If you don't know much about boatbuilding, start by welding
rebar together to frame the gunwales and keel. Then form the
hull with layers of chicken wire, and trowel a stiff
1/2-inch-thick mortar mix onto the mesh. This simple technique
was used by engineering students at the University of Illinois
back in 1971 to build the winner of the first concrete-canoe
race. Though it weighed 360 pounds, the ungainly boat managed
to defeat its closest (and only) competitor, a craft that was
sleeker and lighter by 235 pounds but had trouble staying
afloat.




To build their vessel for this year's National Concrete Canoe
Competition, engineering students from California Polytechnic
University in San Luis Obispo, Calif., placed a 1/8-inch-thick
layer of concrete in a foam mold (A), then added fiberglass
mesh and carbon fiber reinforcement (B) and a second layer of
concrete. They lined the bottom of the boat with an
Escher-inspired prefabricated foam tile appliqué (C).
Sponsored by the American Society of Civil Engineers, the 2007
competition took place in June at the University of Washington
in Seattle; the Cal Poly team (D) took fifth place.
However, if you have a few thousand spare man-hours of labor
available, plus boatbuilding software and access to
computerized routing equipment, you're ready to build a
state-of-the-art concrete canoe. Settle on a design, then cut
the female mold out of foam blocks. After assembling the
blocks, line the mold with plaster of Paris, sand it smooth,
and coat it with latex primer (which will act as a form
release). For a thickness gauge, lay in speaker wire when the
concrete is applied.
You may need to experiment a bit to formulate a concrete mix
both light enough to float and strong enough to support a crew
and survive collisions. Omit stones and gravel in favor of
lightweight aggregates; seasoned builders recommend hollow
glass microspheres or fabricated shale. For admixes, consider
superplasticizers, pozzolans, shrinkage agents, and latex for
flexibility. Instead of rebar reinforcement, use carbon fiber
or even fiberglass mesh. Enlist a few dozen friends armed with
trowels, rolling pins, and sanders to place and finish the
concrete.
The final step is presentation: What good is a fast, light boat
if it looks homemade? A custom tile appliqué looks
better than paint and provides an artistic touch.
After the concrete has cured properly and you've applied
sealer, your concrete canoe will be ready to race at the
national or international level. —
Andrew
Wormer