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TABLE SAW TIPS FOR DIY'ERS
CURVES, BABY!
HOW TO BEND BOARDS TO BUILD A BEAUTIFUL DECK
By Kim Katwijk
The ability to bend man-made decking materials is taking builders and homeowners to new heights of imagination
and creativity. All you have to do is look at the last four year’s winners of NADRA’s (North American Deck & Railing Association) national deck competition to realize curves are where it’s at.
If you are a homeowner thinking of upgrading, replacing or building a new deck, you might be wondering if you can create the deck of your dreams yourself, or will you need a professional? After reading this article, you should have a pretty good idea of what it takes to create a curvy deck.
A LITERAL LEARNING CURVE—MY JOURNEY INTO BOARD BENDING
I am in my 25th year of building decks full time. With that many years of experience under my belt, I guess I qualify to fill you in on how it’s done. But first, let me confess my failures.
My first attempts at board bending were with Trex decking some twenty years ago. I had built a curved Cambara wood deck for a client. The client wanted a curved railing to match, so I thought I’d try to heat and bend a Trex composite deck board as the top railing board.
s The board-bending process basically requires heating man-made decking products between two heating blankets or "skins" until they're flexible. A small probe, which is connected to the control unit, is inserted into the board’s edge to monitor its internal temperature.
The first heating apparatus I created was a 20-ft. long by 20-in. diameter Sonotube (cylindrical concrete form) laid on the flat with rebar shoved through the sides to suspend the decking. Two kerosene space heaters forced hot air into each end of the tube. This method produced uneven heating and dismal results.
Next, I tried a water-bath heater using a PVC pipe cut in half lengthwise. I glued four inlets into the half-pipe, then inserted a water tank heater into each inlet. I was able to heat the water to boiling. After an hour of boiling a board, I could bend a 20-ft. composite board to a radius of about 18 feet. That’s not very good. To get the 5-ft. radius I needed, I had to rip the composite boards into three strips, heat them, bend them to a 5-ft. radius, then glue and screw them back together. It was passable.
On another project, I tried to get higher temperatures by insulating the pipe and capping it with rigid insulation. This succeeded so well, the tank melted.
I gave up on bending deck boards until, at a trade show, I discovered the Heatcon bending system. Working with this system, I was able to bend a flat piece of 5-1/2-in. Azek cellular PVC decking to a radius of 22-1/2 inches. Impressive! This opened the door to new levels of artistic expression.
I used Heatcon with great success for years, but when it came to bending the popular Trex Transcend capstock boards, the system would end up either not heating the core layer enough to bend, or it would melt the softer top layer and ruin the embossed grain patterns.
In 2016, I was with other professional board benders at Bendfest in Seattle. The discussion turned to the problem of bending theTrex Transcend capstock. My friend, Jason Russell, brilliantly came up with the idea of using two Heatcons set at different temperatures and cross blanketing them. This just might do the trick! And yes, it worked, the downside being now you needed to buy two units instead of one. I approached Heatcon
To shape the boards, you’ll need to construct a shaping jig prior to heating them. Similar to a concrete form, this will be a temporary construction (usually made of wood) designed to hold the flexible board in a particular radius until it cools and becomes rigid, retaining the new shape. The board is pressed into the shaping jig and clamped or fastened as needed. s
about developing a dual control unit, but that was not something they were willing to do.
Two and half years later, I developed my own system, and started my own company, Inblazen—heating gear with dual-control skins. Voilà! Capstock bending problem solved! DESIGN YOUR DREAM DECK
All good things begin with a plan. If you have a hard time seeing how something will look just from a drawing on a paper, you’ll probably want to hire a professional deck designer/builder. If you are imaginative and determined, you can design your own dream deck with the help of a good software program. Most top deck builders use Real Time Landscape Architect. At $400 for the software, it is very reasonably priced. It’s quick and easy to learn the program, and the 3D photo realistic renderings help you visualize how the deck will look. (See sidebar on Designing the Whale Deck). BENDING SYSTEMS
If you are serious about creating your own deck masterpiece, you will need a way to heat and bend the boards. To be fair and thorough, let’s look at your choices. There are three systems designed for board bending.
Which Decking Materials are Best for Bending?
The array of composite and PVC boards has increased dramatically over the past twenty years. Because it’s my business, I try diligently to know the pros and cons of most of them. Any manmade decking that contains plastic can bend, but how well each of them bends is variable.
How tight can you bend a 5-1/2” wide board? It all depends on the makeup of he decking. The tightest that I know of is 8-1/2” inside radius in a 360° circle with ClubHouse Decking.
I have independently done my own field evaluations and bend testing of numerous boards. There are some types of decking that are fine boards, but are not formulated for bending. Following is the list of boards that I have tested and which ones are suitable for bending. CLUBHOUSE DECKING ClubHouse Decking bends easily, is dimensionally stable, and has a warranty that stays in effect even on bent boards.
