What is delamination and how can you fix it?

If you start to notice the floor of your motorhome feeling a bit spongy underfoot or making a noise, you shouldn’t ignore it. This could be something called delamination.

Delamination is when the glue which binds the different layers of your vehicle’s floor starts to wear off.

It’s a common problem, but one that needs swift action so it doesn’t become a bigger issue.

In this article, we’ll talk you through your options on getting it fixed, which ultimately boil down to you doing it yourself or calling in the experts.

A quick and effective fix will ensure your pride and joy remains in its best condition.

After all, the reason you bought a motorhome in the first place was for its superior levels of comfort when you’re out on the road.

 

What causes delamination?

You might be wondering if you’ve caused your motorhome’s floor layer to separate.

But the likelihood is that it’s nothing you’ve done – unfortunately the special glue that binds the plywood and Styrofoam insulation that makes up the layers of any motorhome floor becomes weaker and less effective over time and that’s when separation starts to happen.

Damp or a water leak can exacerbate a delamination. There are some horror stories out there from motorhome owners who have sprung a leak and it goes on to cause all sorts of expensive delamination issues.

However, there doesn’t have to be a leak for delamination to occur. Even dry floors can delaminate. The areas that are most prone to delamination are where the most ‘traffic’ is i.e. the parts of the floor that you spend the most time walking on.

 

Understanding delamination in motorhomes

Delamination in motorhomes is a process where the different layers that make up your vehicle’s floor begin to separate. This usually happens when the special glue holding these layers together starts to fail, leading to a spongy or springy sensation underfoot and sometimes odd noises as you walk.

Just like concrete delamination—where layers of concrete separate due to issues like corroded rebar or poor bonding—motorhome delamination can compromise the comfort and safety of your living space. The separation of these layers doesn’t just affect the feel of your floor; if left unchecked, it can lead to more serious structural problems.

Understanding how and why this process occurs is the first step in keeping your motorhome in top condition and ensuring that your adventures remain comfortable and worry-free.

 

What causes delamination?

You might be wondering if you’ve caused your motorhome’s floor layer to separate. But the likelihood is that it’s nothing you’ve done – unfortunately the special glue that binds the plywood and Styrofoam insulation that makes up the layers of any motorhome floor becomes weaker and less effective over time and that’s when separation starts to happen. Delamination can be caused by many factors, including environmental conditions such as temperature and humidity, which affect the integrity of the floor layers.

Damp or a water leak can exacerbate a delamination. There are some horror stories out there from motorhome owners who have sprung a leak and it goes on to cause all sorts of expensive delamination issues.

Cracks can also form in the floor layers, which may propagate and contribute to delamination. However, there doesn’t have to be a leak for delamination to occur. Even dry floors can delaminate. Air voids trapped during the construction process or due to an improper concrete mix can also lead to weak zones and delamination.

The areas that are most prone to delamination are where the most ‘traffic’ is i.e. the parts of the floor that you spend the most time walking on. For example, metal reinforcements in concrete floors can corrode, with corroded rebar creating internal stresses that result in cracks and delamination. Oxidized metal and surface corrode can weaken the bonds between layers, making delamination more likely.

Neighbouring cracks and neighboring cracks caused by repeated stress or environmental factors can join together, forming larger fracture planes and leading to a larger volume of the floor being affected. As an example, a combination of water ingress, improper concrete mix, air voids, and corroded metal reinforcements can result in significant delamination in a motorhome floor.

 

Types of delamination in motorhomes

Delamination in motorhomes can take several forms, depending on what’s causing the separation of the floor’s layers. The most common type is when the glue binding the plywood and styrofoam insulation weakens, often due to age, repeated stress, or environmental factors.

High temperatures can accelerate this process, as can heavy loads applied perpendicular to the high strength layers of the floor, which introduce shear stresses that the material can’t handle. In some cases, delamination occurs even without water leaks, simply because the polymer matrix that holds the constituent layers together becomes much weaker over time.

In more complex laminated composites, such as those used in some modern motorhomes, delamination can also result from the breakdown of the bonds between different materials, especially if de-icing salts or other chemicals penetrate the floor. Each of these scenarios can lead to the separation of layers, creating a weaker polymer matrix and reducing the overall strength and durability of your motorhome’s floor.

 

How to diagnose delamination

Spotting delamination early can save you a lot of hassle down the road. Start with a simple visual inspection of your motorhome’s floor—look for areas that feel soft, spongy, or make unusual noises when you walk over them. These are often the first signs that separation is happening beneath the surface:

• If you suspect delamination, you can use a delamination repair kit to address small areas, but it’s important to determine the extent of the problem first. Measuring the crack length and checking the thickness of the affected area can help you understand how far the issue has spread.

• For those interested in a more technical approach, a double cantilever beam test can be used to assess the interlaminar fracture toughness of the material, which essentially tells you how resistant the floor is to further separation.

 

 

How can you fix delamination with a delamination repair kit?

As we’ve already mentioned, if you just leave a delaminated floor, it can start to spread throughout your motorhome. Delamination is an important factor in structural failure, as it often leads to the layers of the laminate becoming separated, which can compromise the integrity of the floor.

