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GAF Shuts Down Composite Decking Segment

Wednesday, September 7th, 2011

GAF Materials Corp. will exit the composite decking industry after announcing last week that it will cease manufacturing and close its composite decking manufacturing facilities in Lenexa, Kan., and Biddeford, Maine, by the end of the year, according to an article on the website of Compositology LLC, a research and marketing company focused on the composites industry. Both manufacturing facilities will be fully closed by the end of the year. The closures mark the end of GAF’s four year foray into the composite decking industry.

The company will continue to honor warranties for its products and it will continue to sell products it has already produced. The company said it is getting out of the industry because it is not getting the financial return it was looking for. GAF has not determined whether it will sell the composite decking brands.

GAF, best known for manufacturing shingles and roofing materials, became involved with composite decking in 2007 following its purchase of ElkCorp and its Elk Cross Timbers line of decking. In 2009, GAF purchased Correct Building Products and acquired its CorrectDeck CX line. The company currently markets its decking lines under the DuraLife brand, which includes railings and products made for docks and porches.

This article was originally posted on ProSales Online.

Tags: GAF, industry news
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New Decking Made with Plastic and Wheat Straw

Friday, June 24th, 2011

For its Terra line of deck and fence boards, Wyoming manufacturer Natures Composites uses a combination of recycled high-density polyethylene and wheat straw that it says is stronger and ecologically friendlier than competing wood-plastic composite materials.

TerraDeck, which comes with a 20-year warranty, resists water absorption, shows low amounts of thermal expansion, and will not splinter or crack, says the company.

The product’s “green” appeal is that 94 percent of it is made from recycled milk jugs and wheat straw – an agricultural by-product and a renewable resource.

The 1-inch-by-5 3/8-inch planks come in three lengths – 12 feet, 16 feet, and 20 feet – and in two profiles: slotted to accommodate hidden fasteners, and solid. Available in six colors, the boards have better color retention than conventional composites, according to the company, and do not require painting or staining.

Natures Composites also manufactures a co-extruded plank, the Ultimate series, in three colors.

Natures Composites is a new iteration of Heartland BioComposites, a company that produced composite lumber from 2006 until its doors closed in 2009. After that, its assets were purchased by a group of investors that included Heartland president Heath Van Eaton, and the company was revived last year in its original location in Torrington, Wyo.

The company declined to provide pricing and said it was working on a national distribution plan that would be announced later in the year.

Scott Gibson is a writer in East Waterboro, Maine.

Natures Composites, 307/532-9942, naturescomposites.com.

This article was originally posted on Professional Deck Builder Online.

Tags: products
Posted in Decking, Site & Landscaping | 2 Comments »

Arch, Osmose Settle Deck Treatment Patent Dispute

Wednesday, June 15th, 2011

Under an agreement by wood preservative manufacturers Arch Treatment Technologies and Osmose, Arch will license micronized-copper wood-treatment technology from Osmose. The agreement, whose terms the companies did not release, brings to a close a patent-infringement lawsuit filed by Osmose in March 2010 immediately after it received a patent for its MicroPro treatment process.

In the previous copper azole (CA) formulas, the copper is dissolved in a carrier, whereas in micronized-copper treatments, the copper is ground into tiny particles so a solvent isn’t necessary. The manufacturers claim that the result is less corrosive to metal fasteners and hardware. According to Huck DeVenzio, marketing communications manager at Arch Chemicals, the agreement applies to the micronized-copper azole treatment Arch uses for Wolmanized Outdoor Wood in the Eastern U.S., but that customers “will see no change.”

For Wolmanized Outdoor Wood in Western states, treaters use Arch’s dissolved version of copper azole, which is not subject to the licensing agreement. DeVenzio noted that Western wood species, like hem-fir, have more heartwood than Eastern species (thus, they need to be incised for treatment to penetrate) and are rarely treated with MCA, though Arch does have approval (ESR-1721) from the International Code Council Evaluation Service (icc-es.org) for MCA to be used on incised hem-fir. – Laurie Elden, Professional Deck Builder

Tags: lawsuits
Posted in Decking, Site & Landscaping | 1 Comment »

New Eco-Friendly Deck Ingredient

Wednesday, May 11th, 2011

Soybeans could be the next plastic-decking ingredient. Marysville, Ohio–based Biobent Polymers now makes a bioplastic material, called Panacea, out of soy meal, polyethylene, and polypropylene. The company says the soy meal can replace up to 40% of the petroleum used. – Laurie Elden, Professional Deck Builder

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Remodelers Snatch Up Free Reclaimed Products

Thursday, March 10th, 2011

Two remodelers shared how they recycled others’ trash into creative solutions for their green remodels during a recent Webinar for GreenExpo365.com–free products they would have missed if they weren’t on the lookout for opportunities.

