building a better deck & rail: using trends, installation, and design elements aia continuing...

Building a Better Deck & Rail:Using Trends, Installation, and Design Elements

AIA Continuing Education Program Provided By:



Overall Course ObjectivesAfter this program, learners will be able to:

– Select the right material for their needs by recognizing the different Decking and Railing Categories

– Identify five characteristics to consider when selecting decking or railing materials within the different categories

– Identify Market Trends of Decking and Railing

• Market Size

• Life Cycle Costs

• Anticipated Growth

– Identify Installation Trends of Decking and Railing

– Identify the three most notable code listing agencies

related to decking and railing

• Reports each listing agency provides

– Benefits of Reports

– How reports work on a Job Site

– Identify support requirements as it relates to the Acceptance Criteria 174

– List three installation criteria as it relates to composite decking and railing


Selecting the Right Material


Three Decking and Railing Categories

• Traditional Wood– Pressure Treated Lumber– Cedar– Redwood– Exotic Hardwoods/IPE

• Wood Plastic Composite/PVC• Other

– Vinyl– Metal– Aluminum– Variety of other specialty materials

US decking and railing markets can be divided into three broad material segments:

WPC Deck

Redwood Deck


Five Decking and Railing Considerations

In comparing the decking and railing

categories and their specific functions, this presentation will cover five specific considerations that focus on the application of your project:

• Safety

• Maintenance

• Color/Appearance

• Longevity

• Environmental Impact


Pressure Treated Lumber

• Safety– Slippery when wet– Will considerably check/split after 15 years of

exposure– Potential health hazard when burned– Over time splinters may occur– Chemicals in pressure treated lumber may degrade

the fastener and create screw shear

• Maintenance– Requires annual cleaning and reapplications of

staining and sealing

– Possible screw corrosion • Colors

– Stain to desired color– Purchase pre-stained

Pressure-treated lumber (PTL) will continue to benefit from its low cost, wide availability, and familiarity to both consumers and contractors.


Pressure Treated Lumber

• Longevity– Average Lifespan: 15 -20 years

• Some pressure treated products have a warranty beyond this but will need significant maintenance to keep it safe and aesthetically pleasing

• Environmental Impact– Supply & Demand Issues– Vast majority of PTL was treated with CCA – a chemical

preservative and pesticide regulated by the Environmental Protection Agency (EPA)

• Now Prohibited• CCA has been replaced by other EPA approved

preservatives

Pressure-treated decking and railing has lost market share to wood-plastic composites and other alternative materials, as these alternatives do not require the ongoing maintenance associated with pressure-treated decks and rails.


Redwood

• Safety– Class B Flame Rating

• Maintenance– Wash at least once a year– Seal with a preservative sealer

• Colors– Ranges from light red to dark reddish brown but

weathers quickly to grey

Redwood decking and railing is available in over 30 grades determined by quality and appearance.


Redwood

• Longevity– Average Lifespan: – 20 plus years if maintained

• Environmental Impact– Tightened harvesting restrictions– Tightening supply of high quality grades– Harder to obtain in the market

Redwood decking and railing is associated with a number of performance characteristics that make it well suited for many diverse applications.


Cedar

• Safety– Natural resistance to decay and insects

• Maintenance– Wash at least once a year– Seal with a preservative sealer

• Colors– Ranges from light amber to a deep honey brown

and will weather to a silvery gray or dark brown if left untreated

Red cedar is available in a variety of different grades that vary significantly in price, appearance and performance characteristics, largely as a result of the amount of heartwood contained.


Cedar

• Longevity– Average lifespan: 10 – 30 years

• Due to less availability of heartwood lumber which shortens lifespan

• Environmental Impact– Deforestation– Depleted supply of old growth

Features of cedar decking and railing include it’s light weight and the ability to be easily worked.


