PLASTIC LUMBER YARD®
Plastic boards for all your outdoor needs and then some.

Voice: 610.277.3900 Fax: 610.277.3970 E-mail: info@plasticlumberyard.com

 
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The Product:

1) Composition

Plastic Lumber Yard plastic boardsis a solid, non-hollow foamed recycled product made from Recycled High Density
Polyethylene (ReHDPE) plastic. Common HDPE (recycling code # 2) products are gallon style milk, water and
juice containers, as well as some detergent and shampoo bottles.
Plastic Lumber Yard plastic boards is 100% plastic with no wood fillers to rot, peel, weather or blister, and generally contains over
90% recycled HDPE plastic material.

2) Color

Plastic Lumber Yard plastic boards utilizes Ultra-Violet (UV) stabilized colorants added during the manufacturing process to
ensure a long lasting, fade resistant product requiring no staining, painting or sealing of any kind. Even when cut,
the exposed product is colored. Standard deck colors are Teal, Dark Gray, Dove Gray and Weather Teak, White, Ivory and Oak
We also have special order colors and a wood grain embossment available. Subject to an additional charge.

3) Texture

Plastic Lumber Yard plastic boards are manufactured with a slight wood grain-like texture, creating an easy to clean surface that is
no more slippery when wet than a painted or sealed wood deck. A natural film, which can’t be seen or felt, is left on the surface of the material after manufacturing. Sunlight will  normally “burn off” this film in a few weeks. A rougher, slip resistant (knurled) finish is available if required. Keep in mind that the coarser the surface finish, the more likely dirt will tend to collect on it.

4) Product Life

Plastic Lumber Yard plastic boards are still going strong after over twenty years of accelerated weather testing. We haven’t seen the total life span of the product to date. We do have product installed on boat docks since 1976 with no sign of degradation.

5) Maintenance

Plastic Lumber Yard plastic boards are virtually maintenance free! No staining, painting or sealing is ever required! Washing with a garden hose or mop is about all that is needed under normal circumstances. For stubborn stains, a  mixture of bleach and water (1 part bleach to 10 parts water) can be used without harming the product. After all, bleach and acids are normally sold in HDPE plastic bottles.

6) Tools

Standard woodworking tools can be used. You may have to use a lower speed with your router or planer/jointer to prevent “gumming up” of the router bit or the planer/jointer knives. Carbide tipped bits and blades are recommended. Always use tools according to manufacturer’s instructions, and wear protective clothing and safety glasses for your safety.

7) Weight

The weight of this product is comparable to Oak lumber.

8) Sizes and Shapes available for decking

 

Deck Design:

Virtually any deck design can be built using Plastic Lumber Yard plastic lumber boards, while keeping in mind the below guidelines:

1) Board Length

Plastic Lumber Yard plastic lumber will expand and contract along its length, similar to vinyl siding, with temperature changes  It is recommended that the deck boards should not exceed 16’ in length.

Apply deck boards across the shortest length of the deck whenever possible.  Use of multiple deck levels to create transitional zones, or use of board patterns such as herringbone, checkerboard, angles, change of direction, etc. can all be used to increase the overall deck size while maintaining a minimum length on the deck boards.

Working with deck sections larger than 16’

Installation of lengths longer than 16’ should be avoided due to the expansion and contraction of Plastic Lumber Yard recycled plastic decking. This can be accomplished by using any of the following techniques:

Option 1 (for decking surface):

Use feature boards to break up the deck into “manageable” sections of shorter lengths. The structure must be modified to support the feature board while also supporting the ends of the deck boards running up to it. To do this, a wood 6x6 is installed directly below the feature board and two joists are installed on either side of the 6x6. These are all joined together using bolts with nuts and washers.

4) Substructure

Plastic Lumber Yard plastic lumber is not suited for structural purposes. We recommend using a high quality kiln dried treated wood product, or galvanized steel, for your substructure to prevent warping and bowing.

Wind bracing should be installed on a 45° angle to the joists, at 4’ to 6’ intervals, especially on larger decks. Traditional blocking methods may also be used.

Joists shall be installed with spans according to the chart below.

Actual Plastic Lumber Yard Lumber Size (inches) Maximum Allowable Span for 40 psf Uniform Load (inches)
¾” x 5½” 12 12
¾” x 6” T&G 12 12
1 x 5½” 16 16
1½” x 3½” 16 16
1½” x 5½” 23 23

The top surface of the joists must be flat to avoid the flooring taking on any peaks or valleys of the joists. Be sure all bowed joists are installed with the bow up if they must be used. Badly bowed joists should not be used. The joist system should be properly square.

