Sunlight's Impact: Delamination Risk For Campers

Delamination is a serious issue for RV owners. It occurs when the outer layer of fibreglass siding separates from the plywood underneath, resulting in bubbles, blisters, and waves that can lead to wood rot. This is often caused by water damage, but can also be caused by exposure to direct sunlight, which can weaken the bonding agent. The sun can also make delamination more obvious, as bubbles and waves tend to shrink in cooler temperatures. To prevent delamination, RV owners should regularly inspect and reseal their vehicle's seams.

What is delamination?

Delamination is a type of failure where a material fractures into layers. It can occur in a range of materials, including laminate composites and concrete. Delamination can happen when there is a loss of adhesion between a coating and a surface or between coating layers.

In the context of camper sides, delamination refers to the separation of the outer gelcoat or fibreglass layer from the plywood or luan substrate beneath. This results in small cracks in the siding, which gradually spread over time, particularly if water has penetrated the substrate.

Delamination can also affect reinforced concrete when metal reinforcements near the surface corrode. The resulting oxidised metal has a larger volume, causing stress on the concrete. When this stress exceeds the strength of the concrete, cracks can form and spread, eventually causing the concrete at the surface to separate from the substrate.

Delamination can also occur in laminated composites, such as fibre-reinforced plastics, where sheets of high-strength reinforcement are bound by a weaker polymer matrix. Loads applied perpendicular to the high-strength layers or shear loads can cause the polymer matrix to fracture or the reinforcement to debond from the polymer.

What does it look like?

Delamination on a camper can manifest in several ways. Initially, you may notice a tiny bulge on the siding of your camper, which will gradually grow over several months and lead to extensive damage to your RV walls if left unattended. The outer gelcoat or fibreglass layer of your camper will start to pull away from the plywood or luan substrate, resulting in small cracks that will spread over time. Water intrusion will accelerate the development of these cracks.

Delamination can also occur on the camper's roof, taking the form of a convex air pocket that causes the bonding agent to detach from the fibreglass and interior plywood. This will result in bubbles that trap moisture and cause further damage.

• Creases, bubbles, or waves on the fibreglass surface. The fibreglass should typically be flat and smooth. If you notice any abnormalities and the area feels spongy when pressed, it could be delamination.
• A hollow sound when tapping lightly with a plastic object, such as a pen.
• Parking your camper in the shade may help you identify delamination. If the bubbles and waves inside the walls get flatter and smaller, it could be due to delamination.
• In severe cases, you may notice mould growth on the inner wood layer once you peel away the outer layer.
• Leaks on RV accessories, such as exterior mounting brackets, lights, electrical sockets, awnings, ladders, and mirrors, could indicate delamination.

Remember, the earlier you detect these signs, the simpler it will be to address them and prevent further damage to your camper.

How to prevent it?

How to Prevent Delamination on a Camper

Delamination is a structural flaw in an RV's exterior, where the laminated layers separate. It can happen on sidewalls, roofs, and floors, and is often caused by water penetrating laminated panels. To prevent delamination, it is important to take proactive measures such as routine care and maintenance. Here are some steps you can take to prevent delamination:

• Routine Inspections: Conduct regular walk-arounds of your RV, especially after extreme weather conditions, to check for early signs of delamination. Look for hollow sounds, creases, ripples, bubbles, water damage, sponginess, tears, and cracks.
• Re-sealing: Schedule inspections at least once a month, depending on the usage frequency, and re-seal the seams of your camper. Use lap sealant to secure horizontal seams and cracks on the exterior. This will prevent water intrusion and protect the inner layers.
• Early Repairs: Don't wait until the damage gets worse. Repair any cracks or creases on the sidewalls by applying new sealants. This will help prevent delamination from causing further damage.
• Preventative Measures: Take preventative measures such as using the right sealant for your roof type and regularly coating your RV roof. Also, cover your RV when not in use to protect it from the elements.
• Maintenance: Keep your RV clean and free of dust, debris, and dirt. Regularly inspect and caulk areas prone to leaks to ensure they are watertight.
• Address Water Intrusion: Delamination is often caused by water intrusion, so it is important to locate and fix any leaks or broken seals. This will help prevent the water from causing further damage to the inner layers.
• Use the Right Adhesive: Ensure that the adhesive used to bond the layers of your RV is robust and suitable for the materials. This will help prevent separation.
• Protect from Heat: Excessive heat can weaken the bonding agent, so avoid exposing your camper to extreme temperatures for prolonged periods.
• Regular Cleaning: Clean your RV regularly, paying special attention to the seams and exterior walls. This will help remove any dirt or grime that can compromise the integrity of the bonding agents.
• Seek Expert Help: If you are unsure about how to prevent delamination, consult an RV repair specialist. They can provide guidance and recommendations tailored to your specific RV model.