Exotic Hardwoods/IPE

• Safety– Natural resistance to insects and decay

• Maintenance– May require staining & sealing– Can be treated with a UV-resistant coating to

preserve the natural color– Installing has increased labor costs due to

pre-drilling

• Colors– Ranges from red-amber to dark brown

Ipe is an extremely dense, tight-grained wood ranging in color from red-amber to dark brown and virtually clear from knots.


Exotic Hardwoods/IPE

• Longevity– Average Lifespan: 25 year plus if

maintained

• Environmental Impact– Deforestation issues– Some woods are rare in the environment– Harvested in countries with fewer

environmental restrictions

Exotic hardwoods are primarily used in non-building applications such as boardwalks and marinas, in which the favorable performance qualities of the decks outweigh their higher initial costs.


Wood Plastic Composite

• Safety– Skid Resistant– Splinter Free– No harmful staining or sealing solvents– No rot or decay

• Maintenance– Low-Maintenance

• No Annual Staining or Sealing Required• Needs Periodic Cleaning

Composite decking and railing markets benefit from the widespread trend of growing consumer interest in materials with reduced maintenance requirements, as well as desire for materials that look like wood but have a higher durability.


Wood Plastic Composite

• Colors– Wide Variety– Color fading depends on the environment and

the manufacture's materials– Some manufacturer’s use reflective, inorganic

pigments to develop colors that reduce heat buildup

• Longevity– Average Lifespan: 25 plus years

• Environmental Impact– Recycled materials are often used– Installed once versus multiple re-planking

In addition to wood and plastic raw materials, composite decking contains various additives used to improve performance and processing.


Plastic

• Safety– Potential health hazard when burned

• Maintenance– Easily Maintainable

• No annual staining and sealing required

• Needs periodic cleaning with water

• Colors– Wide Variety available– Stable & Consistent

Other alternative materials used in the US decking and railing industry include; vinyl, polyethylene, plastic, aluminum, and a variety of other specialty materials.


Plastic

• Longevity– Average Lifespan: 25 plus years

• Environmental Impact– Not Biodegradable

Plastics and other materials will benefit from increasing penetration in the key residential market as a result of product developments aimed at improving aesthetics and feel.


• Sustainability– Some alternative deck manufacturers incorporate recycled materials into their products– Many manufacturing processes eliminate waste and reuse as many resources as possible

• Fire Resistance– Fire regulations and codes continue to become more important in the building industry.

Other Considerations

With the growing awareness of environmental impacts, many building product companies are changing practices to become more sustainable and offer safer products for the environment.


Decking and Railing Market Trends


Decking and Railing Market

Market Size

• Estimated $3.0 billion in 2009– Total Decking and Railing Market

• Includes – PT Lumber, Softwoods, Hardwoods, WPC,

Plastic Lumber, Rigid Vinyl, Metal

• Yearly increases in demand for WPC for both decking and railing.



Market Breakdown(2009 Estimated Manufacturing Sales by Dollar

Volume Percentage)

Wood-PT Lumber, Softwoods, HardwoodsWPC/PlasticOther-Rigid Vinyl, Metal, etc.

Decking: $1,647.8

Wood – 57%*

WPC/Plastic – 38%*

Other – 5%*($Million)

Railing: $1,272.5

Wood – 64%*

WPC/Plastic – 12%*

Other – 24%*

Decking Market

Railing Market

57%38%

5%

12%

24%

64%


WPC 8%

2000

PLASTIC 9%

WPC 36%

PLASTIC 5%

2010

WOOD 87%

•WPC is projected to be 36%* of total ($3.0 billion)•Approx. 18% APR growth 2006-2010

WOOD 56%


•WPC was 8%* of total D&R market in $ volume ($286* million)•Approx. 25% APR growth 2000-2005

2009 Decking & Railing Market: Est. $2,920 ($Million)


Life Cycle Cost Comparisons By Decking Material (12 X 18 foot deck)

*Deck boards & Standard Railing Only, does not include cost for substructure, footings, or fasteners

** This model accounts for materials costs only, NOT installed costs and labor

Maintenance costs include the cost of cleaner, preservative, stain and pressure treated washer rental

