Why Coosa is an Exceptional Core for DuFLEX® Panels
Fibreglass reinforcement within the core significantly increases flexural strength, enabling longer span lengths and improved load distribution — ideal in marine applications:
- Transoms
- Stringers
- Bulkheads
- Floors
- Structural modules requiring rigidity.
Coosa’s closed-cell polyurethane matrix absorbs 1.5% water or less, eliminating rot, fungal growth, swelling, delamination and long-term degradation.
This makes it a reliable replacement for plywood in environments exposed to:
Continuous moisture
Saltwater intrusion
Chemical or industrial washdown
Condensation or thermal cycling
At up to 60% lighter than equivalent plywood, Coosa significantly reduces structural weight, improving:
Vessel performance and fuel efficiency
Payload capacity
Handling and installation ergonomics
Structural fatigue resistance
Coosa will not absorb water, warp, expand or degrade, providing consistent geometry throughout the life of the structure — a critical requirement in marine, transport and defence applications.
Coosa is resistant to:
Rot
Mould and mildew
Insect infestation
Biological degradation
Its mechanical properties remain stable over decades of service.
When paired with DuFLEX®’s precision epoxy laminates and multiaxial E-glass or carbon fibre skins, Coosa creates a robust, lightweight and extremely stable composite panel suitable for demanding environments.
Applications Across Marine, Industrial, Transport & Defence
DuFLEX® Coosa Panels are used across structural and non-structural components where lightweight strength and moisture resistance are essential.
Marine
Transoms
Stringers and structural floors
Decking, hatch lids and bulkheads
Superstructure modules and reinforcements
Transport & Commercial Vehicles
Floors for emergency vehicles, buses & public transport
High-load truck/trailer flooring
Walls & body modules requiring water resistance
Industrial & Architectural
High-moisture-area wall panels
Freezer/refrigeration units
Amusement park structures and museum exhibits
Industrial cases, instrument housings & modular units
Defence
Lightweight moisture-resistant modules
Marine and amphibious vessel components
Structural elements where rot-free service life is essential
Engineered for Strength, Efficiency & Accelerated Build Speed
DuFLEX® Coosa Panels are purpose-designed to streamline fabrication while delivering superior mechanical performance. By eliminating hand laminating, coring and full vacuum-bagging steps, DuFLEX® provides:
Faster installation with reduced labour
Lower material waste and tooling costs
Controlled laminate quality and repeatability
Improved stiffness and impact performance
Reliable long-term results in moisture-rich environments
Every panel can be engineered and tailored to suit performance requirements including stiffness, load span, impact strength, fatigue life and weight reduction.
Key Advantages of DuFLEX® Coosa Panels
High flexural strength and stiffness
40–60% lighter than plywood
Closed-cell, moisture-resistant, rot-proof
Dimensionally stable under load
Mechanically reinforced with fibreglass
Excellent fastener retention and durability
Ideal for marine, transport, industrial and defence environments
Engineered for Strength, Efficiency & Speed of Construction
DuFLEX® significantly reduces the labour, waste and technical complexity associated with traditional hand-laminated composite structures. By eliminating multiple laminating, coring and full vacuum-bagging steps, DuFLEX® panels enable:
- Faster build times with cleaner fabrication
- Reduced material waste and tooling cost
- Controlled, repeatable laminate quality
- Improved strength, impact tolerance and fatigue performance
Every DuFLEX® panel can be engineered to suit the project — laminate schedule, fibre orientation, resin system, and core density can all be tailored to meet precise structural requirements including:
- Weight reduction targets
- High impact and slamming loads
- Span-driven stiffness demands
- Shock, vibration, fatigue and mechanical resilience
Panels are supplied with peel ply for a contamination-free bonding surface to accelerate secondary bonding and laminating.
