PVC decking

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.

Early manufacturing processes for PVC decking faced high scrap rates, reportedly reaching up to 12%.{{cite web|title=Wood Plastic Composites vs. PVC Decking|url=http://columbus-decks.com/2010/02/11/wood-plastic-composites-vs-pvc-decking/|publisher=Columbus Decks|accessdate=13 September 2013}}{{Cite web |last=Energetics |first=Incorporated |date=2002-06-01 |title=Energy and Environmental Profile of the U.S. Plastics Industry |url=https://www.energy.gov/eere/amo/downloads/energy-and-environmental-profile-us-plastics-industry |url-status=live |access-date=2025-06-01 |website=U.S. Department of Energy |quote=Scrap rates in the PVC segment were once as high as 10-12% due to early processing inefficiencies.}} Advances in technology and recycling have reduced this to below 2% in many factories.Still, commercial production remains complex, with some manufacturers reporting up to one-eighth of boards being cosmetically imperfect and unsellable.{{cite web|title=Dura teak recycling|url=https://dura-teak.com/2025/01/10/teak_manufacturing_recycling/|publisher=Dura-teak|accessdate=10 January 2025}}

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 co-extruded protective cap layer, but the materials can be temperamental and hard to work with.{{Cite web |last=Kazmer |first=David O. |date=2012-06-14 |title=Plastics Manufacturing Processes |url=https://scholarworks.umass.edu/cgi/viewcontent.cgi?article=1002&context=mechanical_engin_faculty_pubs |url-status=live |access-date=2025-06-01 |website=University of Massachusetts Amherst – ScholarWorks |quote=Coextrusion requires precise control over viscosity, material compatibility, and die design to maintain layer integrity. The complexity of multilayer polymer flow often results in instability or defects if not carefully managed.}} 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.{{cite web|last=Webb|first=Craig|title=Composite or PVC: Which One is Best?|url=http://www.ecobuildingpulse.com/green-products/composite-or-pvc--which-one-is-best-.aspx|publisher=EcoBuilding Pulse|accessdate=13 September 2013}}

The extruded planks 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(a standardized European color matching system).

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PVC decking offers the most significant fade, stain, and mold resistance among decking products.{{Cite web |last=Martin |first=James W. |date=2010-03-01 |title=Weathering of Polymers |url=https://www.nist.gov/publications/weathering-polymers |url-status=live |access-date=2025-06-01 |website=National Institute of Standards and Technology |quote=The resistance of polymers to outdoor weathering, including UV degradation, varies by formulation; PVC is among the more weather-stable commodity plastics.}} 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.{{Cite web |last=U.S. Environmental Protection Agency |date=2016-11-01 |title=Advancing Sustainable Materials Management: 2014 Fact Sheet |url=https://www.epa.gov/sites/default/files/2016-11/documents/2014_smmfactsheet_508.pdf |url-status=live |access-date=2025-06-01 |website=United States Environmental Protection Agency |quote=Recycling of durable goods, including plastics like PVC, contributed to a net reduction in greenhouse gas emissions and overall waste generation.}} While PVC decking is lighter than most wood-plastic composite boards, it can still be heavier than natural teak wood due to its dense polymer composition.

Additional benefits:

• recyclable material
• does not absorb red wine and other liquids
• easy to clean
• durable, maintains appearance for 8–10 years

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:

• In the heat of summer, the products of certain manufacturers get very hot{{Cite web |last=Akbari |first=Hashem |date=2011-07-01 |title=Cool Roofs and Heat Islands |url=https://www.nrel.gov/docs/fy11osti/51312.pdf |url-status=live |access-date=2025-06-01 |website=National Renewable Energy Laboratory |quote=Polymer surfaces such as PVC can reach high surface temperatures under direct sunlight, impacting material selection in hot climates.}}
• Installation requires expertise
• Heavier than teak wood

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• Composite lumber
• Wood-plastic composite

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Category:Plastics applications

Category:Floors