INTEPLAST / WOLF DECKING Inteplast and Wolf boards can be bent to an inside radius of 3’ or less.
AZEK DECKING Azek decking can be bent to a radius of 4’ or less. The tightest I have achieved with Azek was a 22.5” inside radius. Boards will swell a tiny amount when heating.
s Building with flexible boards opens a new world of design possibilities, such as curved handrails.
Trex Customcurve – The Box • Priced at $8,499.00 plus shipping • Includes a Forming table 4’x8’ • Able to heat two 8’ boards at the same time • Able to heat railing, decking and trim • Adjustable temperature up to 300° F • Weighs 330 lbs., 24”H x 40”W x 128”L (need a fork lift) • Operates on LP gas and 110V, 15-amp service
Having used this system, I find that 8-ft. boards are just too short. You can never use all the board, so having a joint every 7 feet is annoying. The table is nice to work with, especially when you try to bend railing.
Heatcon® HC99-300 – Heat Forming Kit • $2,700.00 plus shipping for a 10’ kit • Includes 2 - 8″x10′ heating blankets
FORTRESS DECKING, MOISTURESHIELD Fortress and MoistureShield are capstock deck boards and bend easily to about a 6’ radius.
TREX TRANSCEND DECKING Trex Transcend is a capstock product. It can be bent to an inside radius of 10’ or less. The tightest I’m aware of is an 8’ radius. This is where the InBlazen system really shines. By heating Trex face down and setting the lower skin at 200° and the top skin at 260°, Trex can be bent to under 10’ without melting and distorting the grain pattern. TIMBERTECH Capstock. Can be bent to 14’ radius.
TRUE NORTH DECKING Capstock. Can be bent to 15’ radius.
DECKORATOR Capstock. Heritage™, Vista™, and Classic™ can be bent to 15’ radius.
FIBERON DECKING Capstock. Can be bent to 15’ radius.
TAMKO Capstock. Can be bent to 16’ radius. DÉCOR DECKING Cellular PVC. Usually bends easily, but when temperature is high enough to bend, the grain pattern begins to vanish.
DECKORATOR EOVATION DECKING Does not bend.
(Note: If I do not mention a particular brand of decking, it is because I have not been sent any boards for evaluation. — Kim Katwijk)
s The bent boards can be installed horizontally or vertically for construction of circular decks with curved ribbons along the rim.
• Adjustable temperature up to 300° F • Able to heat a 10’ deck board • 2 kits can bend 20’ boards • Operates on 110V, 15-amp service • Weighs 25 lbs., easily carried and stored
Heatcon’s web page states, “Not recommended for capstock materials.”
InBlazen – Heating Gear • $2,500.00 for 10’ gear (Also comes in 12’ gear) • 2 - 8″x10′ Heating Skins • Adjustable temperature up to 350° F • Dual control (Each skin can be set to desired temperature independent of the other, specially designed with all Capstock decking in mind.) • 2 kits can bend 20’ deck boards • Operates on 110V, 15-amp service (option of 240 volts for worldwide use) • Weighs 25 lbs., easily carried and stored
Both Heatcon and InBlazen heating systems need insulation. We use Ultra-Touch Denim Insulation, because it’s more pleasant to work with than fiberglass.
The basic heating method for these systems is to lay down the insulation on a flat surface like a garage floor, then lay the skin or blanket on top of the insulation, then the board face-down, then the second skin or blanket, and finish off with the second strip of insulation. This is how all bending is done. If it is wet or windy, we will put down plastic sheeting, and then fold it over the whole pile to hold in the heat and keep it dry.
A medallion inlay is a popular way to give your deck a custom look. s FRAMING FOR A CURVED DECK
Want to use a bent board to trim the curved edge of a deck? Once the deck joists are in, you will put a nail in the center, attach one end of a wire to it, then attach a pencil to the other end of the wire. Use the wire like a compass to draw the curve on top of the joists. Now, you have a line to follow as you skillfully cut the joists using a chainsaw. Yep, that’s how I do it. The chainsaw will allow you to cut any angle.
After cutting the joists, you need to cut blocking to install between the joists. This makes your rim. If you plan to install a ribbon to trim the outer edge of the deck, use another set of blocking to support all the board ends. All boards must be supported within 3 inches of the end.
INLAY AND PATTERNS IN THE DECK
Inlays and patterns can be a lot of fun. Just remember that every piece needs adequate support beneath. This can be done with blocking to support both sides of every piece of the design, or—a slick trick to use, especially when the design has many small pieces—install a 1-in. fiberglass grid beneath the design. The grid can be obtained from McNichols Fiberglass Grating.
