Composite Deck

Follow Me on Twitter.

By Tim Carter
©1993-2010 Tim Carter

Summary: There are many factors to consider when selecting composite decking. Not all composite decks are made the same. Some newer composite deck materials contain recycled materials. Not all composite decking have the same density and strength.

DEAR TIM: Composite decking has been on the market for some time. A friend has a composite deck, but it looks shabby and faded. Were composites decks oversold with respect to performance? I’m tired of maintaining my wood deck, but am worried about what composite decking material to purchase. I did some research and discovered that there have been class-action lawsuits, some companies have gone out of business and other products have been pulled off the market by the manufacturers. What do you think is the best composite decking on the market at this time? Sandra G., Monroe, GA

DEAR SANDRA: There are thousands of consumers out there that feel your pain, and thousands more who are suffering because they have composite wood decking that doesn’t look at all the way it did when it was first installed. In fact, the house I’m in right now has a composite wood deck that was installed by the previous owner seven years ago. The finish is blotchy, the exposed wood fibers are gray instead of brown and it’s not the best looking deck by any means. But does this mean I would never have composite decking materials installed on one of my jobs or on another home? No is the answer. Get the right product and you’ll be happy for quite some time.

You can see the weather beaten gray wood fibers in this older composite deck. The new sample piece has a coating that shields the wood from the damaging effects of sun and water. PHOTO CREDIT:  Tim Carter
You can see the weather beaten gray wood fibers in this older composite deck. The new sample piece has a coating that shields the wood from the damaging effects of sun and water. PHOTO CREDIT: Tim Carter
If you continue your research, you’ll discover that there are many manufacturers of composite deck boards and composite deck railing. Some might say that there are too many, and that we’ll see more companies disappear or get folded into the stronger brands. Be aware of this possibility, and that if you purchase a product that succumbs to market pressure, you may not be able to get replacement material or your warranty can be of little value.

Once you understand how composite decking is made, you can begin to understand why there have been failures and disappointment. It’s most basic form, composite deck boards are made by mixing wood fibers and plastic. It’s similar in some respects to concrete which is a combination of large and small stone, sand, Portland cement and water. The plastic in composite decking is the binder, while the wood fiber acts to provide strength. But be aware there are vastly different grades of plastic and wood fibers. If you start with low-quality ingredients, you end up with a substandard product.

But it’s even more complicated than that. Some of the past failures of composite materials has been traced to the fact that the plastic has not been able to encapsulate and soak into the wood fibers. Water in the wood is usually the demon. Water and plastic repel one another in the manufacturing process. What’s more, if water is in the tiny wood fibers, the plastic simply can’t get to where it needs to go. The top composite decking materials contain wood fibers that are as dry as the Atacama Desert, considered by many to be the driest place on the planet.

But even with the best wood fibers, the best plastic and the best manufacturing process, you can still get a product you might not be happy with. Many of the composite materials end up with exposed wood fibers at the surface. These will discolor over time, and they probably will rot away as they get wet.

One of the most interesting products I’ve seen lately is a composite decking material that uses lots of recycled plastics, high-quality bone-dry wood fibers and has a protective layer of embossed plastic that has a deep wood grain and completely covers the top and sides of the decking. This coating eliminates the possibility of exposed wood fibers and all the issues that go along with it. Because of it’s high amount of recycled plastic content, it’s perhaps one of the greenest composite decking choices you can make.

Be aware that there is no such thing as maintenance-free decking. You’ll still have to wash your deck periodically to remove dirt and mildew. Often regular liquid dish soap and water will do the job. Be sure to always use the cleaner recommended by the decking manufacturer. If you have mildew problems, understand that trees surrounding your home release aerosol sugars that are food for mildew. Regular dirt and dust can also be food sources. Don’t blame the decking material if you have mildew, as it’s Mother Nature’s fault.

Be very careful when you make your purchasing decision. Not all composite decking products have the same density and strength. Some products can be easily dented with a hammer or incur damage from objects you might drop. I urge you to buy just one piece of all the products you’re thinking of using. Do your own drop tests using common things you might carry on your deck like a filled propane container, tools, etc. Drop them onto your sample pieces and see what happens. Pound the materials with a common hammer.

Cooking grease can be a real issue. If you have a composite deck that has exposed wood fibers, the grease can soak into the wood fibers. Use an oxygen bleach and warm water to get rid of these stains. The oxygen bleach will also remove the gray coloration from any exposed wood fibers if you own a weathered composite deck.





