Composite Decking Technical Guide - RIBA Product Selector · Hybrid Composite Decking by ... Making sure Duraflex customers have a ... Accelerated weathering results further reinforced

COMPOSITEDECKINGTechnical Guide

Duraflex Composite Decking | Technical Guide2

Hybrid Composite Decking by Duraflex Page 4

Decking With A Difference Page 5

Hybrid - The Best of Both Worlds Page 6

Safety & Durability Page 7

Data Table, Performance Specification & Components Page 8

Marketing Material Page 9

Marine & Commercial Page 10

Solid vs. Hollow Boards & Material Properties Page 11

Slip Resistance Tests + PVC & Sustainability Page 12

Material Technical Data Page 13

Notes Page 14 - 15


Index

Hybrid CompositeDecking by DuraflexThis Duraflex investment is based on confident, professional, forward planning, backed byover twenty years’ experience. We are creating the ideal environment for innovativeproduct design, quality production, reliable logistics and all of the necessary customersupport services. Staffed by people who know the products and the specialist needs of theindustry, providing Duraflex customers with continually evolving cutting edge products andservices and meeting the exacting demands of the changing marketplace.

Making sure Duraflex customers have a competitive advantage in the marketplace meansproviding a total quality service at best value. Product cost is important, but to assess thereal value it is necessary to consider the total picture. Attention to detail and qualitythroughout the facility enables us to make a significant difference in the development of ourproducts. It is reassuring to know that you are in a supply partnership with a companybacked by the resources of the internationally respected Masco Group. Equally, you can beassured that our company is completely customer focused and understands the commercialrealities of your business.


Decking with a differenceThe Hybrid decking board from Duraflex is no ordinary deck board. Made with both PVC and woodthis product provides you with their unique properties rolled into one single base material with thelow maintenance and durability of PVC and the appearance and strength of wood.

The result of this is a decking product of extremely high quality, which exhibits excellent slipresistant properties tested against the Health and Safety Executive’s grading system, as well asexcellent resistance to organic growth matter.

An accelerated weathering test further strengthens the view that Hybrid decking provides theperfect performance criteria.

Hybrid is a material that is strong, resilient, water resistant, low maintenance, slip resistant,combined with an option for an attractive, ribbed or brushed finish, as well as a range of colours tosuit your particular application.


- the best of both worldsHybrid composite decking combines all the advantages of wood and pvc

Our hollow core system is made from wood and pvc providing you withthe advantage of technology, whilst still maintaining the natural materials look and feel.

This gives you the best of both worlds, the warmth and texture of wood with the lowmaintenance and durability of pvc. This combination means it is available in a range ofnatural colours, giving your creative thoughts free rein to transform your surroundings intosomething to be proud of and enjoy for many years to come.

Enhance your space with this beautiful decking that will create a perfect environment torelax with friends and family and enjoy the perfect outdoor setting. Whether it’s a quietSummer’s evening you want to enjoy, or a barbeque with friends, Hybrid composite deckingwill make the experience that much better.

Our Colour RangeIt is available in a range of naturalcolours, so you can give yourcreative thoughts free rein andtransform your surroundings intosomething to be proud of andenjoy for many years to come.


Olive Green

Charcoal

Chesnut Brown

Slate Grey

Decking that is safe,durable and carefree

Slip ResistantWhether wet or dry,non-splinter, concealed

fixings.

Low MaintenanceNo staining, paintingor sealing required.

Rot ResistantNo wood preservativerequired to extend life.

Fire ResistantWhen exposed to

flame, our product willself extinguish.

Resistant to WaterDesigned for use inMarine applications.

Easy to CleanNo chemical cleaners

required, just soap, water,a non-abrasive cloth, orsimply a jet-wash.

ColourfastNo treatment required tomaintain the colour. Doesnot ‘grey’ with age, asexperienced withunprotected timber.

Environmentally FriendlyAll deck board is 100%recyclable, with a natural

appearance.


Our decking has all the warmth and feel of wood without the associatedmaintenance problems, making it more durable and easier to live with,so is ideal for the home, caravan and marina markets.