Builder Matt Belcher of Belcher Homes in St. Louis saw the city tearing down a repossessed house next to the one he was remodeling. The 100-year-old hand-cut limestone blocks stocking the foundation caught his eye.

“They were going to demolish and haul all that stuff off,” said Belcher. “We convinced the city to leave the stones behind so we could use them to terrace the yard with. You can’t find better landscape materials.”

And in Pheonix, Ariz., the pavers leading to the doorway of one of Philip Beere’s renovated projects were scored out of the driveway Beere, of Green Street Development, demolished during the renovation. – Evelyn Royer

Tags: green building, green products, stone
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U.S. Demand for Decking Forecast To Rise 2.7% per Year Through ’14

Thursday, February 3rd, 2011

Demand across America for decking will revive from the 0.6% annual drop in 2004 to 2009 to increase 2.7% per year and reach 3.5 billion lineal feet–worth $6.2 billion–in 2014, the Freedonia Group forecast today.

Wood products will continue to dominate the market, accounting for 77% of the market in 2014 vs. 86% in 2009, but demand will rise just 0.5% per year, going from 2.604 billion lineal feet in 2009 to 2.67 billion in 2014. In contrast, wood-plastic composite and plastic lumber decking will enjoy double-digit growth rates, the Cleveland-based market research firm said.

Wood-plastic composite decking, which saw demand shrink 1.4% per year between 2004 and 2009 to reach 349 million lineal feet, will see 12.9% annual growth through 2014 to hit 640 million lineal feet. Meanwhile, plastic and other lumber (PVC, mainly), which had seen demand fall 2.1% per year to total 73 million lineal feet in 2009, is forecast by Freedonia to grow 13.9% per year over the next five years, hitting 140 million lineal feet in 2014.

Freedonia tied its predictions to the housing market’s decline and expected recovery. The residential market accounted for 59% of all decking demand in 2009, it said, noting that the percentage normally would be much higher had it not been for the recession in home building. Nonresidential market demand will rise 2.4% annually through 2014, it said.

“Through 2014, decking demand gains will be driven by an expected advance in housing completions from their low 2009 base,” Freedonia predicted. “Rebounding housing completions and improvement and repair expenditures will spur gains. Growth also will be supported by homeowner desire for larger decks.”

It said demand for wood decking “will be restrained by competition from composite and plastic decking materials. Interest in tropical hardwoods, such as ipe, will provide growth opportunities in the residential building and non-building construction markets.”

The forecasts are part of a new 350-page report on the decking market that Freedonia sells for $5,100. –Craig L. Webb

This article originally appeared in ProSales.

Tags: decking, trends
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High-Low Split in Decking Market Forecast

Wednesday, October 6th, 2010

America’s decking market appears to be splitting between high-priced synthetic and low-priced treated wood products, speakers at a Principia Partners conference in Charlotte, N.C., said Monday. Wood remains the big leader, and its proponents see an opportunity to produce upscale products that will move into the market space being vacated by composites.

Several speakers at Principia’s Wood-Plastic & Natural Fiber Composites Conference predicted that makers of non-wood decking will, within a few years, stop producing products consisting solely of a wood-plastic composite. Instead, all synthetic products will be either PVC goods or will be composites that have been “capped,” or bordered, with a PVC-like substance.

About $2.75 billion worth of decking will be sold this year, said Steve Van Kouteren of Principia, the conference chair. Of that, wood accounts for $2 billion, composites figures in $750 million of the sales and PVC decking contributes another $100 million.

Wood generally is used in new-home construction and projects where cost matters significantly. Composite and PVC decking often gets installed on higher-end new-home projects and when homeowners decide to replace their worn-out wood decks with a product that requires less maintenance. Building material dealers sell the lion’s share of synthetics, but Principia estimates that the role of big boxes has grown to account for one-third of sales.

Christopher Grandpre, president of Outdoor Living Brands Inc. of Richmond, Va., which includes the 200-franchise Archadeck design-build firm, said there was about a 50-50 split in the number of wood vs. synthetic products used in Archadeck-built projects in 2008. Last year, wood’s share rose to 54%, apparently because of financial worries, he noted, but so far this year synthetics figure in 52% of the projects.

