, and other potential sources of wear and tea , we will be showing a video soon of a few tests we put some hdpe panels threw 🙂

[@andrewallen9993]

HDPE welds are exactly as strong as the HDPE sheets.

[@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?

[@paulmeynell8866]

Love it that’s amazing. How long did it take to build?

[@Formation_Plastics-Bradford-UK]

Thank you!☺️ It’s hard to say, we worked on it on and off for a few months.

[@Howard675]

A boat made from oil products. Nice job.

[@Formation_Plastics-Bradford-UK]

The long Jevity of the barge, and the recyclability of the materials used should be considered, as a win.

[@andysmedley-mj8fo]

Brilliant idea, but what about damage from bumping into lock walls/canal sides etc? Then there's the ballast, how would HDPE hold up to all that weight resting on it?

[@Formation_Plastics-Bradford-UK]

At 5mph, it will literally bounce off 😂 We are still developing this ‘Proof of Concept’.

[@andysmedley-mj8fo]

@@Formation_Plastics-Bradford-UK I get that, I was thinking about over time all those knocks will erode the plastic.

[@shaunmoir9403]

@@andysmedley-mj8fo HDPE (High-Density Polyethylene) is a highly durable and resilient material, making it an excellent choice for various marine applications. Its resistance to impact and abrasion ensures that it can withstand damage from boat walls, locks, and other potential sources of wear and tear. In terms of ballast, HDPE can easily handle around 8-10 tonnes as (a example )showcasing its structural integrity and load-bearing capacity. The use of HDPE in boat construction is well-established, with successful applications in workboats, small fishing vessels, lifeboats, and emergency boats worldwide. This proven track record underlines the material's reliability and effectiveness in marine environments. Although no canal boats have been constructed with HDPE yet, the material's resistance to erosion and its enduring performance in other boat types suggest it will be an innovative and sustainable choice for this new application.

[@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 😂😂😂

[@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 🤔

[@ayzzya7124]

Do this boat warp? If so how to fix it?

[@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

[@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]

[@fallen4u248]

are you into S & M then?

[@_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 🤣

[@Altair885]

How well is this going to withstand impacts compared to a steel hulled vessel? Barges after all do tend to get a bit knocked about!

[@Formation_Plastics-Bradford-UK]

The HDPE will deflect a little, giving any bump, a cushion effect. Barges rarely go above 5mph so, any impacts will result in little to no damage.

[@Altair885]

@@Formation_Plastics-Bradford-UK Yes I agree, but what about the hull getting pierced by anything that has an angular edge etc, or it splitting if the impact is severe enough? Obviously steel will give and stretch quite a way before it finally splits, just wondering if the plastic offers similar levels of resilience? Do the plastic welds hold up as well as the surrounding material? Also, what is the effect of long term exposure to the sun? Does this type of plastic degrade very quickly in strong sunlight? Certainly a novel project and I applaud you guys for your efforts!

[@Formation_Plastics-Bradford-UK]

@@Altair885 That’s a lot to unpack 😂😂😂 I will have a word with the engineers tomorrow,and get back to you. If someone called ‘Shaun’ replies here, he works for us, and might be able to answer your questions.

[@Altair885]

@@Formation_Plastics-Bradford-UK Yes, I suppose it is. Sorry, I do tend to get a little over enthusiastic sometimes! 😁

[@Formation_Plastics-Bradford-UK]

@@Altair885 We welcome questions, no matter how many. Unfortunately, I am unable to answer them 😬. We will get back to you though 👍🏻

[@75blackviking]

Wasn't there a movie titled, "HDPE FLOATS"? I can only imagine the builders got everything they HDPEed for.

[@Shadow-k9w]

2 years on...Hows it holding up?

[@Formation_Plastics-Bradford-UK]

You won’t believe this but… This was a side project. Something we did while we were quiet. We then got overwhelmed with day to day work. So, it’s been sat in our car park up until now 😮 We recently transported it to the local canal, for kitting out. Check out our latest video for an update.