Whether you choose to tackle the job of doing it all yourself or to find a professional who can bring your ideas to life for you, beautiful outdoor living spaces with free-flowing, curving lines are now available to homeowners around the world! Bending technology allows your imagination to flow as you think outside the box to create the thing we call a deck. H
s Constructing curved stairs is another way to set your deck apart.
HIR
DECK CONSTRUCTION BEST OF THE BEST
Compiled by Christopher West
ELEVATE DECKING FROM MOISTURESHIELD
The HIR team attended the launch of MoistureShield’s Elevate capped wood-composite decking at the International Builders Show in Las Vegas, where it was a finalist for Most Innovative Building Product. An attractive, low-maintenance decking product available at an entry-level price point, Elevate deck boards have a scalloped underside and a strong, protective cap which shields each board from impact, corrosion and harsh weather. The company estimates that Elevate INTERNATIONAL BUILDERS SHOW FINALIST FOR MOST INNOVATIVE BUILDING PRODUCT decking can help homeowners upgrade to the benefits of composites--such as no splinters, increased aesthetics and low upkeep--for only 15 percent more than a wood deck. And Elevate features the Solid Core Difference, a proprietary manufacturing process offering protection against moisture absorption, warping, rotting, and damage from insects. This technology has resulted in zero structural field failures whether the boards are in the ground, on the ground, or even underwater. Visit www.MoistureShield.com.
HIR
DECK CONSTRUCTION BEST OF THE BEST
SURE DRIVE DECK FASTENERS
From composite deck screws to stainless screws and coated exterior screws, Sure Drive USA offers one of the largest varieties of exterior fasteners. The comany's Capstock Composite Deck Screws are color-matched for MoistureShield, Trex and other popular deck boards, and feature a Star-drive bit system. Sure Drive's Copperguard Deck Screws are great for pressure-treated and redwood decks, featuring Tan and Redwood colors SURE DRIVE USA OFFERS ONE OF THE LARGEST VARIETIES OF EXTERIOR FASTENERS with the patented Woodmaster serrated thread design. Also available are Rustguard deck screws with a Type-17 self-drilling point and selfcountersinking nibs under the head, and Sure Drive's trim-head screws reduce "mushrooming" in composite decking. For saltwater environments, use the Seamaster Stainless Steel Deck Screws. Need to install a deck's fascia board? The Sure Hold fascia board screws have wings that auger through the fascia and trim board, creating oversized pilot holes. The oversized holes allow for expansion and contraction movement to keep fascia boards straight. No pre-drilling is required. Visit www.suredrive.com.
DECKWISE DECK TILE SYSTEMS
DeckWise offers an ever-expanding line of decking products with joistflashing tape, stainless steel cable railing, installation tools, decking screws, oil finish products and hidden fasteners to build stronger, longerlasting hardwood decks. The company's WiseTile Hardwood Deck Tiles are modular solid Brazilian hardwood tiles that will transform any horizontal surface such as a balcony, an unsightly cracked concrete slab, or even an existing deck into a modern living space. As an affordable option for homeowners, installations are quick, easy, and only take hours to install. The Deckwise pedestals can level and elevate deck tiles over any uneven surface--even rooftops. Visit www.deckwise.com
HIR
DECK CONSTRUCTION BEST OF THE BEST
TREX OUTDOOR FIRE & WATER COLLECTION
Homeowners love to "deck out" their decks with accessories and amenities, prompting the Trex Company to launch its Outdoor Fire & Water collection of stylish outdoor fire features, water elements and decorative planters. The new collection delivers the aesthetics, durability and low-maintenance benefits that homeowners want for an "outdoor living room" experience. The collection is comprised of fire pots, fire tables, water spillways, water bowls and planters, MADE WITH HEAVYGRADE COPPER AND STAINLESS STEEL AND MANUFACTURED IN THE USA all made with heavy-grade copper and stainless steel and manufactured in the USA. All Trex Outdoor Fire & Water pots and tables feature a unique burner design that creates a large, full flame to deliver the look of a natural wood fire. Visit www.trex.com.
ALX CONTEMPORARY RAILING
For a sleek deck rail, Deckorators offers the ALX Contemporary pre-assembled railing with a modern appearance and a beautiful powder-coated finish that resists scratches and corrosion. The welded aluminum panels are available in four powder-coated colors featuring a rectangular rail profile with square balusters. The panels are sold in 6- and 8-ft. on-center lengths when installed using 2.5-in. posts, and they're backed by a lifetime limited warranty. You can also top the rail posts with ALX solar post caps. These solar-powered caps are low-maintenance and provide a soft glow at night. Visit www.deckorators.com.