“We see that, in a couple of years, two of every three jobs [we do] will involve some sort of low-maintenance materials,” he said. Fiberon president Douglas Mancosh went so far as to say he doesn’t expect any manufacturer to produce uncapped wood products two years from now.

Michael Salazar, director of purchasing at TW Perry in Gaithersburg, Md., said he sees the decking market splitting into two segments. The lower end will be cost driven and dominated by wood, he said. The higher end will consist of so-called ultra-low maintenance PVC and capped products, such as Trex’s Transcend series. (One speaker predicted that “capped” decking will get marketed as “prefinished” goods.

Robert Lett agreed. “The wrapped products are what we see as the future,” said Lett, vice president for sales and marketing at Wolf, the York, Pa.-based distributor that on Monday announced announced today it has terminated its distributor relationship with AZEK effective Nov. 5, has become the exclusive supplier of another PVC decking product–CEVN–and will introduce its own proprietary PVC decking and railing products. (Story)

As for wood, Kirk Hammond, sales manager for Arch Chemicals, said wood producers are reaching out to deck builders to speak up for wood. He said the industry can push some laminated and related wood products that cost more than regular treated lumber but costs less than the cheapest composite.

“There are wood products out there for the high-end deck builder that will perform,” he said. “We can absolutely put a good-performing product out there that the consumer will appreciate. … We’re looking to start filling that middle with a higher-end laminated product.”

This article was originally posted on ProSales Online.

Tags: forecasts, industry news
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Know Your Codes

Friday, August 27th, 2010

Every spring kicks off deck building season, when homeowners can’t wait to have a deck party and builders start signing contracts for both rebuilds and new decks. As a building official, I find it’s a time when I refer a lot of folks to the code book.

Knowing the code requirements helps you to do it right up front. In my mind, a deck builder who doesn’t own a copy of the International Residential Code (IRC), even an outdated one, is like a lawyer who doesn’t own a law book. Now, most deck builders don’t need to own a copy of the International Building Code (IBC), which is geared more toward multi-family and commercial construction. But there are times you might find it helpful, say when you get that big job in an apartment or condo complex. Once the building you’re working on houses more than two families, the IBC becomes the governing code — and it’s a real game changer. This article will use the 2003 IRC as a base reference, and contrast it with the 2003 IBC when necessary.

When residential builders transition to multi-family or commercial work, one of the most common mistakes involves railings, which code books refer to as “guards.” Guards are used not only around a raised deck, but also alongside stairs. Guard heights vary between the IRC and the IBC. Single-family homes and two-family dwelling units (code classification R3) share the requirement of minimum 36-inch-high guards anywhere the walking surface is 30 inches or more above the adjacent floor or grade. However, three-family and larger residential properties, as well as motels, hotels, dormitories, apartments, and the like — classified as R2 — require a minimum 42-inch-high guard for the same conditions.

I don’t know how many times I’ve heard the argument, “Yeah, but they’re all residential units!” That doesn’t matter. You need to build to the standards of the code adopted where you live, and most of the country makes a distinction as described above. Every state has passed amendments that alter sections of the code; however, the basic concepts remain the same. I encourage builders to buy the “Commentary” version of the code, which explains things in laymen’s terms.

Guard Heights
Let’s look at sample guard heights for two different scenarios. If you’re building a new deck or restoring an old one in an R3 building, the guards must be at least 36 inches high and the stairs will require a minimum 34-inch-high guard and a graspable handrail (the Stair Manufacturers’ Association provides a good visual explanation of this at stairways.org). For an R2 condo project, however, you must install 42-inch-high guards for both new construction and replacements of existing guards. The guards along the exterior stairs also must be 42 inches high, and a graspable handrail on both sides of the stair is required.

These instances depict standard differences in residential occupancies versus multi-family residences; neither has anything to do with special circumstances, such as restricted spaces, or replacement with “like” materials when historical elements come into play.

Mixed R3 and R2
Sometimes R3 and R2 uses collide. Where I work, it’s fairly common for owners of two-family (R3) dwelling units to add a third or fourth apartment, bringing in significant additional monthly income. In order for them to add the additional dwelling unit(s), there has to be a “change of occupancy” from R3 to R2. On an existing deck, guard rails with the R3 required height of 36 inches won’t need to be changed. But decks for the new unit(s) will look different because their guards will have to be 42 inches high.

That won’t be the only difference. Any new stairs to the R2 decks won’t be allowed to exceed a 7-inch rise and an 11-inch run (in Connecticut, where I work, stairs on the original R3 deck could have an 81â„4-inch rise and a 9-inch run). And if you rebuild the existing R3 deck, it will then have to comply with R2 requirements.