Costs WPC PTL Plastic Redwood/Cedar

Hardwood

Total Deck Cost($)

$3,900 $2,540 $4,400 $3,250 $4,165

Annual Maintenance ($)

$75 $375 $75 $375 $375

Five Year Ownership Cost($)

$4,275 $4,325 $4,775 $5,125 $6,040


The Advantages of Alternative Decking and Railing

• Several Performance Advantages– Durability – longer life expectancy– Lower Maintenance Requirements– Color Retention– Mold and Mildew Inhibitors

• Appearance– Multiple profiles, colors & finishes to choose from– Consumers desire non traditional materials to look like

natural products

• Some manufacturers have created products that represent the hardwood look

Demand for wood-plastic composites and other alternative materials will continue to benefit from growing consumer awareness and product availability in lumberyards.


Increases Home Value

BEFORE

Remodeling Magazine’s 2006 Cost vs. Value Report estimates a national average of a 76.8% return on investment for deck additions

AFTER


Design & Installation Trends


Design Trends

• Inlays• Planter Boxes/Benches• Multiple Deck Levels• Accessories

– Lighting– Railing– Hidden Fastener Systems– Deck Drainage System

Design elements provide value to the deck and improve the aesthetic appeal.


Design Trends

Inlays allow for design versatility

• Can be created with most Wood Plastic Composite Materials

• Contrasting Colors are often used

• Framing and blocking dependent upon design

Inlays


Design Trends

Inlay Photo Gallery


Design Trends

Planter boxes and benches add value and functionality

• The sizes are similar to dimensional lumber

• Multiple designs are possible

Planter Boxes/Benches


Design Trends

• Multiple deck levels allow the opportunity to segment the outdoor living space.

• Allows for outdoor kitchen space

Multiple Deck Levels


Design Trends

Lighting is often used as a safety mechanism and adds ambiance.

• Many local codes require lighting

• Increases the Usability

• Low voltage and solar type lighting available

• Products are made from vinyl or aluminum and come in different styles and colors

• Easy to install and very little maintenance required

• Products often include post top module lights and accent lighting for the front and sides of the posts

Lighting

Accent Light


Design Trends

• Adds Unique Design & Style– Decorative Centerpieces, Post Caps, & Pipe Railing

• Variety of Materials Available:– Vinyl– Metal– Wood– Wood Plastic Composite– Cable– Glass– PVC Wood Railing

• Many WPC and alternative deck manufacturers have matching rail systems

Railing


Design Trends

Glass Railing

Cable Railing

Wood Railing

Railing Photo Gallery


Design Trends

PVC Wood Railing

WPC Railing

Metal Balusters

Railing Photo Gallery


Installation Trends

• 30% increase in demand for hidden fasteners• Generally installed between planks• Allows the plank to be the focus, not the

fasteners• Controls uniform gapping• Some fasteners can be installed using a

pneumatic gun

Hidden Fastener Systems provide a seamless, nail and screw free surface that preserve the beauty of the deck board and highlight the investment in premium composite materials.

Hidden Fastener Systems


Installation Trends

Hidden Fastener Systems

1

2

31st Plank

Hidden Fastener

Additional Planks

Relax4


Installation Trends

• Easy installation with no visible screws

• Some product profiles span 24" on-center for reduced structural needs

Tongue & Groove is a product advancement that allows for ease of installation and maximum span ability.

Tongue & Groove


Installation Trends

• Some products secures to the joists of any new or existing deck with 12" and 16" on-center joist spacing

Deck Drainage Systems provide leisure and storage space for second story deck applications.

Deck Drainage System


Challenge Your Creativity


Technical Guidelines


Code Listing Agencies

The most notable are:– ICC-ES– Architectural Testing, Inc.– Underwriters Laboratory

In the past, wood plastic composite and plastic composites have not been addressed directly in the building code. However, as of 2009 the IRC has added these materials to the code. A significant amount of work is still underway to complete this process, but definitely a step forward. Currently there are several listing agencies that conduct code compliance evaluations.


