TYPES OF DECK COATINGS
What kind of deck coating do we have on our deck(s)?
This is a very common question, one that is often difficult to answer, especially when only looking at a picture. Visual inspection and sometimes destructive testing will reveal the type of coating, if not the manufacturer. It is important to know what type of coating one has on their decks, as most coatings that are similar have very similar maintenance requirements. At the worst, knowing what type of coating will suffice for probably 90% or more of your needs.
We have broken down the typical deck coatings found on HOA's and Apartment Communities into seven distinct types of coatings and down below, also listing the manufacturer's we know make them. Many manufacturer's of these types of systems make several types of coating systems, for example, Mer-Kote Products manufacturer's a slip sheet system and they also make a metal lath system too. Excellent Coatings and Hill Brothers make metal Lath & Acrylic coatings and they also make Fiberglass systems. Click on the blue link to go down the page to what you want to see.
Differentiating between some coatings isn't easy, however, some things to look for can help you tell what type of coating one has. Slip sheets usually sound hollow when tapped on with a spoon. A flat finish also indicates a slip sheet. Urethanes are usually given away by the presence of sand in the top coat. Metal lath systems and fiberglass systems look alike as the top finishes are usually done the same way, so they are difficult to tell apart by just looking at them. Vinyl decks will look like your kitchen floor, Pebble Bond Systems have a unique look and so does Magnesite.
We recommend that you use our Questions to Ask list that we developed that will help you understand the different deck coatings you might be presented with as options, interview contractors with and do your due diligence as any Board member or anyone should. Another thing to investigate is whether or not the product you are considering has been tested and rated by ICC Evaluation Service Inc. This independent evaluation service tests manufacturer's products for fire resistance amongst other criteria. Click here to look up ICC Evaluation reports. (This will open a new page on ICC's website.)
New in 2007, reports issued by ICC are taking Wind Ratings into account for deck coatings. This will be a very important issue to watch out for; some deck coatings are rated for buildings in high wind zones-up to 120-150 mph. Some deck coatings have ratings for wind zones that are much lower-80 mph. The other tricky factor that will trip up many is the building height. Many coatings are limited to buildings that are 40' in height or less. Has your installer read and understood the plans? If they specify a product that doesn't meet the ICC codes and city building requirements, there may be a liability issue. This problem applies to all different types of deck coatings,
Don't get blown off your decks with the wrong coating!
Fire ratings for deck coatings available are Class A, Class B and so on as well as a separate "One Hour Rating". Thoroughly check out any coating you may be considering for it's fire rating. You don't want to find our after the fact that you need a fire rated coating over your deck. Click here to go to Professional Roofing magazine; an article on fire ratings will help you understand. You can also click here to go to Underwriters Laboratories for further fire rating information.
It is extremely important to know and understand that One Hour Fire Resistive deck coatings can have very different requirements in order to get a One Hour rating. An example is Polycoat Products Polycoat Walking Deck ICC rated ER-4789 urethane system requires 3/4" Plywood with 2" x 10" joists. Then look at the requirements for Desert Crete from Hill Brothers. Their ICC ESR-1661 report requires 5/8" plywood over 2" x 8" joists.
There are big differences with different coatings, one in terms of costs of framing, certainly, but also calculating loads, footings, and clearances.
A client recently inquired about Fire ratings, looking to substitute Life Paints Life Deck AL ER-5416 instead of the specified Pli-Dek ESR-2097 metal lath system called for on the plans. They couldn't find a Pli-Dek installer in their area. A review of the project showed the first building was already framed out and 2 more were coming fast. The building framed out had deck joists that were 2" x 8" with 5/8" plywood on top. Then we looked at Life Deck AL's ICC report. Big problem! Life Deck AL called for a 2" x 10" joist for the One Hour fire rating.
Looking at Pli-Dek's ICC, we found that their basic requirements of 5/8" plywood and 2" x 8" framing met the same requirements that Desert Crete did. By switching to Desert Crete instead of Life Paints Life Deck AL, the owner of the project saved himself approximately One Hundred Fifty Thousand Dollars in change order costs for framing.
Check plans carefully before allowing just any bid on a One Hour Fire Rated deck coating-you might get burned!
Another good site to look at is Coatings Advisor - Your source for coating products and services. This site contains tons of pages on various coatings, including deck coatings, epoxy, and every other type of coating you can think of.
