caravan floor?

Buy floor repair resin, two tins which you will mix. Buy 900mm or so of 6mm dia wooden dowel. Buy 6mm drill. Prepare a few clean tins for mixing.
Remove all upholstery etc, this is a messy job.
Prepare used sealant cartridge, use dowel through nozzle hole to push piston out, clean cartridge out with solvent, fit new nozzle, trim nozzle end for very tight fit in 6mm hole. I prepare two cartridges in this way, just in case.
Level van. Obtain sturdy plank or planks, depending on area you need to repair. Use jack(s) to support these under the delaminated area so the floor is supported from beneath. Prepare weights (concrete block or filled water containers) to weight the floor.
Drill 6mm holes at say 100mm squares over affected area. Do NOT go all the way through floor, you want some holes through the polystyrene but NOT through bottom plywood, others just through top plywood not polystyrene. Each hole will need a 12mm length of dowel as a plug, cut plenty of plugs.
Measure the adhesive into your clean tin and mix. I suggest you use only half the quantities in the kit which is often two to one mixture. Do NOT allow unused mix components to touch each other or they will set!!
Use disposable gloves. Plug the nozzle and pour your mix into the cartridge. Inject into each hole, don't use too much pressure or you will delaminate further. When mix appears from adjacent holes, insert plug into hole and move to the next one.
When all holes are treated and plugged, place your weights evenly over the area. Next day remove surplus material and projecting plugs with angle grinder.
I did two repairs in this way. 14 years later the floors are still as good as new.

Mike
July 2009

Hi, Drill a series of small holes say 12mm diameter in the area concerned at about 100mm centres and then insert round wooden dowel with waterproof PVA glue in the holes. Make the drill holes a close push fit not sloppy to ensure a good bond to the surrounding floor wood.
A further tip is to drill a pilot hole in the end of the dowel rod which will be under the van before it is inserted, screw/glue a flat piece of wood to it to give it a larger "head" before inserting the dowel rod into the hole with plenty of PVA waterproof glue.
Another better way use shortened 4 inch or 6 inch nails with sawn off points to a length just 12mm longer than the thickness of the floor. Get an enginneer or a model maker to put a thread on the sawn off end. Make small thin plates or use large washers inside the van and underneath the van on the nail then tighten up a nut onto the thread from underneath. This is a much better solution but requires a " Die" to make the thread on the sawn off end of the nail.
Instead of nails there are available threaded bolts with countersunk heads you can use with washers on the inside floor of your van these will be flush enough for this purpose. This is possibly the best way to do this repair.

Dave Tromans G4CGB
June 2009

Go to your local dealer for a 'Delamination' kit. The floor is a sandwich of ply and insulation foam as are the walls. Explain what's happened.
Or try this website www.apollochemicals.co.uk

Bob
June 2009