V3. Nov 20 13 Dura Deck Timber Composite Decking Installation Manual and Care Guide Strong and durable, Dura Deck looks and feels like natural wood and its unique formula provides longer lasting decking that is environmentally friendly, easy to install and requires minimal maintenance. Although Dura Deck is easy to install for the very best results we would always recommend that a professional installer is appointed these instructions are further explained in our video on You Tube. If you require any further information, visit www.duracomposites.com or call us on +44
2 Dura Deck has been designed for its simplicity and ease of installation. However, to ensure long-term performance, we recommend that a professional trade person carry out the installation. The installation MUST be carried out in accordance with these instructions including the use of all fixings and accessories otherwise we cannot warranty the product. Dura Composites recommends that all deck designs be approved by a licensed architect or engineer before installation. Please be sure that your plans meet any relevant local building codes before you begin the installation. Safety First Keep children away from the work area until the job has been completed and tools have been stored safely. Refer to operator s manuals for safety guides of all power tools. When handling timber composites, always wear gloves and eye protection and work in a well-ventilated area. Do not burn timber composite off-cuts. Dispose of them safely as refuse. Wear goggles when pressure washing or scrubbing. Dura Deck is NOT intended for use as columns, support posts, beams, joist stringers or other primary load bearing members. 2
3 Dura Deck Parts Tools you will need Dura Deck boards Tape Measure Composite Bearers String Line Fascia Boards Level Composite Timber Screws Square Standard Fixing Clips Compactor Half Length Clips Sawhorse or bench Double Length Clips Extension cords Start/Stop Clips Drop down or circular saw (Any wood cutting blade can be used. Fine teeth are recommended for a professional finish) Anti-Tamper Clips Bearer Clips End Caps Electric drill or screwdriver Adjustable Pedestal 3
4 Deck Preparation 1. Choose the size and location of your deck First you will need to choose where you wish to install your deck, how large it will be, which decking boards you intend to use and in which direction you wish the boards to run. Be aware that very large or raised decks may require planning permission. Raised decks should not be built with the deck level more than 600mm above ground level without specialist advice. 2. Measuring the area Once you have decided on where your deck will be located, measure the length and width of the total area. Using a string line is a great way to measure and visualise your deck. Break down the area into smaller rectangles if you intend to build an unusual shape. 3. Deck Design Now that you know the size of your deck, next you must decide which deck board(s) you plan to use and which direction you wish the boards to run. Once you have decided this, you can determine the length and quantity of bearers required (note that we can supply composite bearers). Below is the range of Dura Deck planks. Type 146 Type 225 Type 295 Type 142 A traditionally sized board for a traditional A heavy duty, very strong board with a re- An extra wide board for a truly unique look. An interlocking plank design without a visible look, grooved one side and smooth sanded the versible grooved or wood grain finish. Spans up to Wider boards mean fewer gaps, faster installa- gap between planks. Spans up to 400mm other. Spans up to 400mm. 700mm. tion. Reversible with 2 groove options. Spans and is suitable for smaller residential ap- up to 600mm. plications. 4
5 4. Direction of the deck There is no correct deck direction it is purely personal preference. Things to consider: Think about where you or your guests will view the deck. Looking along the length of the boards will make the deck look longer, while looking across the boards creates an illusion of width. Would you rather the deck looked longer or wider? Also, most of our deck planks contain grooves. A tip, for better slip resistance, its better to orientate the planks perpendicular to the majority of the footfall so that you get more grip underfoot. Standard board lengths are 3.66metres long. Any special order lengths exceeding 3.66m where butt joint are required is NOT COVERED by our warranty. Also, bear in mind that the extra gapping may negatively effect the overall look of the deck. Dura Deck can be installed in different directions, please check