Comments:

Brian
01 Jun 2009, 10:36
Tim - Thanks for the overview. Based on your research, do TimberTech and Correct Deck have the dry wood fibers and protective layer covering the decking?
AsktheBuilder
01 Jun 2009, 12:14
Brian,

You'd have to check Timber Tech. I know the CorrectDeck has all of what I describe in the column. I visited the factory, saw the wood that was dry as a bone as well as the protective coating being applied.
Edie Kello
03 Jun 2009, 08:44
Tim, you are right on. Thank you for helping educate homeowners on the need to clean their decks, the differences in composite decking options and how newer choices deliver on the promises of the past. Composites provided decking that eliminated splitting, rotting and the need to stain or paint every few years. Now, newer technologies with durable, fusion bonded surfaces are eliminating the stain and fade issues and are looking more like natural, exotic hardwoods than merely painted wood. Consumers are demanding attractive products that perform and manufacturers are stepping up to the plate with beautiful, ultra low maintenance products. PVC decking also answers the need for a Class A fire rated product for fire hazard areas and is perfect for use near water since PVC does not absorb water. These alternative decking products offer a leisure space without the usual maintenance a traditional wood deck requires. Because of the recycled content and the durability of these products, alternative decking is truly a green and sustainable product that lasts for decades.
Toni Soale
03 Jun 2009, 15:26
Brian: I am the Interactive Marketing Manager for TimberTech, and I wanted to help answer your question as it relates to our product offering. We offer two types of decking products – wood plastic composite and cellular PVC.

Moisture is certainly a culprit of wood flour, but how dry it is can also be a function of the wood species. In our composite products, we use predominantly maple wood flour (maple being a hardwood), which inherently minimizes tannin or extractive bleeding. We have found it gives us the best long-term performance. Other manufactures may choose to use lower-end wood species, which can contain higher levels of moisture and cause some issues. We also dry the wood flour to our exact specifications prior to using it in our manufacturing process.

Tim was right on when he mentioned that density and strength is also important. TimberTech is one of the densest products on the market, and this also helps with water absorption.

Our PVC-based product, XLM, does not contain wood fiber at all. It has a PVC cap stock made from a proprietary formulation that is not necessarily a protective coating as suggested, but rather a combination of high-quality raw materials that have been carefully engineered through years of R&D. XLM is an “extreme low-maintenance” product that features excellent scratch and stain resistance and a Class A fire rating.

I hope this helps. If there is anything else you need, please let me know.

Pat M
05 Jun 2009, 11:01
Tim,
I am a representative of Trex and would like to make some comments on composite decking. The process is continually evolving to make a better product, but density does not always relate to better wood encapsulation, and has a negative effect on truck rates and builders ability to carry material. At Trex, we strive to be a green product and the density or weight of product is always a consideration. There have been considerable improvements made by Trex in all our products.
As far as drying the wood, it is practically impossible to extrude a wood fiber than contains moisture (because the moisture will boil and therefore expand and cause an ascetic defect in the product), so at the time of manufacture, the wood used to extrude should all have negligible amounts of moisture, regardless of product. I do agree that wood species must be considered when engineering a product, and that is why Trex is constantly looking for the best wood to provide our customers. But, we must keep in mind that Trex's philosopy is to be eco-friendly in our products and practices - while not sacrificing quality.
I also agree that mold is not a composite problem - but an environmental issue.

Pat M
Trex Company
joan sutherland
07 Jun 2009, 14:46
I am interested in all messages about decking, especially composite as we are in the process of deciding what to use in replacing our deck.
mcandru
09 Jun 2009, 10:57
Researching composite decking materials.
Scott
09 Jun 2009, 13:54
Hi Tim,

I was wondering if you have an opinion of Latitudes Composite Decking. I like that their decks have hidden fasteners so you don't see the screws. But as far as quality goes, how does it compare to Trex?
Pat M
09 Jun 2009, 15:56
In response to your interest in a smooth deck surface finish, I would direct you to look into our Trex Hideaway fastners. Trex offers grooved boards in Trex Brasilia and Accents that can be used with our Trex Hideaway fastening system. This system delivers a fast and easy installation process that allows for a clean, superior, fastener-free deck surface.
Pat M
Trex Company
AsktheBuilder
10 Jun 2009, 06:19
Scott,
I can't render an opinion of Lattitudes as I haven't see the product. Understand, as I said in the above column, there are varying levels of quality in composite decking materials. By no means are they all the same.

Get samples of all you're considering and start to test them for scratch resistance, hammer blows, exposed wood fiber, etc. Many products have hidden fasteners. The CorrectDeckCX product had a cool one that is installed on the top of the joist. Look for a fastener that can be accessed from the top of the deck in case you ever have to replace a board.

     View all comments
*Name:
Email:
Notify me about new comments on this page
Hide my email
*Text:
Security Image:

Visual CAPTCHA


 
Contact us to Advertise on this site.
Have a Suggestion?
Do it right, not over!

Ask the Builder Comment Help

Thanks for stopping by! The Comments Section of my AsktheBuilder.com website are a place for you to share stories about how you've solved a similar problem at your home or carry on a conversation with other visitors. I tried, at the beginning, to be part of the conversation, but there were too many questions being asked and it was impossible for me to keep up and get my regular work finished each day.

If you want to ask me a direct question, you should go to the Ask Tim page of this website.

Helpful Comment Tips: If you need help with a problem, please try these things now before you type in a comment. You could discover your answer in just minutes.
Don't show this alert again.