Before you know it, you’ve got to get the whole floor repaired, which could end up costing you a pretty penny. The orientation of the delamination often runs parallel to the floor surface, and excessive loading or stresses that exceed the material's capacity can cause additional cracks or separation.

So, the key is to rectify it as soon as you notice a bit of extra spring or creakiness about the floor. Failure to restore proper adhesion can result in the layers remaining separated, leading to further structural failure.

In terms of getting it fixed, it’s not inconceivable to do it yourself, even if you don’t have a great deal of DIY experience. If you’re prepared to give it a go yourself, it can prove to be a relatively cheap fix. All you need is a delamination repair kit, which can be easily found online.

A delamination repair kit will usually include a mains substance and hardener which you mix together, like this one sold on Magnum Motorhomes. With your repair kit in hand, here’s how you fix your delamination problem:

 

1. Remove the carpet (you’ll replace it later, don’t worry).

2. Drill holes into the affected areas, approximately 10cm x 10cm in size. The holes need to go through the top layer of plywood and Styrofoam insulation, but be careful not to drill through the exterior layer of plywood.

3. Fill the holes with the adhesive in your repair kit. The glue will harden once you’ve used it, creating a sturdy support structure. The adhesive must provide sufficient resistance to shear loads and restore the original strength of the laminate.

4. Repair the holes that you’ve drilled into the floor. Wooden dowels are often a good hole-filling material. Make sure you buy them in advance and drill the holes to the size of the dowels.

5. Clean up any excess glue that may have spilled out.

6. Refit the carpet.

 

Experimental results from similar repairs show that restoring adhesion between layers is critical to prevent further failure. If the layers have become completely separated, it may be necessary to address the fracture plane and ensure proper bonding to the substrate.

Job done! It’s as easy as that. Once you’re happy that the glue has set – give it 24 hours – you can try to walk on the floor to test it out. Fingers crossed, the springiness and creaking should be gone.

No more waking up your motorhome companions in the middle of the night as you get up to use the toilet. If you don’t feel comfortable repairing your floor yourself, you can always get an expert to do it for you. It goes without saying that this will end up costing you more money, but just how much?

It depends on how big the delamination issue is. That’s probably not the answer that you wanted to hear, but it’s the truth. Determining the extent of delamination is often determined by assessing the area and depth of the affected substrate. It can be as cheap as £100-150 to upwards of £1,000.

While the materials to fix the issue are quite cheap – as you’ve already seen yourself – it’s the man hours which can see the costs rack up. Things can get more complicated – and expensive – if the professionals find a secondary issue like damp or a leak as they go about rectifying the delamination. In some cases, delamination starts at the interface between high strength reinforcement or fiber reinforcement and a much weaker polymer matrix, especially in composite materials.

But, on the bright side – if you can call it that – this would’ve had to be sorted sooner or later anyway, and it’s better that it was spotted now rather than two months down the line when the damage could have been much worse.

 

Prevention strategies

Preventing delamination is all about being proactive during both the construction process and the life of your motorhome. Ensuring that the floor is built with a sturdy support structure and high-quality materials can make a big difference. During use, try to avoid exposing the floor to high temperatures or excessive loads, as these can lead to stresses that cause the layers to separate.

Regularly check for signs of wear or damage, and make sure the floor is properly sealed to keep out moisture. The way your motorhome is constructed—especially the curing of adhesives and the quality of the aggregate used—plays an important role in preventing delamination.

 

Maintenance and monitoring

Keeping your motorhome’s floor in good shape requires regular maintenance and careful monitoring:

• Make it a habit to inspect the floor for any signs of delamination, such as soft spots or creaking noises.

• Keep the floor clean and dry, and avoid using harsh chemicals or abrasive cleaners that could damage the surface or weaken the adhesive bonds. If you do spot a problem, address it promptly—using a delamination repair kit with epoxy or another suitable adhesive can help fix small areas before they become bigger issues.

• Be sure to follow the manufacturer’s instructions to avoid excess glue, which can create its own set of problems.

By staying on top of maintenance and acting quickly when issues arise, you can extend the life of your motorhome’s floor and enjoy worry-free travels.

Is your motorhome still under warranty?

Before you go about carrying out any work, the first thing you need to do is check whether your motorhome is still under the manufacturer’s warranty.

If you think it might be, the best thing to do is to check your paperwork or ask the manufacturer to find out if you’re covered.

If you are, you might not have to worry about buying a delamination repair kit or hiring a professional.

 

What does motorhome insurance cover?

While you're in the business of protecting your motorhome, it's a good time to check you're getting the best motorhome insurance available.

Motorhome insurance can come with many different benefits to help you enjoy your travels to the fullest.

These can include:

• Unlimited cover across all the countries that are part of the European Union.

• Cover for camping personal effects for up to £3,000.

• Up to six months to complete a self-restoration.

• Cover for motorhomes with a value up to £150,000.

• Unlimited mileage cover.

• Introductory NCB allowed.

• Consideration of all claims and convictions.

Note that these features and benefits are subject to eligibility and underwriting criteria. Get in touch with us to see which features apply to your motorhome.

Speak to Motorhome Protect today to get a motorhome insurance policy that’s right for you.