the span tables on page 12 for information on the 3 main designs horizontal, diagonal and chevron as shown above. Design tip: Cutting across a board is much easier than cutting along its length. The composite bearers run perpendicular to the deck boards. Keep this in mind the fewer cuts required the better. Site Preparation Before work commences, it is recommended that the site be compacted with a plate compactor (available at most hire outlets and hardware stores) to reduce settling. The site must be free draining or of a gradient of 1 in 40 to allow water run off. If the area you have chosen is covered with grass, you can either remove the turf or cover it with a weed barrier, as long as its edges are tucked deep into the soil using an edging spade. If your deck is to be at ground level, then the removal of 100mm of soil is recommended. Never install Dura Deck directly onto a solid surface, airflow and drainage beneath the deck is crucial to its longevity. The sub frame is discussed further in the next section. Replace the topsoil with 100mm of compacted gravel. This provides a very solid but free draining site on to which you can build the sub-frame. 5
6 The Sub Frame Dura Deck can be installed on any existing structurally sound sub frame, provided the necessary spans are adhered to. See load table on page 12. New sub frames can be built from timber, composite timber, steel or GRP. For all sub frames please note the following: A sub frame allowing a minimum of 100mm air space between the Dura Deck planks and the ground or substrate is essential to allow sufficient air flow to prevent the build-up of moisture. This air space distance can be reduced to 50mm where at least two sides of the deck are open, allowing air flow. The maximum span between supporting joists depends on the specific Dura Deck product and the decking direction and design please refer to span and Load & Span Table on page 12. Most decks (other than ground level) use a post and beam construction. The support posts (normally placed at no more than 1800mm) centres sit in or on concrete footings, the latter using a metal connector/shoe to attach the post to the concrete floor. Please refer to the Load and Span Table on page 12 to select appropriate spacing's for joists depending on the type of Dura Deck used. If possible, try to make the width of the deck divisible by the width of the chosen board to avoid the need to trim a board along its length. For example, 10 boards of Dura Deck Type 146, plus 6mm gaps in between each board is 1526mm. 10 boards of Dura Deck Type 295, plus 6mm gaps in between each board is 3016mm. Work out approximately how many boards wide your deck will be, then round it up or down to the nearest board. Using Dura Composites Bearer as the Sub-frame Dura Composite Bearers are the simplest and most ecofriendly sub frame option. They are made from 87% recycled material, have a long life expectancy and each composite bearer is uniform in size and straight making installation far simpler. Dura Composites Bearers are designed for installation directly onto hard surfaces, such as concrete or paving and also onto soft surfaces such as soil, sand or grass, provided the area has been compacted and bricks, pavers or concrete slabs are placed periodically beneath the bearers. Please note when fixing expansion clip to Bearer to locate Dipped head screw in centre grove of Bearer. 102mm Composite Bearer with S/S Clip When building a deck on sand, soil or grass, use concrete slabs or bricks underneath the bearers at intervals of 1200mm. Ensure slabs or bricks are level. 6
For raised decks, up to 860mm, adjustable pedestals are available from Dura Composites. Bearer Installation 1. Secure bearer to concrete by drilling stainless steel bearer clip into the sub-strate. 2. Drill a pilot hole first using a masonry drill bit, then drive an 8-gauge masonry screw through the pre-drilled clip and into the base surface. 3. Continue installing bearers in this fashion, remembering to space them according to the required span for each type of Dura Deck board. 4. Once bearers are secure and level, you can begin installing your Dura Deck. 7 Adjustable Height Sub-frames Dura Composites 102mm Composite Bearer can be supplied to be installed in conjunction with adjustable pedestals. Adjustable Pedestals 7
