Our Products

Our range of panels includes Poly Premium Honeycomb with advanced fibreglass reinforcement for maximum strength, Poly Standard Honeycomb for lightweight durability, and Ezyfloor Ply & Ply Panels for streamlined installation.
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Worthington Industries exclusive one-piece Poly Premium Honeycomb seamless flooring
Worthington Industries One-piece Poly Honeycomb flooring manufactured in Victoria, Australia
Caravan trailer using Worthington's One-piece Poly Honeycomb floor

POLY Premium Honeycomb

Exclusive to Worthington Industries, this advanced, one-piece seamless flooring solution is specifically designed for today’s performance-driven caravans, RVs, and motorhomes. Lightweight, it is impervious to water and impact-resistant.

It is the only Poly Honeycomb on the market that is reinforced on both sides with fibreglass woven roving and thermo-fused (heat welded) to the honeycomb, combining strength and durability. Unaffected by the elements or insects and combined with its lightweight construction, the flooring is unrivalled in the industry.

Worthington Industries exclusive one-piece Poly Premium Honeycomb panel construction diagram
Structure Breakdown (refer to image)
A.
Polypropylene sheet - Gives a smooth finish
B.
Woven pp / fibre-glass - Reinforcement
C.
Polypropylene sheet - Heat Welded to Honeycomb
D.
Polypropylene honeycomb - Poly Floor thickness is 17mm.
Benefits
Super lightweight
Up to 40% lighter than standard plywood, reducing overall vehicle weight.
Durable and reliable
Will never delaminate, 100% waterproof, moisture and impact resistant.
Seamless construction
No joins, preventing squeaking, creaking and delamination.
Streamlines manufacturing
One-piece construction up to 7500mm long, custom detailing available saving you time and money.
Environmentally friendly
100% recyclable, making it a sustainable choice for the environment.
Specifications

  • All sheets are 2300mm wide and come in lengths of 5000, 5500, 6000, 6500, 6900 and 7500mm

  • Thickness: 17mm sheets

  • Weight: 4.4 kg/m2

  • Installation: We recommend an MS Polymer adhesive combined with a Polypropylene Primer and flathead screws for fixing the Poly Honeycomb sheets to a chassis. We recommend min. 450mm chassis/subfloor spacing for support.

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Poly STANDARD Honeycomb

Our standard Poly Honeycomb one-piece seamless flooring solution is specifically designed for today’s performance-driven caravans, RVs, and motorhomes. It offers a sleek, modern appearance paired with exceptional durability.

Constructed from thermo-fused polypropylene, it’s impervious to the elements, super lightweight and will never delaminate.

See Poly Premium Honeycomb above for benefits and specifications.

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Worthington Industries exclusive one-piece Poly Honeycomb seamless flooring
Caravan trailer using Worthington's One-piece Poly Honeycomb floor
Worthington Industries one-piece Ezyfloor Ply flooring
Worthington Industries one-piece Ezyfloor Ply flooring
Worthington Industries Ezyfloor Ply flooring
Worthington Industries Ezyfloor Ply flooring being manufactured in Victoria, Australia
Worthington Industries Ezyfloor Ply flooring mounted on a caravan trailer

EZYFloor PLY

Designed to streamline the manufacturing process for caravans, RVs, and more. The Ezyfloor one-piece solution reduces costs, enhances reliability, and improves overall quality by eliminating joint movement, making it a cost-effective and efficient choice for flooring systems.

Specifications

  • Dimensions: up to 2400mm wide and scarfe joined (every 1110mm) as a one-piece floor to any length required

  • Thickness: 12mm & 15mm sheets

  • Weight: approx. 8.2 & 10.2 kg/m2

  • Quality: BD grade Plywood

  • Installation: min. 450mm chassis spacing for support

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GARAGE DOOR Ply Panels

Our ply panels are perfect for tilt lift garage doors. Engineered in one-piece for strength and resilience, they ensure lasting quality, functionality and durability, making it a cost effective and efficient choice for garage doors.

Specifications

  • Dimensions: 2400mm and 2700mm high Ply garage doors to any length

  • Thickness: 6mm or 9mm sheets BB Hoop pine plywood timber

  • Scarfe joins are vertical only, approx. every 1100mm

  • Made from Australian sourced BB Hoop pine plywood timber

  • Structurally rated to F17

  • Made to Australian standard AS/AZS 2269

  • Installation: we recommend the application of a prime coat to the ply surface and no routing deeper than the first veneer. (Note - Plywood is a natural product and needs to be protected from moisture and the elements)

  • Note: if routing, do not penetrate the external veneers

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Worthington Industries Garage Door Ply panels from Australian sourced BB Hoop pine
9mm BB Hoop Ply
Worthington Industries Garage Door Ply panels from Australian sourced BB Hoop pine
6mm BB Hoop Ply

FAQs

How is the Poly Premium Honeycomb constructed?

Our 17mm Poly Premium honeycomb flooring is made from thermo-fused polypropylene with fibreglass reinforced face sheets. It is 100% waterproof and one piece. It is the strongest honeycomb flooring supplied in Australia to the caravan and trailer industry, weighing 4.4 kg/m2, with a very strong compressive strength. It is 100% recyclable.

What sizes does the 17mm Poly Premium and Poly Standard come in?

All Poly honeycomb sheets are 2300mm wide and come in lengths of 5000, 5500, 6000, 6500, 6900 and 7500mm. Custom sizes can be accommodated.

How thick is the Ezyfloor Ply timber floor?

We use a 12mm structural pine plywood coated with a black water resistant coating on the underside.

What is the quality of the pine ply flooring?

We have been supplying the caravan & RV, construction and other industries for almost 50 years with a premium 12mm structural ply certified to AS/NZS 2269. This certification ensures our one piece floors and garage door panels are manufactured with plywood that meets stringent Australian and new Zealand quality standards.

Is the ply flooring one piece?

We use special machinery and processes to join 2400 x 1200mm ply sheets together to make a 12mm thick one-piece floor which weighs approx. 8.2kg/m2. The joins are extremely strong using a specialised polyurethane adhesive tested from a global adhesive supplier. The floor can also be fully machined to meet application sizes and specifications.

Is Ezyfloor one-piece flooring manufactured locally?

Yes, Ezyfloor is manufactured in Australia using scarfe joining innovation from our Bayswater factory in Victoria.

What are your garage doors made from?

Our garage doors are scarf joined and made from Australian sourced sheets of 6mm or 9mm thick BB Hoop pine plywood timber. B grade veneers on the face and back constructed with an ‘A’ bond adhesive and structurally rated to F17. Made to Australian standard AS/NZS 2269.