Demand for greater materials strength and variety and the flexibility to operate in widely varying climates have driven heavy investment in research and development at Dutch deck and flooring systems specialist Bolidt. The company supplies synthetic decking solutions for cruise ships, cattle carriers, naval vessels, submarines, ferries and other high profile vessels worldwide.
“Beyond its visual impact and perhaps its environmental credentials, the key attributes required of flooring and decking after installation are durability and ease of installation maintenance,” says Van Overbeek. “These are the type of characteristics that only become an issue when they are lacking, so it is worth considering the time and expertise that goes into ensuring that such issues do not arise.”
The company’s marine product portfolio has benefited directly from the support given to R&D by its central laboratory facilities in the Netherlands. There is a specially prepared climate chamber which has been upgraded to simulate temperatures between -25o C and +80o C, and relative humidity levels of between 10% and 98%. These ranges allow materials to be tested in conditions that recreate those faced by a vessel which might at times sail in Antarctic waters and at others in the Caribbean.
“Large flooring sectors of up to 4x3m in size can be subjected to various environmental conditions,” he says. “This allows our specialists to undertake the rigorous thermal-shock and thermal-cycling tests required for synthetic deck coverings to satisfy the marine industry.”
He says the climate chamber has been of particular benefit in developing floorings and deck materials for cruise ship and mega yacht projects. Established products widely in use that have been evaluated include the decking systems from the Bolideck series.
Most recently, the facility has been instrumental in the launch of new colours for Bolideck Future Teak, the company’s environmentally friendly decking system, most well known to date for its ‘real wood’ appearance while being half the weight of teak. The new colours will enable naval architects, designers and cruise lines to use this system in more flexible and creative ways.
“Interior ship designers are driven by the desire to create innovative spaces, and it is our job to ensure that the materials are available to allow their imaginations full scope,” says Van Overbeek. “This year marks Bolidt’s 50th anniversary, and since start-up we have been unlocking the potential for traditional materials to be replaced with synthetic solutions in a range of harsh environments. We say the strength of the material has created the strength of the company. Thermosetting synthetics can be ready-made and continue to broaden their application range, since they are wear resistant, maintenance friendly and, due to their elasticity, crack resistant. The materials are also pore free and therefore highly suitable where hygiene is a key issue, and there are even products that withstand corrosive solvents, are fire resistant, sound attenuating or heat insulating.”
It is also important to the company to meet specific imperatives from the shipping sector – notably the wider appetite for ‘environmentally friendly’ solutions. “This is a market where great emphasis is placed on appearance, maintenance and safety, the last of these including the extremely strict requirements with respect to flammability,” he says.
“We also offer specially developed decking for the wet areas in the ship that need to be chemical resistant, but at the same time are routinely cleaned with hot water and normal cleaning products. Another factor is that the marine market is one where traditional materials – woods such as teak – are in high regard.”
The Bolidt test centre was critical in developing the C-Rail system, the composite rail first used on Norwegian Cruise Line’s 2010 delivery, Norwegian Epic. Designed as an alternative to traditional teak handrails, this pre-fabricated system is an example of the broadening applications for synthetic materials onboard cruise ships; it offers significant weight savings and lower maintenance requirements compared to wood, as well as reducing deforestation.
Also born out of the efforts of the Bolidt laboratory R&D team has been a newly developed modular balcony decking system that can be changed out in a matter of minutes, in the event of a need for repair or refurbishment. The robust and easy to handle Smart Balcony system allows either Bolidt technicians or the ship’s own crew to replace a balcony deck while the ship is in service, thereby saving on valuable drydocking time.
“Balcony renovation is a well-known problem in the cruise sector, in particular the renewal of traditional teak,” says Van Overbeek. “Normally, each teak floor takes about three days to replace when the ship is in the drydock; with our system it takes only 15 minutes, which is a huge improvement in efficiency, saving sanding and drying times, and of course cost."
Latest developments include promising tests undertaken on new antimicrobial flooring systems, which Van Overbeek says employ ground-breaking antibacterial technology. “Today’s challenges can turn into the solutions of tomorrow. Initially, this technology was targeted at the healthcare sector, but we are convinced that antibacterial technology will be of considerable interest in the near future to cruise ship operators, for whom hygiene is an increasingly important issue.”
Capital investments in advanced research include an ElectroPuls all-electric dynamic testing system from Instron, which runs cyclic tests on materials to determine tensile and compression strengths, as well as elongation and deformation at the breaking point. The system is primarily used to test synthetic compounds, repair mortars, grouting masses and adhesive bonds.
Another tangible commitment has been the installation of an Instron 5985 universal testing machine, performing tensile and compression tests up to 250kN, where previous equipment was rated to 100kN. This machine has played a pivotal role in research into a specific adhesive bonding project for the Royal Dutch Navy over recent months. It has also been central in tensile testing on a new deck covering material under development at Bolidt which, for the moment, remains under wraps.
“Once a floor or deck is laid, it is not surprising that little thought is given to the work that went into developing the material underfoot,” says Van Overbeek. “The reality is that Bolidt is responsible for everything including R&D, liaison with designers and owners, materials purchasing, production and installation of the product by special teams at the shipyard, to marketing and sales. This means we are responsive to the market and our R&D is critical in ensuring owners not only get materials with the desired look and feel, but also solutions that satisfy their principles for safety, energy efficiency and environmental friendliness.”
This article appeared in the Spring/Summer 2014 edition of International Cruise & Ferry Review. To read other articles, you can subscribe to the magazine in printed or digital formats.