8 Dura Deck Installation Dura Composites has designed a set of unique sub-surface fixing clips to ensure that Dura Deck is barefoot friendly as well as looking neat and uniform. Dipped Head Screw Step 1 Start the deck against the house or wall and work outwards. Use a hidden Standard Fixing Clip against the house or wall to provide the optimum spacing required. Use one Standard Fixing Clip per joist and attach using Composite Screws (available from Dura Composites) and a drill or screwdriver. If the deck is not next to a wall (is free-standing), use a Start/Stop Fixing Clip instead. If you are installing your Dura Deck perpendicular to a wall, a Half Length Fixing Clip can be used to ensure a neat finish. 1 2 3 4 5 6 8 9 7 Half Length Fixing Clips for installation next to walls 8
Step 2 9 Next, push the first board against the hidden Standard Fixing Clips, making sure that the clips are positioned correctly into the manufactured grooves in the board. It may help not to screw down the Composite Screw the full distance until after the board is in place. Step 3 Insert more Standard Fixing Clips on each joist, push the next board into place & repeat. Gapping requirements for Butt Joints If your deck is longer than 3.66 metres, butt joints will be required. These joints should be staggered, as shown in the photo on the left to hide any imperfections (or a breaker board can be used see over leaf). Always ensure boards start and end on a joist. See below for gapping requirements for butt joints. Dura Deck boards will expand and contract slightly with changes in temperature. Expansion is most significant where extreme temperature changes occur and therefore please use expansion gaps in accordance with your region and the temperature at the time of the installation to accommodate for this movement. Always allow 5mm minimum gap where planks meet an adjoining fixed structure/post. Eastern Europe Gaps Region UK Gaps (mm) Middle East Gaps (mm) Install (mm) Temp Deg C Plank Length 1m 2m 3m 3.66 m 1m 2m 3m 3.66 m 1m 2m 3m 3.66 m -25 2.8 5.5 8.3 10.0-20 2.5 5.0 7.5 10.0-15 2.5 5.0 7.5 10.0 2.3 4.5 6.8 9.0-10 2.3 4.5 6.8 9.0 2.0 4.0 6.0 8.0-5 2.0 4.0 6.0 8.0 1.8 3.5 5.3 7.0 0 1.8 3.5 5.3 7.0 1.8 3.5 5.3 6.5 5 1.8 3.5 5.3 6.5 1.5 3.0 4.5 6.0 10 1.5 3.0 4.5 6.0 2.5 5.0 7.5 10.0 1.3 2.5 3.8 5.0 15 1.3 2.5 3.8 5.0 2.3 4.5 6.8 9.0 1.3 2.5 3.8 5.0 20 1.3 2.5 3.8 5.0 2.0 4.0 6.0 8.0 1.0 2.0 3.0 4.0 25 1.0 2.0 3.0 4.0 1.8 3.5 5.3 7.0 1.0 2.0 3.0 4.0 30 1.0 2.0 3.0 4.0 1.8 3.5 5.3 6.5 1.0 2.0 3.0 4.0 35 1.0 2.0 3.0 4.0 1.5 3.0 4.5 6.0 1.0 2.0 3.0 4.0 40 1.3 2.5 3.8 5.0 45 1.3 2.5 3.8 5.0 50 1.0 2.0 3.0 4.0 55 1.0 2.0 3.0 4.0 9
10 Correct Installation of Butt Joints Where butt joints are required, Double Fixing Clips should be used. This method allows for a single screw to be used in the middle of the joist/bearer, adding strength. Breaker Boards You may wish to use a breaker board to reduce the visual impact of butt joints. This can easily be achieved with Dura Deck. Simply install a Dura Deck board at 90 to the direction of the deck. The bearers will need to be adjusted to suit. Breaker Board Step 4 Let the ends of the boards hangover the end of the deck and cut them all to size at the same time once all boards are laid. Step 5 For the last board on the deck, furthest from the starting board, use one Start/Stop Clip per joist to neatly keep it in place. Start/Stop Clips should be used whether or not Fascia board are used. Note: Only Dura Composites sub-surface fixing clips and decking screws should be used to install Dura Deck. Installation using other fixing methods will invalidate the Dura Composites warranty. Screws should never be driven into the face of the boards. 10
11 The Finishing Touches Dura Composites Fascia Board To complete your deck, use Dura Composites Fascia Board to cover the edges of your deck and the sub frame. If your deck design includes stairs, you can use Dura Composites Fascia Board for the step risers. Dura Composites Fascia Board is made from the same materials as Dura Deck, assuring the best possible colour match and longevity. The Fascia Board can be attached using Dura Deck Screws through the surface of the Fascia, directly into the edge of the decking boards, or into the sub frame. When using Dura Composite Bearers, the position to screw the Fascia Board onto the bearers is in the centre of the bearer as indicated here: When screwing fascia boards into position always drill a pilot hole to avoid splitting. Screws can also be inserted into the side of the Dura Deck boards but not the ends of the boards, (again pre-drilling pilot holes). Insert 2 screws along the Fascia Board at intervals of no more than 200mm. Dura Composites Fascia Board measures 230mm x 9mm and should be cut to a maximum length of 1800mm for installation, leaving 3mm expansion gaps between butt joints. 11
