For years, RVs have used plywood or OSB for flooring, but these materials can be compromised by water intrusion.
Ask almost any longtime RVer about their biggest maintenance nightmare, and water damage will probably make the list. Even a small water leak that goes unnoticed can eventually lead to rot, expensive repairs, and in severe cases, structural damage.
Coachmen believes there is a better way.
The company recently announced a partnership with Supersede, an Arizona-based engineering company that manufactures composite structural panels made from recycled polypropylene. Beginning with the Catalina and Aurora travel trailer lines, Coachmen is replacing traditional wood decking with Supersede’s Marine Board, a fully waterproof composite material designed specifically for structural applications as a drop-in replacement for plywood and OSB.
A Change Years in the Making
This wasn’t a quick decision.
According to Coachmen General Manager Mike Gaeddert, the company spent nearly three years searching for the right composite flooring solution and worked directly with Supersede for roughly a year and a half before moving forward.
Rather than relying entirely on laboratory testing, Coachmen built between 500 and 600 travel trailers with the new flooring and put them into service. The company also conducted extensive testing, including screw retention, load deflection, water immersion, temperature exposure, and adhesive performance, before deciding to introduce the material into full production. This was a huge engineering change that required thorough testing.
Why Flooring Matters
Most RV owners rarely think about what’s underneath their vinyl flooring until something goes wrong.
Wood performs well structurally, but once exposed to moisture, it can break down. Once water penetrates the floor over time, rot can begin, eventually creating the dreaded “soft floor” that many used RV buyers know all too well.
Supersede’s composite-material approach to the problem differs. Because the material itself does not absorb water, the flooring cannot rot, swell, or support mold growth the way traditional wood products can. Repairs are necessary to fix the source of the leak, but water intrusion won’t damage the flooring.
For RV owners, that’s potentially one of the biggest long-range benefits.
More Than Just Waterproof
Water resistance is only part of the story.
Coachmen says the composite flooring demonstrated excellent fastener retention while upholding structural performance comparable to traditional wood decking. The material also performs across a temperature range from -40°F to 180°F, making it appropriate for virtually every climate RVers are likely to encounter.
Perhaps just as important, Coachmen was able to incorporate the new material without redesigning its production process. Aside from different adhesives, screws, and drill bits, the company says the panels can be integrated into existing manufacturing methods with no major factory modifications or production delays. That’s significant because revolutionary products usually struggle to gain adoption if manufacturers must completely redesign their assembly lines.
Sustainability Comes Along for the Ride
An interesting aspect of the partnership is Supersede’s closed-loop manufacturing process. End users do not discard manufacturing offcuts. Instead, they’re returned to Supersede, ground back into raw material, and re-extruded into new panels.
The company says every panel is fully recyclable and estimates that replacing 72 sheets of half-inch plywood saves one tree. Also, this process diverts thousands of pounds of recycled polypropylene from landfills or the ocean. Sustainability may not be the primary factor driving purchasing decisions, but cutting waste while improving durability benefits both manufacturers and owners.
Could This Represent the Start of a Larger Shift?
Both Coachmen and Supersede believe composite materials will become increasingly common throughout the RV industry. Coachmen views flooring as only the beginning, suggesting that composite materials could eventually find their way into slide floors, roofs, and other structural components.
Supersede agrees, noting that once manufacturers can point to successful production-scale implementations, adopting new materials becomes much less of a leap. Coachmen’s decision may provide exactly that proof point for the rest of the industry.
What It Means for Buyers
Only time will tell how these composite floors perform after years of use in the elements. Long-term durability can only be proven through years of real-world ownership. Still, it’s encouraging to see manufacturers investing in improvements that address one of the most common long-term concerns of RV owners rather than simply adding another cosmetic feature. If composite flooring performs as expected, it might mean fewer soft-floor repairs, lower maintenance costs, and potentially stronger resale value for future owners.
Innovation in the RV industry often happens one component at a time. While flooring may not be the most glamorous feature on a showroom floor, it might prove to be one of the most meaningful improvements for RV owners in years to come.
What do you think?
Want to learn more about Supersede? Listen to our episode with co-founder, Sean Petterson.
Would composite flooring impact your next RV decision, or do you want to see long-term results first? Share your thoughts below.
Leave a Reply