Code Listing Agencies

• If a product complies with code requirements, the listing agency publishes a report to that effect

– Each listing agency issues different types of reports.• ICC-ES issues: Evaluation Service Report (ESR)• Architectural Testing, Inc. issues: Code Compliance Research Report

(CCRR)• Underwriters Laboratory issues: UL Listing

• The report is then available to the public and local building officials

• The local building officials use the reports to evaluate the given products suitability to the given application


Technical Evaluations

Under this criteria, materials are evaluated for:– Stiffness & Strength– Ability to withstand environmental factors– Evaluated for

• Termite Damage• Decay• Fire Performance

Each code listing provides technical evaluations of decking and railing products based upon Acceptance Criteria 174 (AC 174)


Support Requirements

• Decking materials are evaluated to a minimum span/load combination of 16” at 100 pounds per square foot

• Railings for residential use are evaluated to a design load of 200 pounds

For other than 1 & 2 family dwellings under the IRC: •In addition to the 200lb design load, the railings are also subjected to a minimum of 50lbs per linear foot in a uniform load test.


Support Requirements

For railings:

• This is a minimum of 500 pounds in residential applications and 125 pounds per foot for non residential application

• That is 1000 pounds on an eight foot section of rail!

The deck spans and rail test loads are subject to safety factors of two and a half and any environmental adjustment factors based upon test results


Benefits of Certification

• Product Liability Issues– The certification ensures that the product has been produced and tested accordingly

• Traceability– The certification has a paper trail that enables it to be traced from the job site to the

raw materials

• Safety– The certification process requires the product to be tested as a system (railing)– Provides a higher degree of confidence in reliability


How Listings Work on the Job Site

• Labeling & Packaging– Allows the field inspector to verify that the

materials have met the appropriate requirements

• Installation– Products are to be installed per the

manufactures instructions


Installing Wood Plastic Composite

• Tools– Saw Blades (should be new, sharp and

clean); PVC specific saw blades– Drills

• Difference:– Typically have higher thermal expansion

coefficients and need to be spaced at both the ends and edges of the boards to allow for expansion and contraction

Wood Plastic Composites are as easy to install as wood using:


Gapping

• Allow 1/8” minimum gap between the end joints of planks and 1/4” minimum gap where the planking meets an adjoining structure

• Refer to the manufacturers installation & maintenance guide for detailed instructions

• Many of the hidden fasteners on the market today provide the needed gap spacing for the manufacturer specific product.


Joist Span

• Generally the joist spacing on residential and commercial applications is 16” on center

• Some Wood Plastic Composite manufacturers can span up to 24” on center

• Check with the manufacturer on specific details for their profiles


Railing—Planning and Installation

• Make railing part of the design element, not an afterthought. Pay attention to stair locations and proper spacing of each railing section.

• Plumb 4x4’s or support posts are critical in achieving a dimensionally and physically sound railing system.

• Double check both manufacturer installations and code listing specifications to ensure compliance.

• Consult your local building official regarding any specific regulations for the designated area of construction.

• Measure Twice, Cut Once!


Care & Handling

• Storage– Store WPC products under cover to

maintain a clean surface

• Stacking– To decrease damage of the product, stack

the units with banding and bottom supports aligned

• Handling– Carry planks on edge for better support– Never dump materials when unloading


Care & Cleaning

• Requires periodic cleaning

• Does not require painting, staining, or sealing

• Scratches, nicks, cuts & grooves– Varies by product

• To Combat Mildew– Maintain a clean, dry deck surface


WPC Warranties

• On average: 10 – 25 years; some are pro-rated.

• Generally includes splinter, cracking, rotting & warping

• Check with the manufacturer on specific warranty information


THANK YOU

Questions?

Thank you for taking the time to familiarize yourself with composite decking and railing!

building a better deck & rail: using trends, installation, and design elements aia continuing...

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