Here is a basic discussion on the deck coating categories . Links to manufacturer's are below each category listing. You will note that manufacturer's may be listed in multiple instances under different categories, that is not a mistake.
www.merkote.com www.dexotex.com
Slip Sheet decking is a coating that is comprised of multiple layers of materials over a paper that "slips" over the plywood deck surface. These systems are chemically bonded only to the flashings around the perimeter of the deck. There are only two manufacturer's of slip sheet systems, Crossfield Products Corp (Dex-O-Tex) and Mer-Kote Products Inc.
The theory here for slip sheet systems is that framing and plywood decks move as a natural course from heat/cold, expansion/contraction. The slip sheet moves with the deck/framing, allowing it to flex without cracking.
Proper preparation is vital on these systems, and cleaning the flashings of bond breaking oils is absolutely essential, as is venting the decks to allow moisture to escape out.
Careful use and strictly following the manufacturer's maintenance instructions will ensure maximum life from these coatings. Of the two, Mer-Kote has the least resistance to damaging UV; the Weatherdek© system relies heavily on a lot of regular maintenance.
For HOA's, slip sheets are probably not the best option available; high maintenance combined with low UV and damage resistance suggest that you look for other options.
Mer-Kote's Weather Deck coating system apparently is not a One Hour Fire Rated system; on their web-site is a page that has a "One Hour Addendum" to achieve a One Hour Fire Rating (critical to have, especially on decks over living spaces or garages.) See Mer-Kote's page by clicking here to go to the addendum. This is a "watch out for" when bidding, it seems it will certainly add additional costs onto a bid where other competing coatings are already One Hour fire rated.
Click here for Maintenance Instructions for Mer-Kote Weatherdeck. We recommend that you use our Questions to Ask list that we developed that will help you understand the different deck coatings you might be presented with
www.alldeck.com www.excellentcoatings.com www.plidek.com www.desertbrand.com
There are quite a few manufacturer's who make fiberglass systems. In the
early days of waterproofing decks, fiberglass was glued down to plywood by many
manufacturer's, however today, only one still specifies fiberglass over plywood
decks. The rest have adjusted their specifications to using fiberglass systems
to renovate existing decks, such as Magnesite, Dex-O-Tex's Weatherwear and to
repair cracked concrete slabs and walkways.
All-Deck is the one manufacturer we know of still specifying fiberglass over plywood; Desert Brand, Excellent Coatings, Pli-Dek and a few others do not. Improvements in resins have helped the bonding issues that can occur on plywood, however, large decks that would have some movement in it on a long term basis to feel secure to use fiberglass only.
Basically fiberglass coatings use a 3/4 oz. non-directional woven mat of fiberglass, bonded to a surface with a water resistant resin. A basecoat is applied over the fiberglass to provide protection, then a variety of finishes can be put over this. Fiberglass systems are self flashing on block and cement walls with proper attention paid to the details of lapping it up the wall and applying bonder/resin.
The great advantage fiberglass systems have is in their ability to restore decks and concrete with cracks in them. This can save costs in tearing out decks or sidewalks and re-pouring them. After any cracks are properly repaired, the fiberglass applied over the surface helps hide the cracks, preventing them from telegraphing up through the coating. We have seen this done with great success on pool decks, lightweight concrete decks poured over steel pan decks and even driveways!
We wouldn't be comfortable putting fiberglass over plywood decks; we have seen (and used) fiberglass systems to renovate existing decks that aren't leaking. An inexpensive alternative to tearing out an old system an installing a new one.
Click here for Maintenance Instructions for All Deck We recommend that you use our Questions to Ask list that we developed that will help you understand the different deck coatings you might be presented with
www.waterproofingmaterials.com http://www.lifepaint.com/ * http://westcoat.com/ * www.excellentcoatings.com www.desertbrand.com www.merkote.com www.plidek.com www.endurokote.com
Metal lath and Acrylic coatings have become the coating to put on
decks with all the major tract builders in Southern California. Heavy marketing
efforts, SB-800, multi-million dollar settlements for water intrusion issues,
builders seeking better materials that help them in their risk reduction
efforts, all have combined to thrust these coatings into the limelight. At PCBC
2006, five manufacturer's were at the show marketing their metal lath decking
systems to builders, architects and sub-contractors.
With this system of galvanized metal lath, acrylic modified cements, fiberglass (depending on the manufacturer), and a pigmented sealer, these coatings resist the damage that it's competitors can't. Resistance to UV, cracking, use and abuse combine to make these coatings desirable for builders. Fiberglass is being used by several manufacturer's, with what appear to be superior results over the multi-layers of cements and sealers.