12 Dura End Caps In some instances, Dura Composites Fascia Boards will not be suitable or necessary to cover the ends of the decking boards. In this instance, use Dura Composites End Caps to cover the board ends and provide a sleek look. Dura Composites End Caps are available in matching colours and simply click into place. For longevity, they should be glued into place with a suitable adhesive. Please ask us for details. Dura Deck Load & Span Table The following table indicates the maximum spans and working loads of Dura Deck products. Spans listed represent the distance between joist centres. Board Max. Residential Span (mm) Max. Commercial Span (mm) Working load at 400mm span using 2.5 factor of safety Type 146 400 300 193 kg Type 225 700 600 435 kg Type 295 600 500 361 kg Type 142 400 300 225 kg Alternate Design Span Guide Board 90 Span 45 Span 30 Span (horizontal) (diagonal) (chevron) Type 146 300 250 200 Type 225 600 550 500 Type 295 500 450 400 12
Dura Deck Care & Cleaning information 13 Whole Dura Deck requires no oiling, sanding or staining throughout it s lifetime, you may need to clean your deck occasionally to keep it looking at its best. Here are the solutions to common cleaning issues. PROBLEM SOLUTION General dirt & debris Oil/Grease/Food/Drink Tannins from spillages/ water spots Marking for cutting Spray with a hose to remove surface debris. Use warm soapy water and a soft bristled brush to clear dirt and/or debris from grooves/contours. Pressure wash to remove more stubborn stains. Remove and mop as soon as possible spray with a hose and use warm soapy water and a soft bristled brush. Pressure wash for more stubborn stains. Any surface stain that has been absorbed can be also easily removed with light, progressive sanding using coarse (22-60 grit) Emery paper. Do not sand more than 0.5mm into the surface. Tannins will naturally be released from long lying material/ vegetation, wine spillage etc. This should be sprayed with a hose and brushed off using a soft bristled brush and soapy water. Pressure wash for more stubborn stains. Any surface stain that has been absorbed can be removed through light sanding with a coarse Emery paper (22-60 grit). Do not sand over 0.5mm into the surface. Always use a non-permanent marker such as baby powder/dustoff marking chalk or plumb line wherever possible. Tannins from Dura Deck product All wood based products will release Tannins including Dura Deck. This will naturally stabilise after approximately 12 weeks, depending on the temperature, UV and exposure to rain. Rust stains & engrained dirt Cleaning products containing Oxalic or Phosphoric acid can be used. Do not bleach, as this will lighten the product. With any cleaning product, test it on a small inconspicuous area first, following manufacturer s instructions. Ice & snow Use a plastic shovel or broom to remove snow. Use rock salt or calcium chloride to melt frozen precipitation/ice. 13
14 Cleaning Techniques TECHNIQUE DESCRIPTION Basic Cleaning Pressure Washing Sanding Spray will hose to remove surface debris. Use warm soapy water and a soft bristled brush to clear dirt and/or debris from grooves/contours. Pressure washers up to 1500psi may be used to maintain cleanliness of WPC. In order to prevent any damage, always keep the pressure washer nozzle at least 15cm (6 inches) from the surface, and avoid concentrated spraying on one area for more than 3 seconds. Use of a pressure washer in this manner will not shorten the life of the material. Sanding should be used only when basic cleaning or pressure washing fail to remove stubborn stains. Sanding should only be used for very stubborn scuffs and/or marks. Always use coarse grade Emery paper (22-60 grit). Sanding should be carried out lightly and progressively harder if necessary to a maximum of 0.5mm surface depth. Most marks blend naturally after 12 weeks weathering. Product Disposal TYPE SOLUTION Commercial Use Domestic Use Safely dispose of any offcuts as per local laws. Do not burn. Treat as construction waste. If unsure always consult your local governing body/ council. Safely dispose of any offcuts as per local laws. Do not burn. Treat as household waste. If unsure always consult your local governing body/ council. 14
For further information, please do not hesitate to call us on +44 (0)1255 423601. 15 Please note that every effort has been made to ensure that the information in this publication is correct at the time of publishing. Dura Composites Ltd. assumes no responsibility or liability for typographical errors or omissions or for any misinterpretation of the information within this publication and reserves the right to change without notice. 15