[@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.

so quick and easy to make yet they will charge a fortune for it

[@Formation_Plastics-Bradford-UK]

Thank you for your feedback, I understand your concern about pricing. However, I'd be more than happy to discuss and demonstrate that our HDPE canal boats are actually priced very competitively-often similar to or even more affordable than current steel ones. Please feel free to reach out, and we can go over the details together

[@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.

[@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.

[@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]

[@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.

[@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]

[@pernielsen9812]

Would be possible to print it. Make the hull double

[@schoolForAnts]

Wait, doesn’t HDPE fusion require the joints to be under pressure to fuse properly?

[@mickkirton7943]

Just needs holding together whilst heat is applied then left to cool. Gas and water supply pipes are welded this way, some of the couplers used have built in wire elements and connectors, plug them into a control unit which applies current for a preset time. It also shows the cool down time so the joint sets fully before any handling or movement. HDPE gas pipes range from 20mm diameter to in excess of 450mm.

[@schoolForAnts]

@@mickkirton7943 I'm an engineer at McElroy Manufacturiing, the leading Pipe Fusion machine manufacturer in the world.

[@tomcoryell]

I want one!

[@Formation_Plastics-Bradford-UK]

brilliant to hear 🙂 if you want more details email [e-mail] and he will help 🙂

[@marvinmarlin9655]

Where the wave height is measured in inches rather than feet, why not?? I would love to see and test the finished product seems like a good solution.

[@andrewallen9993]

They are used as tenders and workboats at Cape Town (popularly known as the Cape of Storms :)

[@FourthWayRanch]

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.

[@gunturguntur7387]

Lokasi pembuatan perahu ini d mna ?

[@Formation_Plastics-Bradford-UK]

kami berbasis di Inggris.

[@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.

[@jonflanagin6682]

Is there a update on this?

[@Formation_Plastics-Bradford-UK]

There is Jon. I posted an update a couple of hours ago. If you check near the end of this video, there should be a ‘card’ taking you to it, or go to the home page.

[@petercurrell9344]

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

[@christopherhopkinson5766]

Had a steel narrow boat for 8 years the amount of times i scraped the bottom must have been in the thousands enough to wear the bottom of a plastic boat the cut is full of old cars push bikes and god only knows

[@tomcoryell]

HDPE is pretty tough.

[@christopherhopkinson5766]

@@tomcoryell I was a pattern maker for 37 years in wood and metal foundry and aircraft and steel stands up well to wear and it's cheap

[@andrewallen9993]

@@christopherhopkinson5766 True that, unfortunately it doesn't stand up well to rust😁

[@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.

[@TeaGuyAJ]

I feel like the only boaters that will use HDPE are those that need a little more flexibility in their lives 😅

[@romandybala]

boom boom

[@shaunmoir9403]

Thank you for that if you are unaware off hdpe please let me explain HDPE (High-Density Polyethylene) is a highly durable and resilient material, making it an excellent choice for various marine applications. Its resistance to impact and abrasion ensures that it can withstand damage from boat walls, locks, and other potential sources of wear and tear. In terms of ballast, HDPE can easily handle around 8-10tonnes as a (example )showcasing its structural integrity and load-bearing capacity. The use of HDPE in boat construction is well-established, with successful applications in workboats, small fishing vessels, lifeboats, and emergency boats worldwide. This proven track record underlines the material's reliability and effectiveness in marine environments. Although no canal boats have been constructed with HDPE yet, the material's resistance to erosion and its enduring performance in other boat types suggest it will be an innovative and sustainable choice for this new application.

[@TeaGuyAJ]

@shaunmoir9403 are you that uptight you can't see humour......

[@shaunmoir9403]

@@TeaGuyAJ 😂as you may appreciate we have been getting a lot of comments not uptight sir just trying to explain the benefit of hdpe 😀😀

[@TeaGuyAJ]

@shaunmoir9403 Pros, durable and long lasting, Cons, extremely flammable ( im sure everyone's seen a bin that has been set on fire by chavs ) and will release micro plastics into our water ways over time further adding the the micro plastics already built up in our waterways. Other than that it really is a great, cheap and easy to work with material.

