Falmouth Harbour Trials the World’s First All-Concrete Pontoon Float to Replace EPS in Marinas

Falmouth, Cornwall, UK. Falmouth Harbour is trialling the world’s first all-concrete marina pontoon float, designed and built by the team at ScaffFloat in neighbouring Penryn, in a first step to removing all Expanded Polystyrene (EPS) floats from its leisure and commercial operations.

The Harbour has pledged to move away from EPS products in the light of mounting evidence that polystyrene microplastics in the world’s oceans inflict serious damage on the marine environment and life within it. Polystyrene, globally used for its lightness and buoyancy, is made from fossil fuels, is virtually un-decomposable, and when it breaks down into microplastics can be ingested by marine life with devastating consequences.

“The amount of broken-up polystyrene around our creeks and rivers, particularly after this year’s storms, is awful to see and very hard to clean up without damaging the delicate ecology of our shorelines. Expanded Polystyrene fragments in the marine environment pose a serious ecological concern, as seabirds, fish, turtles and other fauna mistake EPS beads for food, which can cause internal injuries or death; entering the food chain poses health risks to humans as well.”

Vicki Spooner, Environment Manager, Falmouth Harbour

Inside the Reef Float: an inert, recyclable alternative to EPS

Penryn marine company ScaffFloat Ltd has tackled the challenge of finding alternatives to traditional pontoons by inventing the “Reef Float.” Their first commercial prototype, made entirely from concrete, has been undergoing trials beneath a Falmouth Harbour pontoon. ScaffFloat developed the new product as part of a business development project that received £284,787 from the UK Government through the UK Shared Prosperity Fund as part of Cornwall’s Good Growth Programme.

The Reef Float’s buoyant core is made using ultra-low-density waterproof concrete, instead of EPS foam, and the core is then cast inside a high-strength engineered concrete skin. In the highly unlikely event that a Reef Float ever failed, the materials would simply sit inertly as stone in the marine environment, whereas a cracked-open EPS float exposes its polystyrene foam core to the marine elements.

“We replaced a failing EPS pontoon float at Falmouth Harbour with a Reef Float, where it survived all that this January’s storms could throw at it. It’s what we would expect, of course, as we’ve designed it to be strong with an ultra-long life. But it’s also completely inert in the marine environment and 100 percent recyclable, so a game-changing alternative to the EPS floats currently used all over the world.”

Toby Budd, Founder and Managing Director, ScaffFloat

Local innovation, global stage

Local MP Jayne Kirkham, checking out the new Reef Float in Falmouth, called it “exactly the kind of innovation we want to see in Cornwall: local businesses developing practical but cutting-edge solutions to global environmental challenges. Cutting polystyrene pollution from our waters while creating skilled jobs is a win for our marine environment and our economy. I’m proud to see government funding helping projects like this lead the way.”

“Falmouth Harbour has made the conscious decision to move away from EPS foam pontoons in all our operations, and it’s fantastic that our neighbours at ScaffFloat are the first company to offer a plastic-free alternative. Reef Floats are easily installed, in situ, on a rolling basis, as and when we need to replace old EPS floats, and they have a zero-cost, 100 percent recyclable end-of-life disposal. It’s another tremendous example of Cornish ingenuity, and we look forward to working with them into the future.”

Miles Carden, CEO, Falmouth Harbour

The Reef Float team has been shortlisted for the Innovation Award at Marina26 in Australia this May, with an invitation to attend and present at the biggest marina conference in the world, demonstrating what a major issue EPS has become for the marina industry and legislative authorities alike.

Australia itself lost more than 1,000 pontoons in the 2022 Queensland floods, where they broke up and created an environmental disaster known as the “White Spill,” with the ocean and beaches covered with EPS balls that were almost impossible to clear up.

Learn more. For more information on Reef Float and parent company ScaffFloat, visit scafffloat.co.uk/reeffloat. For more on Falmouth Harbour, including its wide-ranging environmental initiatives, see falmouthharbour.co.uk.

Adapted from a press release issued by Louise Midgley Communications, on behalf of ScaffFloat and Falmouth Harbour.