Deck Board Bearer Plinth Security Clip Easy Board Starter BarDeck Clip

BB BC BD 1004DC 1006DC

W.P.C Wood W.P.C Wood W.P.C Wood Stainless Steel Stainless Steel AluminiumPlastic Plastic Plastic

162 x 28mm 40 x 40mm 7 x 60mm N/A N/A 20 x 9mm

5000mm 2400mm 2400mm N/A N/A 5000mm

Part Number

Material

ProfileDimensionsW x H

Bar Length

PerformanceSpecification

The Hybrid way couldn’t be easierDecking Data Table

2.87Kg / m

1 0 mm0 0

1000mm

21500Kg/m214.5KN/m

Brushed & Ribbed Surface

Brushed Flat Surface ra

f

B ushed Fl t Sur ace

us d

e

Br he & Ribbed Surfac

• Reversible Deck BoardSurface Finish


• 162mm Deck Board

• Maximum WeightBearing Capacity

Components162

28

Deck Board (Pt No: BB)

40

40

60

9

Bearer (Pt No: BC)

Plinth (Pt No: BD)

8.5

8.5

20

Starter Bar

Security Clip (Pt No: 1004DC) Deck Clip (Pt No: 1006DC)


Marketing Material

DL Leaflets covering CompositeDecking for Homes, Marinas,Caravans & Merchants

A1 Composite Decking Display Panel

Hybrid DeckingMarine and CommercialIn 2007, Duraflex was approached by a number of players in the Decking and Wood Plastic Compositeindustry with a request to enter the arena in order to bring sustainability of performance and supplyto this emerging but fragmented market.

Duraflex Marine and Commercial Decking is the result of three years' research, development andproduct evaluation.

During the development cycle, Duraflex evaluated products and materials currently on the market, inthe extensive Research and Development facilities at Masco Headquarters in Michigan.

Concerns were expressed with regard to the variability found with some recycled materials. Unable tosatisfy ourselves that consistent product quality could be achieved with the samples tested, Duraflexmade the decision to work exclusively with virgin polymers.

Investigations led us to the conclusion that raw material selection was a vital consideration.

Discussions ensued with potential customers and further concerns were raised that when in use, someof the composites were deflecting more than anticipated, with this deflection becoming permanentwith time. We therefore, determined that flexural modulus and bend strength were the key designparameters.

It is widely reported that Water Absorption leads to a reduction in flexural modulus, and thereforebecomes the third most important parameter. Our research laboratory performed a 14-day immersiontest of decking material, results as follows:

Typical Recycled Duraflex Decking Polyethylene Decking

Flexural Modulus MPa 6000 - 7000 2500 - 3000

Bend Strength MPa 64 20 - 35

Water Absorption (%) 1 - 5% 10 - 20%

Having established the core physical properties, we then focused on performance, in particular slipresistance, growth of organic matter on the deck surface and weatherability.

Immersion tests showed that the Duraflex deck exhibited the least organic growth when comparedwith typical Recycled Polyethylene Deck filled with wood flour or rice hulls, thus improving the slipresistance in service.

The form and finish of Duraflex decking exhibits excellent slip resistance when tested against theHealth and Safety Executive's published grading system.

Accelerated weathering results further reinforced the view that virgin PVC / WPC gives excellentperformance, as would be anticipated, with the long history of PVC-U as an exterior product.

When compared with hollow or solid recycled polyethylene decking, the Duraflex Deck outperformedall samples tested in terms of △E and LAB colour shift.

Slip Test Results (independently verified)

Dry Board: HSE Classification Extremely low slip potential

Wet Board: HSE Classification low slip potential


Solid vs Hollow Boards


It has been reported that solid boards perform better than hollow boards.

It should be noted though, the case is made "based on boards of similar dimension and materialmake up".

The real debate should be based on the results achieved with firstly the "base material" andsecondly the board itself, irrespective of design or material.

Facts resulting from laboratory analysis comparing board for board, show significant differences inperformance.

Internal and external sources were used to conduct a range of tests, coupled with a comparison ofpublished data.

Material and Board Properties

Tensile Strength(MPa)

Bending Strength(MPa)

Water Absorption*(24hrs%)

Burning Behaviour(LOI%)

Tensile Creep (%)

Density kg/m3

Water Absorption*: The above test results are based on a 24-hour test. In our laboratory weextended the water immersion test with the following findings after 14 days:

Duraflex Board 4.5%Hollow Recycled PE with Rice Hulls 9.5% Hollow Recycled PE with Woodflour 17% Solid Recycled PE with Woodflour 20%

The argument of hollow vs solid has far less relevance than material selection. The choice betweenrecycled polyethylene as a feedstock or PVC, should be made on performance criteria. If we considerthe Flexural Modulus, Bend Strength, Burning Behaviour and Tensile Creep (a critical structural testrarely given for polyethylene), then PVC based WPC becomes an obvious choice.

