PVC decking is composed entirely of polyvinyl chloride (PVC) and contains no wood. [1] PVC decking is a more expensive option in the alternative decking industry, but it provides significant fade and stain resistance and lower maintenance requirements compared to other products, including real teak wood. [1]
The alternative yacht deck covering was developed by the Dunlop company, known in the automotive industry, in the second half of the 20th century. Its popularity began to rise in the early 2000s due to the relatively high price of wooden decking and the maintenance-free nature of synthetic teak. Moreover, manufacturers have developed increasingly realistic alternatives over the decades, which could be installed more quickly and cheaply, even retrofitted on a yacht deck.. [2]
Unlike some other wood-alternative decking materials, PVC decking is not made with any wood. It is made completely from plastic instead of from a combination of materials. [2]
Producing PVC decking is a relatively difficult process called co-extrusion. During production, various stabilizers and colorants are added to the PVC granules, which are melted by the extruder and shaped into teak planks through a specialized mold. In the process, the thermoplastic material is formed at high temperatures and then solidified in a cooling medium. The deck board core is coated and bound with an outer plastic shell, but the materials can be temperamental and hard to work with. Commercial production is challenging, not only for this reason, but also because about one eighth of the deck boards produced are considered unsellable and therefore scrapped. The fragile nature of this production process requires careful ingredient mixing and precise execution. [3]
The extruded strips need to be manually processed, glued together, caulked, and then adhered to the deck. The high labor requirement makes the process relatively expensive. Due to the desire for realism, it can only be automated to a limited extent. However, this method provides the installer with great flexibility, as these coverings have properties that make them highly shapeable, formable, and bendable.
With the colors of the caulking, a great variety can be achieved. Some manufacturers offer caulking colors that can be selected from the RAL color scale.
PVC decking offers the most significant fade, stain, and mold resistance among decking products. The products are marketed as low-maintenance and are typically easy to clean and maintain. PVC decking typically doesn't require staining, sanding, or painting. It is sometimes partially composed of recycled plastic material, making it an environmentally friendly, efficient use of resources. The product is significantly lighter compared to wood composite products and can be bent and shaped to create custom configurations. [1]
Additional benefits:
Compared to other synthetic decking products, PVC is the most expensive. The 100% PVC makeup of the board makes it costlier than the wood powder/plastic mix used in composite decking. This cost means that PVC will be a more expensive investment up front, although manufacturers claim that the long life and low maintenance requirements of the deck make it an economical decision in the long run. PVC lacks the realistic feel of wood. Although manufacturers form the product with a realistic wood grain or brushstroke, some contractors and homeowners simply do not like the artificial sheen of the product. PVC is also formulated to resist scratches, stains, and mold, but some wear will still show over the life of the product.
Additional disadvantages:
Polyvinyl chloride (alternatively: poly(vinyl chloride), colloquial: vinyl or polyvinyl; abbreviated: PVC) is the world's third-most widely produced synthetic polymer of plastic (after polyethylene and polypropylene). About 40 million tons of PVC are produced each year.
A thermoplastic, or thermosoftening plastic, is any plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling.
Siding or wall cladding is the protective material attached to the exterior side of a wall of a house or other building. Along with the roof, it forms the first line of defense against the elements, most importantly sun, rain/snow, heat and cold, thus creating a stable, more comfortable environment on the interior side. The siding material and style also can enhance or detract from the building's beauty. There is a wide and expanding variety of materials to side with, both natural and artificial, each with its own benefits and drawbacks. Masonry walls as such do not require siding, but any wall can be sided. Walls that are internally framed, whether with wood, or steel I-beams, however, must always be sided.
In architecture, a deck is a flat surface capable of supporting weight, similar to a floor, but typically constructed outdoors, often elevated from the ground, and usually connected to a building. The term is a generalization from the deck of a ship. A level architectural deck may be intended for use by people, e.g., what in the UK is usually called a decked patio. "Roof deck" refers to the flat layer of construction materials to which the weather impervious layers are attached to a form a roof. It is known as the "roof deck", and they may be either level or sloped.
A deck is a permanent covering over a compartment or a hull of a ship. On a boat or ship, the primary or upper deck is the horizontal structure that forms the "roof" of the hull, strengthening it and serving as the primary working surface. Vessels often have more than one level both within the hull and in the superstructure above the primary deck, similar to the floors of a multi-storey building, that are also referred to as decks, as are certain compartments and decks built over specific areas of the superstructure. Decks for some purposes have specific names.
Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet, or "film" when referring to thinner gauges and certain material types, is heated in an oven to a high-enough temperature that permits it to be stretched into or onto a mold and cooled to a finished shape. Its simplified version is vacuum forming.
Vacuum forming is a simplified version of thermoforming, where a sheet of plastic in various forms of High Impact Polystyrene Sheet (HIPS) for low impact products, or ABS for bathroom shower trays, and HDPE for exterior vehicle parts, plus various other types of vacuum formable materials) is heated to a forming temperature, stretched onto a single-surface mould, and forced against the mould by a vacuum. This process can be used to form plastic into permanent objects such as turnpike signs and protective covers. Normally draft angles are present in the design of the mould to ease removal of the formed plastic part from the mould.