There may be other requirements as well. You don’t want to have to rebuild something you built in error — it always costs more to do it twice. A mistake could cost the monthly payment for that 4×4 pickup. Why not call your local building inspector first to verify the requirements? Then the additional costs are only those of a simple change in what you order for the project.

Jim Eggert is a former builder, and a building official in New Haven, Conn.

This article originally posted on Professional Deck Builder.

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2010 Builders’ Show Products, Part 1

Wednesday, January 27th, 2010

Hanley Wood product editors scoured the exhibit floor of the 2010 International Builders’ Show in search of the latest and most interesting introductions. Here is a sampling of 12 products on display at last week’s event.

For 35 more products from the show, see our Builders’ Show Preview.

Aquatic. Designed to appeal to a broader range of users with hydrotherapy and accessible bathing needs, the Ava Bath includes a range of unique features. Rather than a swing-open door typical of most accessible bathtubs, Ava’s automated door runs the full length of the tub, and raises and lowers completely for unprecedented ease of access. The roomy design functions like a traditional soaking tub, allowing for more complete immersion than a traditional bath with a bench, and a patent-pending quick-drain feature empties the 70-gallon tub in 30 seconds or less. Four Ava bath models include soaker, whirlpool, air bath and air/whirlpool designs in a 60-inch-wide tub, suitable for remodeling. www.aquaticbath.com. –Lauren Hunter

Eldorado Stone. Designed to make it easy to create and install outdoor stone features, Eldorado Outdoor comprises glass-fiber reinforced concrete building blocks that assemble on site in a variety of configurations for outdoor kitchens, fireplaces, seating walls, and more; the cabinet units are scratch-coated for no-prep installation of the company’s stone or brick profiles. The lightweight units do not require additional concrete footings and can be installed directly over existing solid flooring surfaces.
Cut-outs for grills, sinks, and other elements can be done on site. According to the firm, the product reduces installation time for an L-shaped island from 64 hours to eight hours. www.eldoradostone.com. –Katy Tomasulo

Generac. The company’s new CorePower system offers the convenience of an automatic standby generator and transfer switch at an affordable, $1,799 price point. The 7-kW model can power a range of household needs during an outage, which it responds to automatically. The unit features an all-weather composite enclosure; three of its four sides slide off for easy servicing. It runs on natural gas or propane. www.generac.com. –K.T.

Clopay. The garage door manufacturer will now offer fiberglass and steel entry doors. Numerous decorative window styles with matching sidelites, transoms, and leaded garage door windows are available. The entry doors are factory finished and pre-hung for easy installation. The fiberglass products include a polyurethane foam core for added insulation and strength, along with tempered, triple-glazed insulated glass. Steel offerings are insulated with polyurethane. Select doors qualify for the energy tax credit. www.clopay.com. –Victoria Markovitz

LifeTime Lumber. Made with fly ash recovered from power plants mixed with polyurethane, LifeTime Lumber decking is fire- and mold-resistant, impervious to termites and dry rot, and will not split or fade, according to the firm. The decking cuts and fastens like wood, and features a redwood-based wood-grain. The 2×6 deck boards have a joist span rating of 24 inches. Six colors are offered. www.lifetimelumber.com. –K.T.

TimberTech. Available in cedar or gray colors, ReliaBoard decking offers homeowners an alternative to wood decking that features the durability and low maintenance of composite at a lower price point. The boards feature a flat-grain surface and a square edge, and are available in 12-, 16-, or 20-foot lengths. The maker is offering a 25-year limited, one-time transferable warranty. www.timbertech.com. –L.H.

Behr. Ideal for drywall installers, Premium Select High Build Primer & Sealer is designed to help professionals save time, money, and materials during the drywall-finishing process. The high-viscosity primer goes on thick to fill and hide minor imperfections before applying color topcoat. The high-build properties minimize imperfections such as paper fuzz, minor sanding grooves, nicks, and pinholes, and ensures topcoats present a smooth and consistent sheen. Available through special order only. www.behrpro.com. –L.H.

Simpson Strong-Tie. The LSCZ connector provides a concealed connection between the stair stringer and the carrying header or rim joist, replacing additional framing and toe-nailing. The product is suitable for solid or notch stringers, the firm says, and is field-slopeable to all common stair stringer pitches. A ZMax coating provides corrosion protection. www.strong-tie.com. –K.T.