[@yveslegrand9826]

Stainless steel beams are a bit expensive...but would make this boat absolutely u destructible.

[@Formation_Plastics-Bradford-UK]

Very true, but as you say, the cost is a bit prohibitive. We are looking at alternatives to ‘I’ beams though. This is a proof of concept, so some things will change.

[@shaunmoir9403]

HDPE (High-Density Polyethylene) is a highly durable and resilient material, making it an excellent choice for various marine applications. Its resistance to impact and abrasion ensures that it can withstand damage from boat walls, locks, and other potential sources of wear and tear. In terms of ballast, HDPE can easily handle around 8-10 tonnes,as (a example ) showcasing its structural integrity and load-bearing capacity. The use of HDPE in boat construction is well-established, with successful applications in workboats, small fishing vessels, lifeboats, and emergency boats worldwide. This proven track record underlines the material's reliability and effectiveness in marine environments. Although no canal boats have been constructed with HDPE yet, the material's resistance to erosion and its enduring performance in other boat types suggest it will be an innovative and sustainable choice for this new application.

[@romandybala]

@@Formation_Plastics-Bradford-UK Try laminated timber.

[@Formation_Plastics-Bradford-UK]

@@romandybala Funny you say that, as I was replying, I was remembering some TikTok videos I’d seen involving wooden ’I’ beams. 😀

[@NobbyWright]

How much?

[@Formation_Plastics-Bradford-UK]

Hello, if you provide the exact size you are looking for to [e-mail] we will get back to you thanks

[@WaheedRafiq]

What is HDPE

[@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

[@aggabus]

40 ft??

[@MrTwinkieeater]

Now make one out of UHMW.

[@Formation_Plastics-Bradford-UK]

That would be a near impossible challenge 😆

[@MrTwinkieeater]

@@Formation_Plastics-Bradford-UK I believe in you 😁

[@Formation_Plastics-Bradford-UK]

@@MrTwinkieeater thank you 🫡

[@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.

[@Kaspertube513]

A much better idea would be to fully encapsulate the original steel in 4mm in plastic/rubber

[@deezacharo]

overall weight deduction must be enormus vs traditional steel 60- 70% I guess

[@thomas82311]

barge NO NARROWBOAT YES

[@RoyParavinic]

What is HDPE?

[@zopEnglandzip]

High density polyethylene, what coke bottles are made from.

[@negergreger666]

Bottles are overwhelmingly made out of PET. Soda bottles I would think are never made out of HDPE as it cannot be made transparent like PET, only translucent.

[@shaunmoir9403]

High-density polyethylene (HDPE) is an excellent material for boat building for several reasons: Durability and Impact Resistance: HDPE is known for its exceptional toughness and resistance to impact, which is crucial for boats that must withstand the rigors of the marine environment. Corrosion Resistance: Unlike metals, HDPE is resistant to corrosion and rust. This makes it ideal for use in saltwater environments where corrosion is a significant concern. Lightweight: HDPE is much lighter than traditional boat-building materials like wood or metal. This makes the boats easier to handle and improves fuel efficiency. Low Maintenance: HDPE boats require minimal maintenance compared to wooden boats that need regular painting and varnishing or metal boats that need protection against rust. UV Resistance: HDPE is resistant to UV rays, which means it can endure long-term exposure to sunlight without degrading, a vital property for any boat material. Flexibility and Strength: HDPE combines flexibility with strength, allowing it to absorb shocks and impacts that might crack or break more rigid materials. Ease of Fabrication: HDPE can be easily molded and welded, making it suitable for creating complex shapes and designs without the need for heavy machinery. Environmental Friendliness: HDPE is recyclable, making it an environmentally friendly choice for boat building, reducing the overall ecological footprint. These properties make HDPE an ideal choice for building durable, low-maintenance, and long-lasting boats.

[@davidgormley4419]

Would it be more costly than steel?