DuraflexDeck

35.45

64.31

1.1

26

0.156

1.398

Solid RecycledPE/Wood: Board 1

1.3

31.5

0.6

Not Given

Not Given

Solid RecycledPE/Wood: Board 2

Not Given

20

Not Given

Not Given

Not Given

Hollow RecycledPE/Wood: Board 1

4.42

36.2

1.07

Not Given

Not Given

Slip Resistance Tests

PVC and Sustainability


Increasing safety by reducing risk Test 1- TRRL 55

Wet A 54 53 52 52 51 51 50 51 51 PTV Wet B 53 53 53 52 53 52 52 51 53 PTV Dry 75 74 74 74 74 75 74 74 74 PTV

Customer name: Duraflex HSE Guidelines: Test Number: CR026138 0-24 High Risk for Slip potential Operator: Glenn MacLaughlan 25 - 35 Medium Risk for Slip PotentialDate of Test: 09/11/2010 36+ Low Risk for slip potential.Date of Application: N/A 60+ Extremely low risk On Site: Lab Test Pendulum Calibration Number: Wessex - C1973 Pendulum Serial Number: SK1595 Slider Type & Certificate No: 55 & 96 Contaminate Description: Water Surface: Composite decking

Floor Safe: 5 White Hill Rd - Barton Ie Clay - Bedfordshire MK45 4PF. 0845 643 1317

Many misconceptions exist in terms of the environmental credentials of PVC-U

Less than 50% of the feed stock used in the manufacture of PVC is oil-based derivatives, unlike otherbulk polymers, such as Low Density Polyethylene and High Density Polyethylene, where oilderivatives are the major ingredient.

PVC primary feed stocks are Common Salt (57%) and Ethylene (43%). In more recent times, thereliance on oil derived ethylene has been further reduced with the production of ethylene fromsugar.

With respect to PVC/WPC, the ethylene requirement is further reduced by the addition of 50% woodflour. In this regard, Duraflex has made a decision to use wood flour that carries PEFC certification,further enhancing the sustainability credentials.

The recycling of WPC/PVC can be handled either directly through Duraflex, taking the benefit of ourin-house recycling facility or by using one of our partner members of Recovinyl, who segregatematerial types on receipt and recycle accordingly.

Currently, very little WPC is entering the recycle market, however, as volumes grow, the industry willinevitably expand its recycling capabilities. The market requirement for recycled quality WPC is fargreater than the current availability.

On a more general note with regard to the environmental credentials, Duraflex have exceededgovernment energy saving targets for the 10th consecutive year, which has resulted in a surplus ofover 9,000 tonnes of CO2 (Carbon Credits).

Material Technical Data


Density ISO 1183-1 Method A 1,398 kg/m³

HDT ISO 75 Method A 1,80 Mpa 77,8 ºCMethod B 0,45 Mpa 79 ºC

Tensile Properties ISO 527/1B E-Modulus 5841 Mpa Tensile Strength 35,45 Mpa Strain at Break 0,85 %

Brinell Hardness EN 1534 3KN 171 Mpa

Water absorption EN 317 24 hours Thickness Swelling 1,47 % Weight Increase 1,1 %

Flexural Properties ISO 178 E-Modulus Extrusion Direction 5298 MpaBending strength Extrusion Direction 64,31 Mpa Strain at Break Extrusion Direction 1,24 %

Tensile Creep ISO 899-1 I 30°C/9 Mpa Elongation 480h 0,156 %

Resistance to soil PRCEN/TS Durability Class 1 Classinhabiting soft 15534-1rotting microfungi Annex D

Linear Thermal ISO 11359-2 Extrusion Direction 0,020 mm/mºCExpansion

Burning Behaviour ISO 4589-2 LOI 26,0 %

Vicat Temperature ISO 306 Method B50 89,7 °C

Reaction to fire NF P 92-501 Epirator M4 Class NBN S21-203 Epirator A4 Class DIN 4102-1 Kleinbrenner B2 Class

Notes



Notes

Severn DriveTewkesbury Business Park

TewkesburyGloucestershire

GL20 8SF

Tel: 08705 351351

www.duraflex.co.uk

Duraflex Limited – a Masco Company

Documents

Composite Decking Technical Guide - RIBA Product Selector · Hybrid Composite Decking by ... Making sure Duraflex customers have a ... Accelerated weathering results further reinforced