Verve Living Systems. The firm has added thermostat control to its wireless system of lighting and fan controls. The product’s self-powering, battery-free switches can be programmed at home by the homeowner for control of individual or groupings of lights and fans. By combining radio frequency with energy-harvesting technology, Verve eliminates the need for wiring between light fixtures and light switches, saving installers time and money. www.vervelivingsystems.com. –V.M.

Danfoss. Reflect electric floor heating installs under laminate and engineered wood without the need for grout or another substrate during installation. A Styrofoam backing gives the product an additional R-value. www.danfoss.com. –V.M.

Kohler. The company has introduced a new line of automatic standby home generators that focus on design as well as the performance of the products. Including in the launch are three new sizes–10-kW, 13.5-kW and 20-kW–that will replace existing residential models of similar kilowatt output. These new offerings, the company says, offer faster response time, quieter power, and a new composite shell that is corrosion-proof even in harsh elements such as salty coastal areas. It comes in the company’s cashmere color. www.kohler.com. –Nigel F. Maynard

Fusion15ga_FN65DA_3Qt Senco. This nailer looks like slightly like a weapon from a J.J. Abrams sci-fi flick, but we guarantee you it is not. The company has combined the flexibility of a cordless nailer with the power of a pneumatic to produce the Fusion15- and 18-gauge finish nailer line. It eliminates the drawbacks associated with traditional gas- and battery-powered nailers, including fuel cell replacement costs, tool weight, and ramp-up times. Fusion uses an 18-volt lithium-ion phosphate battery that can reach an 80 percent charge in 15 minutes and Reflex Shot technology for added power and to provide up to 500 drives between charges. www.senco.com. –N.M.

Tags: ibs2010, new product
Posted in Bath, Decking, Site & Landscaping, Doors, Home Technology, Paints & Coatings | 2 Comments »

Trex Unveils High-Performance Alternative Decking, Expands Contractor Program

Wednesday, December 2nd, 2009

Trex Transcend decking and railing in tree house and vintage lantern.

Trex has launched what it is calling a “game changer” for alternative decking: a product that combines the benefits of composite and cellular PVC, but without some of those materials’ drawbacks.

Trex Transcend consists of a traditional Trex composite core—which is made with 95% recycled plastic and wood flour—wrapped three-quarters around with a coextruded layer. The outer shell, made of a secret blend of nine elements, protects the core while providing stain-, scratch-, and mold-resistance. The manufacturer says the shell’s thickness, about two to three times greater than cellular PVC’s, also provides for superior fade resistance, wear resistance for high-traffic areas, and a deeper wood-grain. The claims are backed by the industry’s only 25-year fade and stain warranty.

Also different than cellular PVC planks is the decking’s three-quarter shell, a detail that allows moisture to drain, says senior product manager Adam Zambanini, thereby providing for better long-term shell-to-core adhesion.

While I obviously can’t verify the product’s longevity, in seeing Transcend side-by-side with cellular PVC products, it’s evident that the surface offers a lower sheen and deeper, more distinctive wood-grain than cellular PVC deck boards, and therefore a more natural look. Another editor felt the surface also is more natural looking when compared with Trex and competitive composite products.

Transcend deck boards come in four colors—gravel path (gray), tree house (light brown), fire pit (reddish brown), and vintage lantern (dark, rich brown); railings come in those hues as well as black and white. The color choices stem from what Zambanini reports is a continued growing demand for darker colors.

Zambanini acknowledged that the alternative decking category may getting saturated with the recent influx in cellular PVC products (even Trex now has five brands of decking, including a PVC offering). “I do think in two years there’s going to be a shakeout” across the category and possibly within the Trex brand, he says. In the meantime, the company does not have any immediate plans to eliminate its Escapes cellular PVC product or other lines.

In addition to the new decking line, the manufacturer is expanding its TrexPro program, a network of 2,000 independent contractors who, in exchange for undergoing training and installing a predetermined number of Trex decks each year, receive special lead and marketing opportunities.

New elements to the online TrexPro database provide customer reviews based on surveys homeowners receive in their deck warranty welcome packet. An industry first, this aspect gives consumers the ability to compare and contrast Trex deck builders in their area with unbiased ratings, officials said.

The program also now offers expanded marketing materials and lengthier company profiles, including pictures, on the Trex online contractor directory.

For more information on TrexPro and Transcend, including video demos of the product’s stain resistance and cleanup, visit www.trex.com. —Katy Tomasulo

Tags: decking
Posted in Decking, Site & Landscaping | 9 Comments »

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