The Deck Handbook (Continued):

Composite Deck Materials

Courtesy Epoch Composite Products, Inc. This Evergrain® composite decking is almost indistinguishable from the Ipe wood it imitates. Composite materials are commonly made How Much Does it Cost?

The first question we are usually asked about any deck material other than treated pine, is "How much more does it cost?". Here's the answer. These are the average prices in 2007 for a single level 16'x20' deck in the seven midwestern states as compiled by Remodeling Magazine. The price of materials has climbed quite a bit during the last year, so expect slightly higher prices today.

	Cost	Cost S/F
Treated Pine Deck
Build 16'x20' pressure treated pine deck with joists supported by 4x4 posts anchored to concrete piers. Install surface nailed pressure-treated deck boards in a simple linear pattern perpendicular to the joists. Include a built-in bench and planter of the same material. Include stairs, assuming three steps to grade. Provide a simple but complete railing system using pressure-treated wood posts, railings, and balusters. Does not include staining or sealing. Assumes level site and construction at ground level.
	$10,546	$32.96
Composite Deck
Build a 16'x20' composite deck using pressure-treated joists supported by 4x4 posts anchored to concrete piers. Install surface fastened composite deck material in a simple linear pattern perpendicular to the joists. Include a built-in bench and planter of the same composite material. Include stairs, assuming three steps to grade. Provide a complete railing using a matching system made of the same composite as the decking material. Assumes level site and construction at ground level.
	$15,368	$48.03

Other Factors Affecting Deck Prices

Size:	A larger deck is a more expensive deck.
Fastening:	Fastening through deck boards is faster than using hidden fasteners.
Height:	It takes nearly twice a long to build a deck working from ladders or scaffolding
Stairs:	Building a strong, good looking staircase takes time.
Railings:	Railings also take time, and the fancier and more involved the railing, the more time they take.
Levels:	Multi-level decks require more framing, take longer to build, and cost more than single-level decks.

of a combination of wood fibers and plastic bonded under great pressure. The theory is that the wood fiber helps the plastic resist UV deterioration while the plastic coats the wood to resist fading and insect damage. The practice is getting closer to the theory, but the products are not perfect yet (See "GeoDeck Products Recalled" below). Composites are offered in a huge and growing variety of different textures, colors and styles. Many look so much like wood that you actually have to get nose to the deck to tell the difference. One product, EON decking, defies even this very close examination. It almost looks more like wood that actual wood does.

The perceived advantage of composite materials is their relatively low maintenance. This has been oversold, however. There are no "maintenance free" decking materials. Every material needs at least an annual washing. Trex got in trouble (see sidebar) because its promoted its material as no maintenance, which proved not to be the case. Mold, mildew and dirt attack every deck - plastic, metal, wood or composite.

Moreover, the maintenance difference between wood and composite decks is shrinking rather rapidly. New multi-year and even "lifetime" sealants and coatings can make wood decks about as worry free as the best composite, and for a lot less cost. (See "Staining and Sealing"). So at this point the choice of composite deck is cosmetic rather then functional. If you like the look of a composite deck better than a wood deck, then that's what you should get. Don't look for any substantial maintenance savings over a properly sealed wood deck, however.

Composites may be used for deck flooring, railings, balusters and benches, but are not nearly strong enough to be used for structural support. Composite materials also have environmental benefits as they are often made from excess wood chips and plastic that have been recycled. But they are not fire resistant and can give off toxic fumes when burned.

GeoDeck Products Recalled
August 16, 2005

Proving that not even the best product testing is fool proof, the GeoDeck composite decking products top rated in 2004 by Consumer Reports have been recalled for safety issues.

The Consumer Products Safety Commission announced a voluntary recall of certain GeoDeck products for dangerously rapid degradation, especially in hot climates. Although no-one has yet been hurt, the recall was prompted by several hundred confirmed reports of composite deterioration to an unsafe condition.

For more information and to see if your deck qualifies for the recall, visit GeoDeck Recall Information.

Trex Settles Product Lawsuits
September 14, 2004

Trex and Exon-Mobil (the former owner of Trex) have agreed to settle a class action lawsuit. The suit claimed that Trex decking rotted, splintered and degraded, contrary to widespread advertising and marketing claims by the company, and that Trex failed to live up to its warranties against product defects. After initially calling the lawsuit "frivolous", Trex agreed to stop all advertising claims that its deck products do not require sealant and are maintenance-free. Trex also agreed to replace any defective product sold between 1992 and 2004. For more information, contact 1-800-289-8739 or question@trex.com.

Trex settled a similar suit by one of its large distributors in 2000 for fraudulent business practices in which it was claimed that Trex materials tended to "disintegrate, crumble, turn pink, turn blue, spot, bubble, blister, contain lumps, contain hidden defects such as metal objects .., or grossly warp if exposed to sunlight or weather" and that the company failed to honor its warranty. The actual settlement terms are secret. The number of composite manufacturers is large and growing daily. Probably the most well-known is Trex - with about 60% of the composite market - the 800 lb. gorilla of composite decking. Distributed through a dealer network and by the big lumber stores like Home Depot, Lowes and Menards, Trex probably has the widest variety of products, styles, colors, textures and finishes. It has had product reliability problems, however, and has been somewhat reluctant to honor its warranty when problems arise, resulting in at least two lawsuits by consumers. (see sidebar).

Less well known but scrambling to catch up is GeoDeck. Rated a Consumer Reports Best Buy in 2004, its products are amazingly realistic, durable and fairly easy to install. Still not at the do-it-yourself level, this ease of installation does translate into less labor and therefore lower initial costs for the deck owner.

Heat Retention

If you live in a place like most of Nebraska with very hot summers, you need to be very aware of heat retention.