Wood–plastic composites (WPCs) are composite materials made of wood fiber/wood flour and thermoplastic(s) such as polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), or polylactic acid (PLA).
A flat roof is a roof which is almost level in contrast to the many types of sloped roofs. The slope of a roof is properly known as its pitch and flat roofs have up to approximately 10°. Flat roofs are an ancient form mostly used in arid climates and allow the roof space to be used as a living space or a living roof. Flat roofs, or "low-slope" roofs, are also commonly found on commercial buildings throughout the world. The U.S.-based National Roofing Contractors Association defines a low-slope roof as having a slope of 3 in 12 (1:4) or less.
Vinyl composition tile (VCT) is a finished flooring material used primarily in commercial and institutional applications. Modern vinyl floor tiles and sheet flooring and versions of those products sold since the early 1980s are composed of colored polyvinyl chloride (PVC) chips formed into solid sheets of varying thicknesses by heat and pressure. Floor tiles are cut into modular shapes such 12-by-12-inch squares or 12-by-24-inch rectangles. In installation the floor tiles or sheet flooring are applied to a smooth, leveled sub-floor using a specially formulated vinyl adhesive or tile mastic that remains pliable. In commercial applications some tiles are typically waxed and buffed using special materials and equipment.
Compression molding is a method of molding in which the molding material, generally preheated, is first placed in an open, heated mold cavity. The mold is closed with a top force or plug member, pressure is applied to force the material into contact with all mold areas, while heat and pressure are maintained until the molding material has cured; this process is known as compression molding method and in case of rubber it is also known as 'Vulcanisation'. The process employs thermosetting resins in a partially cured stage, either in the form of granules, putty-like masses, or preforms.
Vinyl siding is plastic exterior siding for houses and small apartment buildings, used for decoration and weatherproofing, imitating wood clapboard, batten board and batten or shakes, and used instead of other materials such as aluminum or fiber cement siding. It is an engineered product, manufactured primarily from polyvinyl chloride (PVC) resin. In the UK and New Zealand a similar material is known as uPVC weatherboarding.
Closed-cell PVC foamboard is a lightweight rigid material used primarily in the manufacture of signs and displays. It is considered robust for outdoor use, being immune to rain and resistant to wind and sunlight.
Plastic lumber is a plastic form of lumber made of virgin or recycled plastic. It is mostly made of plastic and binders such as fiberglass or rebar; not to be confused with wood-plastic composite lumber. Widely employed in outdoor decking, it is also used for molding and trim and garden furniture such as park benches. Resistant to cracking and splitting when appropriately installed, plastic lumber can be molded with or without simulated wood grain details. Even with a wood grain design, plastic lumber is still easy to distinguish visually from natural timber: the grains are the same uniform color as the rest of the material.
Disposable food packaging comprises disposable products often found in fast-food restaurants, take-out restaurants and catering establishments. Typical products are foam food containers, plates, bowls, cups, utensils, doilies and tray papers. These products can be made from a number of materials including plastics, paper, bioresins, wood and bamboo.
A synthetic fence, plastic fence or (when made of vinyl) vinyl or PVC fence is a fence made using synthetic plastics, such as vinyl (PVC), polypropylene, nylon, polythene (polyethylene) ASA, or from various recycled plastics. Composites of two or more plastics can also be used to increase strength and UV stability of a fence. Synthetic fencing was first introduced to the agricultural industry in the 1980s as low-cost, durable horse fencing. Now, synthetic fencing is used for agricultural fencing, horse race track running rail, and residential use. Synthetic fencing is generally available preformed, in a wide variety of styles. It tends to be easy to clean, resists weathering and has low maintenance requirements. However, it also can be more expensive than comparable materials, and cheaper products can be less sturdy than more traditional fence materials. Some types may become brittle, faded or degrade in quality after long exposure to extreme hot or cold conditions. Recently, titanium dioxide (TiO2) and other UV stabilisers have proven to be a beneficial additives in the manufacturing process of vinyl. This has greatly improved the durability of vinyl by providing essential UV protection from the sun's harmful rays, preventing premature ageing and cracking of the product, making it more durable than other materials such as wood.
Plastics are a wide range of synthetic or semi-synthetic materials that use polymers as a main ingredient. Their plasticity makes it possible for plastics to be molded, extruded or pressed into solid objects of various shapes. This adaptability, plus a wide range of other properties, such as being lightweight, durable, flexible, and inexpensive to produce, has led to their widespread use. Plastics typically are made through human industrial systems. Most modern plastics are derived from fossil fuel-based chemicals like natural gas or petroleum; however, recent industrial methods use variants made from renewable materials, such as corn or cotton derivatives.
Composite lumber is a material that is a mixture of wood fiber, plastic, and some type of binding agent. These ingredients are put together to form a material that is denser, stronger, and heavier than wood alone, a wood-plastic composite.
Trex Company, Inc. is a manufacturer of wood-alternative composite decking, railing, and other outdoor items made from recycled materials. Headquartered in Winchester, Virginia, Trex is the world's largest manufacturer of wood-alternative decking and railing. Trex composite products are made of 95% recycled materials. In redirecting more than 400 million pounds of plastic and scrap wood from landfills each year, Trex is one of the largest plastic film recyclers in the US.