The diagram to the left shows a brand using a fiberglass layer. This type of system has an added advantage of preventing cracks that may develop from showing through the surface. The total of this system is greater than the sum of it's parts. Each layer performs a distinct function that all work together to provide a top quality deck system.
Metal lath systems, just like everything else, comes in varying levels of quality. Installer know how is critical, we've seen these systems fail, but it seems when they did, it was an installer error that caused the deck to fail.
*Recently we were queried by a client who wanted to know about Westcoat Specialty Coatings, the new firm of Paul Koury. They wanted to know, but could not find, any information on ICC's website whether WestCoat Specialty Coatings had any approvals for walking decks from ICC/ICBO. The installer they were working with told them it was the same thing as Life Deck and there was no problem. Well, this contractor was wise enough to not just take his sub's word for it that he shouldn't worry about it, as the plans specified an ICC approved product.
As we understand the situation, Life Paint, Inc., and Paul Koury are engaged in a law suit. Paul Koury has split from Life Paint and formed Westcoat Specialty Coatings. Product labeled as "Westcoat Specialty Coatings" is now being shipped to wholesalers in California and other western states.
Life Paint, Koury's previous business associate, is selling Life Deck branded products to wholesaler and retailers in California.
Our investigation into the question shows that there is no ICC or ICBO approved products from Westcoat at this time. A check of ICC's website reveals no approvals/reports on file. From what we are told by Matt Ranzau, a representative from Westcoat, there is an application in and they expect to have an ICC# issued to them shortly.
Language on Westcoat's website might lead one to believe that their product has meet ASTM tests and has a Class A fire rating. We have not found any documentation to prove their claims, nor would Westcoat Specialty Coatings provide us with any information in writing, despite Matt Ranzau's claims in a phone call to me last week (June 21st, 2007) that they had data in their office that proved it. Our request for a technical binder on their product lines was refused by Matt Ranzau, he citing that they didn't want to give a binder to someone who was "just interested in information." Jeez, what are they afraid off? Giving out information that the public should have before making a critical decision on waterproofing? As a contractor and consultant, I've never had a manufacturer refuse my request for their technical binder.
As of 7/12/2007, I was supplied a copy of a Westcoat Specialty Coatings binder from an installer who wasn't interested in installing the product and had no use for the binder.
On (June 2nd or so), I received an email from Paul Koury's attorney, in regards to a website link that listed his clients registered web address and when clicked upon, sent the person to his clients competitor. Sorry for the confusion, we have changed that on the pages the link appears on. The attorney also continued on about why we were so interested in "intermeddling" and provided some of his clients side of the dispute. So, Click here to read Westcoat's side in their attorney's letter to me. Our interest lies in providing our clients and web visitors with accurate information on coatings, report news that may have an effect on the industry, and provide our opinion on what we would do in a situation.
So, our opinion is*-
We would caution buyers of Westcoat's ALX products to be careful, putting down materials that are not ICC or in the case of their tile waterproofing system, Ceramic Tile Institute approved approved building products may you exposed to liability, particularly if on new construction, an architect specifies an ICC or ICBO approved product. Usually on a set of plans it may, for example, call for "Life Deck AL, ICBO # ER-5416 or approved equal. Using a non-approved product or one without the same ratings could violate the architects direction and would probably leave you exposed if the non-approved/lower rated product failed later on, or what if on an inspection, it's noticed that an approved, specified product is not being used? Think about what it would take if you were made to tear out the non-approved work? Always inquire with the architect and get their direction first. Legal counsel may be advisable as well, GET WESTCOAT directly involved; let them write the spec's and insist that they take on liability in the case of failures or legal issues later. On any current or future jobs where Life Deck's AL deck coating product was specified as the system to be installed, and your installer is putting in Westcoat Specialty Coating Systems ALX without your prior approval as an equal or better substitution; you need to act to ensure your interests are fully protected.
*Again, this is only our opinion and you should inquire with your own experts and counsel and come to your own conclusions.
Life Deck distributors have been switching over to Westcoat products who are shipping them out to installers. Some wholesalers who are stocking Westcoat Specialty Coatings products are Smalley & Co., Lowry's, and others.
Another opinion*-
At this time, we can only recommend that if your project specifies products with an ICC/ICBO #, that you do not accept any products that don't carry an ICC/ICBO# without doing your research and making proper inquiries. Getting approvals ahead could save you a lot of headaches later in the case an ICC/ICBO approved product was called out for.