A deck exposed to direct summer sun gets hot. A wood deck gets hot enough so that walking barefoot is mildly uncomfortable.

All composites and plstics get a lot hotter than wood. It's merely a function of density. Dense materials retain more heat and get hotter than non-dense materials. Wood contains a lot of air pockets, so it is not nearly as dense as composites. Composites and vinyl decking get very hot — often to the point of being absolutely uninhabitable for the summer months.

This does not mean don't build a composite or vinyl deck on the sunny side of the house, but it does mean provide some shade. If natural shade from trees is not available, consider a pergola. EON decking is another up-and-comer. The only composite made without wood products. It is 100% plastics so it does not fade. In fact, it is so plastic that it probably should be classified as a plastic decking material like vinyl (See below). We are classing it with the composites only because the manufacturer and retailers classify it that way. Available in 8 wood-look colors, the material is so realistic it even feels like varnished wood. Virtually stain-proof. Even polyurethane varnish will not stick to it (something we found out purely by accident).

Expect composite decks to be a 60% to 400% more expensive than a treated pine (ACQ) deck. While the composite manufacturers suggest that because of longer life and virtually no maintenance, the 10-year cost of a composite deck is less than that of a wood deck (probably true), nonetheless, the up-front cost of a composite deck can be somewhat daunting.

Benefits and Disadvantages of Composite Materials

• Resist discoloration, rotting, deterioration and splintering, but do not wholly eliminate some of these defects. Composites that contain wood fiber can be expected to fade over time. Some have been found to seriously deteriorate in certain climates (See sidebars, above). Just how healthy and environmentally friendly is this stuff?
  
  On the surface, composite materials look mighty un-"green" with lots of unpronounceable chemicals, some of which can be highly toxic. So, are you trading convenience for some sort of ecological disaster when you select composite decking materials?
  
  Ehhhh, probably not. But some of these products are a lot greener than others. For a complete report on the environmental impact of various plastic and composite materials by the non-profit Healthy Building Network go to Guide to Plastic Lumber.
• Require little maintenance, much less than most unsealed natural wood. An annual washing is usually all that is required - regular washing, most manufacturers do not recommend power washing. Most do not need to be sealed, but some do (See "Trex Settles Product Lawsuits" in the sidebar). However, with the new coatings and sealers available for natural wood decks, the maintenance difference between composite and sealed wood decks has almost disappeared.
• Are largely immune to infestations by termites and other wood-destroying pests. Since they are mostly plastics, wood-loving pests leave them alone.
• Can be often stained or painted depending on your budget or aesthetic preference.
• Resist warping - but how much depends on the product. Trex, for example, has reputation for warping; EON for being highly warp resistant.
• Some are notorious in wet climates for growing mold and mildew. Lighter colors show dirt. Unlike wood, dirt does not penetrate into the material, but stays on the surface where it is very visible, and can be very slick to walk on.
• Retains more heat than wood.
• Pricey and more labor intensive to construct than wood.

Conclusion

Composite materials should be your choice if a higher initial cost is not a problem and a balance of appearance, low maintenance, durability, and long life are your objectives. But do your research and choose a composite that works best in your climate — or contact us and we will do the research for you.

Vinyl and Plastic Decks

Courtesy Royal Crown Limited This striking Dec-Lok® vinyl deck is almost maintenance free. The most common plastic used in decks is vinyl. Vinyl (PVC) is a synthetic material used in the construction industry for siding, window frames and flooring. It has become an increasingly popular choice for deck components because of its very low maintenance. The material is not strong enough to be used for structural support but is great for deck flooring and railings – the parts you can see.

Vinyl offers its own distinctive appearance that many believe that to be its downfall. It looks like plastic. As far as we know only EON has mastered making plastic look like wood. Manufacturers have gone to a lot of effort to make it look more like painted wood, but their results have not yet reached the level of sophistication of the vinyl siding companies whose products are often difficult to distinguish from wood except at very close range. (By the way, vinyl guys, embossing vinyl with woodgrain merely makes it look like embossed vinyl — real painted wood seldom shows woodgrain. It shows brush strokes if anything). Vinyl is offered in only a relatively few colors, but its range of neutral and attractive colors will match the decor of almost any home.

Vinyl planks used as decking typically are embossed with treads that enhance the look of the deck, maximize traction and disguise wear. Without them vinyl is slippery. Planking is usually installed using an aluminum or vinyl track that allows the planks to be easily snapped into place — a definite plus for the do-it-yourselfer.

Vinyl is not usually strong enough for newel posts. What looks like a vinyl post is often a wood post covered by a vinyl wrapper. However, recently manufacturers have started offering railing kits that feature posts strong enough to comply with the national building codes. These do not need wood reinforcement. For short lengths, vinyl will work as a railing and vinyl balusters are sufficiently rigid to stand on their own.

Benefits and Disadvantages of Using Plastic Deck Components

• Does not warp, rot or splinter.
• Immune to wood-destroying insects.
• Does not need to be stained.
• Virtually no maintenance. An annual washing will usually suffice.
• Will keep its color without fading. Most products are warranted against fading for the lifetime of the owner.
• Stain resistant.
• Has a somewhat better resistance to fire than wood, but if it does burn produces toxic gases.
• Posts covers, railings and balusters (but not deck boards) scratch and mar fairly easily which can be a problem in heavy traffic areas.
• Retains more heat than wood and most composites. The most heat-retentive material. Not suitable for sun-side exposure in hot climates unless shaded.
• Pricey and more labor intensive to construct than wood.

Conclusion

Plastic should be your material of choice if its higher initial cost is tolerable, the look of "painted wood" complements your house and you want the lowest level of lifetime maintenance possible with today's materials. For a plstic that looks like wood, try EON, but be prepared to pay the price.

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Last revised: 12.08.07