Dual layer construction is is the “cost is no object” inflatable layup, as it involves additional materials and labor to build the board. It starts with an inner bladder made with single layer construction, but then the entire bladder is laminated with an additional sheet of PVC coated fabric. Boards made this way are superior in durability, rigidity, and rocker profile control and are more difficult to puncture and less prone to leakage since they have additional coating layers between the fabric sheets. The additional layer adds about 3-4 lbs to board weight and a significant increase in material cost. This construction can be used to produce a board that feels extremely well balanced and grounded underfoot.
Technically, fusion material also has two fabric layers, but it should be noted that there is a distinct difference between fused material (two layers of fabric fused at the raw material stage, with a single coating applied to the outside surfaces) and actual dual layer construction, in which a second distinct layer of PVC coated fabric is laminated to the board. Dual layer construction generally adds about 3-4lbs to the weight of a board, so comparing board weights can help you discern whether a board is truly made with two distinct layers of PVC coated fabric or if a brand is advertising with creative wording to imply additional layers that don’t exist.
While some manufacturers may be using use similar materials, different methods of constructing the board can make the most impact on the longevity and performance of a board. ERS uses dual layer construction in the V3, Whitewater V3 , and River Surfing series boards, using proprietary construction and assembly methods.