The Evolution Of Composite Decking

Today decks are a must-have for the modern home, but they have been around for more than five decades providing a space for families to enjoy the nature and space common to backyards.

The growth and diversification of the entire decking industry have been significant with changes in technology and availability due to globalization. Here we will focus on the inception and evolution of composite decking.

Regarding composite decking, it’s important to differentiate between the first, second, and third generations which have had marked changes in their structure and success.

At the beginning of the ‘90s, it became apparent that there was a scarcity of trees due to deforestation affecting the availability and price of timber for decking. The innovation in response to the necessity came in 1992 when Trex created the composite decking board which combined wood and plastic.

These decking boards were produced using reclaimed plastics mixed with a ground or shredded wood filler. They were intended and sold as an exceedingly durable and low-maintenance alternative to the wood planks which required treatment during and after installation.

Composite decking enjoyed rapid growth early on thanks to these selling points, becoming very popular with homeowners. However, there were unexpected challenges in the application and long-term use for this brand-new product.

In the first generation composite;

• The organic material that was exposed allowed the growth of mold and mildew leading to de-lamination.
• The mixture of wood and plastic was not as stiff as timber planks which forced contractors to build a more comprehensive substructure to support the boards.
• The traditional decking screws used on composite boards would cause a mushroom effect around the head of the screw which could be beaten down but added time and cost to the project.
• Composites would sag, crumble and crack over time when exposed to direct sunlight.

So alongside massive growth, there was a dissatisfaction that the product didn’t fulfill its initial promise to installers and homeowners. On top of all this, owners typically paid twice the price for composite materials as the expectation was that of a superior product with a longer lifespan.

At the turn of the century, after the explosion in popularity, the second generation of composite decking was introduced as the number of products grew substantially due to new technology.

Some companies decided to remove the organic wood component from the composite decking and use only the plastic component; these were called plastic or PVC decking materials. Coming up with solutions to the problems inherent in composite decking boards caused a new set of challenges with the variety and inconsistency of the products being produced.

PVC deck boards had some shortcomings as they would become brittle or start sagging over time, split with temperature fluctuations, and still suffered mold growth in environments where they were always wet. There were advances however in making the deck mimic timber in better ways with printed or embossed wood grains and limited discoloration due to sunlight over time.

In 2009 the third generation of composite decking was conceived that combined the durability and environmentally recycled plastic along with the organic wood. The new method of creating composite boards utilized what was called cap stock.

By wrapping the organic mix of material in the core with a weatherproof plastic barrier the third generation of composite decking allowed for the continued and sustained growth of the entire product category.

The capping made it possible to create stronger and more resilient decking containing UV inhibitors, anti-oxidants, and colors added at just the right time. The composite board is either covered by plastic on three of six flat surfaces, or four of the six sides as it allows for easy moisture transfer between the deck board and the environment.

Capped composite decking is more expensive than traditional composite and timber decking because of the more involved manufacturing process in adding the second, co-extruded layer to the board. As end-user expectations have evolved, manufacturers and materials suppliers have worked hard to keep pace.

In summary, the evolution of composite decking has been challenging and reflected the benefit of increasing and new technologies to benefit both manufacturers and homeowners to result in a quality product.

Ask your manufacturer or supplier which generation of composite decking they carry and whether they have cap stock because an investment in your garden or outdoor space should last you and bring you as much enjoyment for as long as possible.

Author Bio: After many years in the carpentry industry, Adrian founded Decking Perth to help Perth become smarter decking buyers.

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