In our inquiries to Westcoat Specialty Coatings in regards to using their non-approved ALX products and what potential liability issues there might be, we were directed to consult with an attorney. You should take that advice too.
*Again, this is only our opinion and you should inquire with your experts and counsel and come to your own conclusions.
It seems "factory or wholesaler approved" installers of Life Deck are getting Westcoat products through wholesalers, and non-approved installers are buying Life Deck labeled products through hardware stores such as Ganahl Lumber in Southern California and up around the San Luis Obispo area, Miners Ace Hardware.
2/12/2008 UPDATE-as of January 2008, Westcoat Specialty Coatings ALX system received an ICC approval. The report can be found on ICC's website. However, the coating was evaluated for wind and Class A fire rating's, not the most important ONE HOUR fire resistance.
We still recommend that you look closely at this product, it's short history and consider all your options before making a decision on decking.
We recommend that you use our Questions to Ask list that we developed that will help you understand the different deck coatings you might be presented with.
Click here for Maintenance Instructions for Life Deck
Click here for Maintenance Instructions for Pli-Dek
Click here for Maintenance Instructions for Mer-Kote Shurdeck.
Click here for Maintenance Instructions for Desert Crete
Click here for Maintenance Instructions for Excellent Coatings
Click here for Maintenance Instructions for Westcoat Specialty Coatings
Vinyl decking is just what it sounds like, heavy duty UV resistant vinyl
flooring like what you'd
buy for a kitchen floor. There are some differences of
course, but the basics are all there. Popular in colder climates where UV isn't
as big of a problem. Also used on docks sometimes.
When vinyl deck coverings were first introduced, especially at seams on decks larger than the 12' width of the material, failures occurred. The old technique was to butt the seams together to keep a smooth seam. Now the technique is to lap over the materials by approximately 1".
Vinyl coverings are self flashing, the technique used is to simply roll the vinyl up the wall or down over the outside edge, securing the turned vinyl with bars and screws. Special attention to details such as these is critical to these decks properly performing. Maintenance consists of cleaning the covering quarterly with special cleaner.
Click here for Maintenance Instructions for Duradek We recommend that you use our Questions to Ask list that we developed that will help you understand the different deck coatings you might be presented with
www.tufflexpolymers.com http://www.polycoat.org/
www.carlisle-ccw.com
www.deckote.com
www.multicoat.com
www.polytuffus.com
Urethane coatings are the ultimate waterproofing system; 100% impenetrable by water, they will keep an occupied space free of water intrusion. However, let people walk on it, use it with grills and tables and chairs on it and it's weakness becomes apparent; it can't resist much use and abuse.
There are basically two types of urethanes used for waterproofing decks; solvent based and water based. Tufflex is a well known water based urethane, utilizing plain water to set up and form a heavy layer of flexible materials. Pacific Polymers is a well known manufacturer of solvent based urethanes that cure by absorbing moisture in the air. After the waterproof layers are applied, sand is often broadcast into the pigmented sealer for grip.
Solvent based urethane systems in particular have been hit hard by tougher and tougher VOC standards in the state of California; they have been notorious for using chemical formulations that have links to known carcinogens. Today's urethanes are substantially different than those of years past. They require high amounts of maintenance to protect their tender under layers-think of a rubber band on the dashboard of your car on a hot day. It will become brittle and break easily with just a few hours of exposure. Urethanes have the same problem, lack of UV resistance. Their life depends entirely on being protected from UV with pigmented sealers-sun-block if you will to keep damaging rays from burning up the waterproofing layers. Just like your skin, when the sun-block stops being effective after a period of time, you start to get sunburned.
While inexpensive compared to other waterproofing, the long term maintenance costs and risk of being easily damaged outweigh the benefits of cost. An HOA would be probably better off with other alternatives.
We recommend that you use our Questions to Ask list that we developed that will help you understand the different deck coatings you might be presented with
Click here for Maintenance Instructions for Pacific Polymers (These instructions also apply to most other solvent based polyurethane coatings)
Click Here for Maintenance Instructions for Tufflex (water based urethane)
Click Here for Mandatory Maintenance Instructions for PolyTuff. We've never seen any as tough as this before! We wonder why they call it PolyTuff?
http://www.epoxyproducts.com/riverstone.html (links to repairing Pebble Bond systems) www.lifedeck.com/2002/systems/pebblesystem/pebblehome.htm
While not a true deck coating, we have included the Pebble Bond System here
as we are so often
asked
about these concrete coatings.