How to identify it?

How to identify delamination on a camper

Delamination is a structural flaw in a camper's exterior, where the laminated layers separate. This can happen on the sidewalls, roof, and floor – any panel alongside a seam. It is important to know how to spot the signs of delamination, whether you own a camper or are looking to buy one. The earlier you find these signs, the simpler and cheaper it will be to fix them and the less chance there is of further damage.

The first thing to do is to walk around the camper, ideally when it is parked in direct sunlight, and thoroughly inspect the rear, front, and side walls. You should also look for abnormalities around the roof vents and windows.

The signs of delamination include:

• Creases, bubbles, or waves on the fiberglass. The fiberglass should be flat and smooth, so if you notice any abnormalities that feel spongy when pressed with a finger, it is likely delamination.
• A hollow sound when tapped lightly with a plastic object, such as a pen or spoon.
• If you park your camper in the shade and the bubbles and waves inside the walls get flatter and smaller, this is another indicator of delamination. This is because the bonding agent holding the walls together shrinks in cooler temperatures.
• In severe cases, you may notice the growth of mold on the inner wood layer once you peel away the outer layer.
• Leaks on RV accessories, such as lights, electrical sockets, and mirrors.

If you spot any of these signs, it is important to take preventive measures or fix the issue as soon as possible. Delamination can result in further damage to your camper and can be expensive to repair.

How to fix it?

How to fix delamination on a camper

Firstly, it is important to note that delamination is a structural issue and fixing it to its original state may not be possible. However, you can aim to make it as good as possible. The repair process will require a lot of time and patience, and the amount of time needed will depend on the amount of damage.

• Identify the damage: You don't have to fix everything at once. If the damage is extensive, target a few spots first. Inspect the walls from different angles and under different lighting conditions to properly assess the damage. If the delamination is on a slide-out, make sure to check it thoroughly by expanding and closing the slide.
• Mark the area: Use blue painter's tape to mark the area to be repaired. This will help you set up a bracing support system.
• Create a bracing support system: This is an important step to ensure you don't create further issues with the repair. Use wooden pieces and clamps to create a strong support system.
• Make an injection tube assembly: You will need a syringe and tube connected together to inject the resin/hardener solution into the delaminated area. Buy multiple syringes as the resin can harden over time, making the syringe difficult to use.
• Remove blocking access: Remove trims, windows, or lights that may hinder your access to the delaminated area or make it difficult to set up the bracing system and clamps.
• Prepare the epoxy resin and hardener solution: Mix the resin and hardener in a ratio of 5:1 (5 parts resin to 1 part hardener) as per the brand's recommendation. Remember to have everything else ready before mixing, as the mixture will harden quickly.
• Inject the solution: Slowly inject the solution into the delaminated area and press hard temporarily. Inject slightly above the area you want to fix so that the solution runs down as you apply. Once injected, immediately clamp the whole section for 15-20 hours.
• Repeat the process: Apply the same steps for other delaminated areas on your camper.
• Reinstall and reseal: Reinstall any panels, trim, windows, and doors that were removed during the repair process. Make sure to reseal them properly.

• Work from the bottom up, clamping as you go.
• Cover the area with plastic and painter's tape to protect the surface from dripping epoxy.
• Inject the solution above the area to be treated so that it drips down.
• Apply pressure after each injection to spread the epoxy evenly.
• Mix small batches of the solution to prevent premature hardening.
• Do a dry run before starting the repair to ensure you have the right tools and materials.

Frequently asked questions