Choosing the best material for your Rigid Inflatable Boat (RIB) is more than just a technical decision—it’s a long-term investment in durability, performance, and value. The two most commonly used materials, Hypalon vs PVC (CSM), serve different purposes depending on climate, usage, and budget.
In this guide, backed by expert insights and industry standards, we’ll explore how PVC compares to Hypalon in real-world conditions—so you can make a confident decision for your inflatable boat.
What Is PVC? The Affordable Entry-Point
PVC (Polyvinyl Chloride) is a lightweight, cost-effective synthetic plastic polymer widely used in inflatable boats. It’s especially popular for entry-level models due to its affordability and ease of manufacturing.
Pros of PVC
- Budget-friendly: Often 70–90% cheaper than Hypalon
- Lightweight: Easier to transport and store
- Heat-welded seams: Streamlines production
Cons of PVC
- Shorter lifespan in sunny or salty environments
- UV sensitivity: Degrades quickly with prolonged sun exposure
- Not ideal for re-tubing: Difficult to repair and less durable over time
Best For:
- Cooler climates (e.g., Northern US, Europe, Great Lakes)
- Occasional or seasonal use
- Indoor or shaded storage setups
What Is Hypalon (CSM)? The Premium Performance Standard
Hypalon, now technically known as CSM (Chlorosulfonated Polyethylene), is a synthetic rubber engineered to handle extreme conditions. It’s the material of choice for commercial operators and serious boaters who prioritize reliability and longevity.
Pros
- Incredible durability: Lasts 15–20+ years with proper care
- Resistant to UV, saltwater, and chemicals
- Easy to patch and repair with glue
- Eco-friendlier due to its long lifespan
Cons
- Higher upfront cost
- Heavier material compared to PVC
Best For:
- Tropical or high-UV regions (e.g., Florida, Gulf Coast, Australia)
- Commercial operations
- Frequent or full-time use
Real-World Example:
Top-tier RIB manufacturers and re-tubing specialists such as A.I. Boats use Orca 866 Hypalon—a premium, multi-layered fabric designed for high-performance boats.
Grades to Know:
- Orca 215, 820, 828 – For standard-grade use (990D–1100D-Tex)
- Orca 866 – Heavy-duty, 1500 denier fabric ideal for harsh climates and extended use
These fabrics have been tested for over a decade in commercial settings and are often chosen for military, rescue, and offshore operations.
Search Keyword Used: Orca 866 Hypalon re-tube, Hypalon grades for RIBs
Side-by-Side Comparison:
| Feature | PVC | Hypalon (CSM) |
| Cost | Low | High |
| Lifespan (Cool Climate) | 3–5 years | 15–20+ years |
| Lifespan (Hot Climate) | 1–2 years | 10–15+ years |
| UV Resistance | Poor | Excellent |
| Chemical Resistance | Moderate | Excellent |
| Maintenance | Moderate | Low |
| Weight | Light | Heavier |
| Repairability | Difficult (heat welds only) | Easy (glue patches work well) |
| Eco-Friendliness | Low (shorter lifespan) | Higher (longer lifespan) |
Why Material Choice Impacts Your RIB Investment
Choose PVC If:
- You’re on a tight budget
- You use your boat occasionally in freshwater
- It’s stored indoors or out of direct sunlight
Choose Hypalon If:
- You boat in tropical, sunny, or saltwater environments
- You want your RIB to last 15–20 years
- You plan to use the boat often or commercially
Search Keyword Used: PVC boat tube problems, Best material for inflatable boats
Expert Advice: Maximize Your Tube Lifespan
Here’s how seasoned marine professionals recommend you get the most from your boat’s fabric:
- Climate Match: PVC fails quickly in hot, sunny conditions—Hypalon thrives
- Storage: Keep any RIB out of direct sunlight whenever possible
- Cleaning: Rinse after every saltwater use and use tube-safe cleaners
- Inspection: Look at seams and valves regularly, especially on PVC boats
- Retubing? Ask for Orca 866 Hypalon to get top-tier performance
Final Verdict: Hypalon Wins for Long-Term Value
If you’re looking for the best inflatable boat material, Hypalon (CSM) is the clear winner for performance, lifespan, and repairability. While PVC is a great entry-level option for light use, it simply can’t stand up to the rigors of real-world marine environments over time.
Investing in Hypalon, especially premium options like Orca 866, ensures your RIB will go the distance—saving you money and giving you peace of mind for years on the water.
About the Author
Rob Creemers
President, Ai BoatsRob Creemers has led Ai Boats, one of the top-rated RIB service and re-tubing companies in the U.S., for over 12 years. With extensive hands-on experience in marine fabric technology, Rob helps boat owners make smart, long-lasting investments in their vessels.