Pebble Bond Systems, or "Pebbles in Epoxy", are all over southern California, much to the dismay of many an owner; who was apparently never told (or maybe it was down played by the salesman) that these concrete coatings need to be resealed frequently. The manufacturer's rosy 2-3 year resealing schedule doesn't work very well in the high UV exposure areas. The reality appears to be a 1 year, maybe 18 month resealing schedule, especially as epoxies VOC limits are affected, it will be tougher for them to get higher UV resistance- a true challenge to chemists.
Life Deck is the only manufacturer of a whole pebble bond system that we have found. The other link tells you how to fix these troublesome coatings, once the stones start breaking loose, it's bedlam when they get in the pool!
While these coatings are nice to look at, we think you should consider these systems very carefully before putting them on your concrete areas and don't ever be believe that they can be used to waterproof a deck over living space!
Click Here for information on repairing Pebble Bond Surfaces-This will open a new window that will take you to another site that is not related or affiliated with us but contains good information on these products.
We recommend that you use our Questions to Ask list that we developed that will help you understand the different deck coatings you might be presented with
Another
unique coating, Magnesite is the granddaddy of deck coatings. Made by Hill
Brothers Chemical Company for over 60 years now, Magnesite is magnesium
oxychloride cement, a non-combustible cement that dries very quickly, can be
shaped into unique architectural details and has been put on millions of square
feet of decks and walkways and stairs on buildings throughout greater Los
Angeles, the Bay Area and beyond. It is seen everywhere as it is an architects
design favorite. Magnesite is still sold today and though not as popular, is
finding a resurgence in new applications for flooring solutions inside and out.
Every manufacturer of decking drools at the thought of selling the amount of
material Hill Brothers has with Magnesite.
While it will last well over 30 years, performance comes at a price, which is maintenance. Weak points are at the areas where railings penetrate to the wood subfloor. Movement in the railings invariably allows the cement to crack a bit, leading to water penetration if not caulked. Cracks that appear on the surface need to be treated and the surface resealed about every 18 months.
Classic styling, durability and uniqueness will keep this product around for a while; keep up on the maintenance and it will last and last.
WARNING- Magnesite made prior to 1972 was manufactured with asbestos in it. If you are working on buildings built through 1974 you are advised to test for the presence of asbestos prior to removing any Magnesite. Contractors in California are REQUIRED to have a license for asbestos removal on any amount of area over 100 square feet. Exposure to asbestos is hazardous and continued exposure may cause cancer. Removal of Magnesite without mitigation could expose Building owners, HOA's and others to potential liability for exposing tenants, owners, visitors and workers to asbestos. Proposition 65 signs need to be installed if they are not already. Visit www.cslb.ca.gov for further information on asbestos.
Click here for Maintenance Instructions for Magnesite. We recommend that you use our Questions to Ask list that we developed that will help you understand the different deck coatings you might be presented with
www.pacpoly.com www.lifedeck.com www.plidek.com www.merkote.com www.polytuffus.com www.lifepaint.com
We have included tile decks here as we are asked about them quite often. Tile decks should only be put on new buildings with all conditions designed for the installation of tile, not as an afterthought.
Tile decks are not waterproofed by tile; rather they are first waterproofed in a conventional method, using deck coating waterproofing systems that can then have tiles placed over it. Most deck systems can have tile put down over them, however there are only a few that have been rated and approved by the Ceramic Tile Institute of America. See their website for approved tile waterproofing deck products. Very careful planning is required, as is engineering to carry the extra loads that tile places on a buildings framing system. We recommend that you use our Questions to Ask list that we developed that will help you understand the different deck coatings you might be presented with
An excellent article about tile decks and flashing/waterproofing issues can be found by following this link- www.ctioa.org/reports/fr101.html This article has a lot of great information that must be read by anyone contemplating installing tile!
Tile decks need to have their tile and grout sealed, one to keep from getting stained and dirty, these sealers are the first line of defense in keeping water away from the waterproofing.
HOA's with existing decking systems are not good candidates for putting tile over- We do not recommend that tile be placed over an existing deck system, we have seen the results that can happen with that-tile over the stucco weep screed, blocked up scuppers, weep holes on sliding doors weeping water under the tile, the list goes on. Often times the hidden damage that occurs will end up costing the Association many times the cost of redoing the decks properly in the first place.
Click here for more information on consulting, inspections, bid analysis or seminars.