5) Fascia / Skirting

All exposed wood joists, and optionally the area between your deck and the ground, should be covered to complete the deck. 3/8” x 6” T&G, 1/2" x 8” or 5/8” x 12” Plastic Lumber Yard boards are designed for this application.  It is recommended that these boards be installed vertically or diagonally due to the effect of expansion and contraction. Horizontal installation is acceptable with the use of expansion gaps and caps covering the expansion areas.

5) Wrapping Wood Posts

Wood support posts can be wrapped with Plastic Lumber Yard materials. This will enhance the overall look of your deck as well as further reduce the maintenance your deck will require.

Use either 1/2" or 5/8” thick materials wide enough to be ripped down to the widths necessary to cover the post. Be sure to only fasten plastic to plastic and to leave a gap at the bottom to allow for movement.

This gap can be covered with cutoff trim pieces. DO NOT fasten the material to the post  except at one point at the top to hold it in place. This will allow the expansion and contraction of the material.

Installation:

1) Posts

Posts should be mounted before installation of the flooring. The posts should be thru-bolted to the joists using a minimum of two 1/2" carriage bolts with the nuts to the inside of the deck. This will allow the bolt heads to be easily covered later with a fascia board if bolted through the rim joist.

NOTE: Be sure the rim joist is securely braced wherever a railing post is to be fastened to prevent movement of the post in the finished railing assembly.

2) Board clearances

Ideally, Plastic Lumber Yard boards should be installed at the midrange of normal temperatures for the area at the time of installation (i.e.: approx. 60°F in northern climates).

A space must be left next to building walls and around posts to allow for expansion and contraction of the Plastic Lumber Yard plastic lumber. Generally, a 3/8” gap is sufficient, depending on the temperature of the boards at the time of installation and the length of boards being installed. Please refer to the expansion / contraction chart below to verify this. A trim board can be used, if desired, to cover the gap. Pre-cut post base trim pieces are available.

 NOTE: When cutting notches into Plastic Lumber Yard plastic lumber, drill or router a rounded corner in the cut out to prevent cracking at the corner, as you would with any other hard surface material. This can be accomplished by drilling a 1/2" hole at the corners of the notch and then cutting up to the drilled holes.

3) Board Edge Overhang

A 1” finished overhang of the deck boards beyond the rim joist is recommended.

NOTE: It is generally easier to allow additional overhang of every floorboard during installation, followed by trimming this overhang on a straight line when finished. A slight radius can be added to the trimmed floorboards’ top edge with a router to create a more aesthetically pleasing effect.

4) Fastening

3/4" x 6” T&G floor boards

Blind screw through the tongue into each joist with # 7 x 2 1/4" self-tapping stainless steel trim head screws. This results in a very clean and neat looking deck floor with no visible fasteners.

NOTE: No pre-drilling is required with this installation method. A small amount of lubricant (soap or oil) applied to the screws may aid installation in some joist material, such as Douglas Fir.

Firmly secure decking starting nearest to the house, working away from the house, down the entire length of the board.

4) Fastening (Continued)

3/4" x 5 1/2" Flat floor boards

Face screwing with two # 10 x 3” self-tapping stainless steel screws into each joist is recommended. Boards should be predrilled and slightly countersunk to have the cleanest looking installation. A small amount of lubricant (soap or oil) applied to the screws may aid installation in some joist material, such as Douglas Fir.

NOTE: If you don’t pre-drill, you may want to “tap down” the little mushrooms that may form when using selftapping screws. This will hide part of the screw head for aesthetic purposes. Firmly secure decking starting nearest to the house, working away from the house, down the entire length of the board.

Notes:

Installer and/or purchaser should consult local building codes prior to the building process. Plastic Lumber Yard plastic lumber should be stored on a flat surface prior to installation, and boards should be carried on edge for better support.

Two cuts must be taken when rip cutting Plastic Lumber Yard plastic lumber. This is due to the difference in density between the outer “skin” of the board and the board’s center. For example, if a 3/4" X 5 1/2" board needs to be ripped to 3/4" x 4”, 3/4" should be ripped from both sides.

Information included in this guide is subject to change without notice.

PLASTIC LUMBER SIZES
FOREVERDECK®

FOREVERDOCK®

OUTDOOR FURNITURE

SAMPLES
PVC VINYL PRODUCTS

PICNIC TABLES & BENCHES

PHOTO GALLERY
ENGINEERING DATA
SEARCH
PLASTIC LUMBER F.A.Q.'s
ROOFING
LUMBER COLORS
APPLICATIONS
MAP
SHIPPING
WARRANTY
FASTENERS
ASK CINDY!
HOME