[@MartinJones-o2x]

Cool

[@Formation_Plastics-Bradford-UK]

Thank you! 😎

[@bruceburns1672]

I cannot believe it they are putting a steel frame inside, CORROSION galore and maintenance, why not aluminium ???????

[@Formation_Plastics-Bradford-UK]

We were advised by our consultant to do this. Although, we are now looking into alternatives.

[@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

[@jameskelly7193]

Well splice my main brace and shiver me timbers

[@Formation_Plastics-Bradford-UK]

It’s a Pirates life for me 😂🏴‍☠️

[@FrankensteinDIYkayak]

HDPE is such good stuff easily weldable, formable, machinable, etc.i hope prices come down. If anyone has pointers on best way to paint let me know am also looking for the best way to tap. check out my franenstein kayak i welded together and won races with

[@Formation_Plastics-Bradford-UK]

It's a great versatile material, isn't it! Some nice videos you have there

[@shaunmoir9403]

Thank you for your comment. Regarding pricing, we work very closely with certain suppliers to ensure we get the best current prices. We have also found paint specifically for HDPE, which we are currently testing. Now, we are in the planning stage to build a 57ft narrowboat.

[@andrewallen9993]

You can't paint it or glue it. It's why water life doesn't stick to it and it's either welded or moulded.

[@Formation_Plastics-Bradford-UK]

@@andrewallen9993 in regards to painting this , we have actually found a way that you can paint hdpe and we are currently doing our in-depth testing on this and will have results in the next few days ,

[@andrewallen9993]

@@Formation_Plastics-Bradford-UK How long has it lasted so far? It's why the workboats where I live use different colour sheets for making trim pieces look good.

[@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 😇

[@andrew8895]

dear god, why not roto-mold it in mins... Why design like a around steel construction contains, more stress skin, laminated reinforcement would work well.

[@fmphotooffice5513]

Need the hole for the giraffe's neck. (joke)

[@Formation_Plastics-Bradford-UK]

🦒 😂😂😂

[@mattivirta]

super expensive use plastic sheet lot expensive than steel or aluminium boat, but can use used plastic bottle melt sheet.

[@aggabus]

Motor wheel

[@Horus2Osiris]

It would be interesting to see a 60' trimaran built out of this material. Solar charged electric jets, maybe hydrofoils...

[@Formation_Plastics-Bradford-UK]

interesting indeed 🙂

[@someguydino6770]

the music....so bad....

[@keithschneider6348]

I wish i would have learn something watching this video. Weld temp an rod an welding machine. But NO.

[@Formation_Plastics-Bradford-UK]

We originally videoed it, to use as a reference for future builds. We later decided to upload it here, to show something like this is possible, maybe to inspire others.

[@joshlower1]

Shit won't last a month, need to use aluminum or steel

[@Formation_Plastics-Bradford-UK]

Josh, Thank you and we truly appreciate you taking the time to share your thoughts. Just to clarify though, our canal boat was actually made around three years ago and is still 'going' strong. Additionally, HDPE (high-density polyethylene) has been successfully used in workboats across the globe for many years., hope this information helps clear up any misconceptions.

[@andrewallen9993]

Steel rusts, aluminium dents and corrodes at sea. HDPE does none of these things. PLUS sealife doesn't like sticking to it.

[@mazdarx7887]

Two years since the vid, no updates, barge probably fell apart and sunk, thats why there is no update

[@Formation_Plastics-Bradford-UK]

Literally just added an update 😊 Check it out!

[@shaunmoir9403]

Thank you for your comment. The reason we haven't posted much over the past two years is that, as a fabrication company, we've been deeply involved in various other projects. This boat is our prototype, and HDPE is widely used worldwide for workboats, lifeboats, small fishing boats, and even emergency boats. We have been in constant communication with industry experts to ensure everything we do meets the highest standards. While we appreciate your concerns, I assure you we have not been idle. There has been a lot happening behind the scenes, including winning three awards for innovation and being featured in numerous magazine articles. Thank you for your continued interest and support.