BEAUTIFUL POWDERCOATED FINISH THAT RESISTS SCRATCHES AND CORROSION WON'T SPLINTER, SAG, CHALK OR CRACK AND FEATURES A STAIN- AND FADE-RESISTANT CAP STOCK
VOYAGE DECKING
Voyage varied-plank decking is now available in three different widths to create that custom, wood floor look. Voyage decking is part of the patented Eovations technology line that provides the decking industry’s best strength-to-weight ratio, according to the manufacturer. Featuring a fiber-like structure similar to wood, Voyage is nearly 35 percent lighter than traditional composites and similar in weight to PVC. The deck boards undergo virtually no thermal expansion or contraction and are warranted for installation in the ground or water. Featuring textured embossing for enhanced traction, Voyage decking won't splinter, sag, chalk or crack, and features a stain- and fade-resistant cap stock. Visit www.deckorators.com.
HIR
DECK CONSTRUCTION BEST OF THE BEST
CAMO EDGE CLIPS
National Nail’s CAMO Edge Clips provide an easy way to fasten grooved deck boards. The clips can easily be screwed to the joists using a driver and the accessory Never-Miss Guide. Or, if you want to stand up, try the new CAMO Drive Tool, a powered screwdriver with a extension to fasten the deck clips from a back-and-knee-saving upright position. Setting the Edge Clip is easy; you simply attach the clip's legs around the joist and slide SIMPLY ATTACH THE CLIP'S LEGS AROUND THE JOIST AND SLIDE THE CLIP INTO THE GROOVE the clip into the groove. Slide the next board into place, and you're ready to screw the clip and board to the joist. If you want to install deck boards in a diagonal pattern, use the CAMO EdgeXClips, which install just as easily as the Edge Clips for boards that are 90 degrees to the joists. Visit www.camofasteners.com.
CONSTRUCTION SCREWS FROM U2 FASTENERS
The code-compliant Construction Structural Screws from U2 Fasteners are the next generation of fasteners that are replacing lag screws (structural and ACQ-treated lumber code-compliant in IAPMO report ER-454).
The new sizes range from 3-3/8 to 6-3/4 inches. The screw’s Dome Head enhances its structural capability.
The Tapper Point consists of the Cork Screw Start and Blade Cutting Thread for easy piercing to alleviate strain on the material. Underneath the screwhead, the Talon Grip holds the screw tight to prevent loosening THE NEXT GENERATION OF FASTENERS THAT ARE REPLACING LAG SCREWS and uses its nibs to dig into the material when countersunk. Below the smooth shank is the Reamer Thread, which enlarges the hole in the material to create a larger passage when drawing materials together, reducing tension on the screw head. Also, check out U2's Universal Screw, which is a superior and featurepacked replacement for your old decking screws. Visit www.U2fasteners.com.
HIR
DECK CONSTRUCTION BEST OF THE BEST
FIBERON COMPOSITE CLADDING
Maybe you've been looking at this whole decking thing the wrong way. The folks at Fiberon suggest you use their composite deck boards on your walls. Composite cladding is an excellent choice for high-performance rainscreen systems. Rainscreen systems are one of the most effective methods to manage moisture and mitigate its damage to residential and commercial structures. A key element for these systems is durable cladding that deflects water and adds aesthetic FIBERON CLADDING IS EASY TO INSTALL AND NEVER NEEDS PAINTING, STAINING OR REFINISHING appeal. Available in eight multi-tonal colors, Fiberon composite cladding delivers a range of benefits not found with wood, fiber-cement or other common materials. The solid wood-composite core prevents splintering, cracking, insect infestation and decay. Plus, the four-sided, patented PermaTech cap layer ensures stain and fade resistance. Fiberon cladding is easy to install and never needs painting, staining or refinishing, so long-term costs are lower, too. Visit www.fiberondecking.com.
DECK2WALL SPACERS
Prevent rot at deck ledgers with Deck2wall Spacers. Deck ledger designs must incorporate water-management practices, because preventing rot at ledger connections is critical to maintaining a safe deck. Deck2wall Spacers provide a space between the ledger and house, allowing water and debris to flow through, which promotes circulation and drying. The Deck2wall Spacers work like stacked washers but are noncorrosive, easier to waterproof, and have a larger diameter for better load distribution. Made in the USA, these polypropylene spacers are available in two sizes and also work well on many other applications including shade structures and posts. Visit www.deck2wallspacer.com.
ZAR SEMI-TRANSPARENT DECK & SIDING STAIN
Whether you're staining a new wood deck or maintaining an old one, ZAR Semi-Transparent Deck & Siding Stain's proprietary formula is infused with biorenewable oils and latex resins to deliver excellent adhesion and abrasion resistance. It offers the rich color and subtle sheen of an oil-based stain combined with the durability, easy application, and simple cleanup of a water-based product. ZAR Semi-Transparent is ideal for use on a variety of surfaces, including new or previously stained decks, railings, posts, sheds, siding and more. Available in four ready-mix colors (and tintable to 30 colors), ZAR's one-coat application protects against mold, mildew, UV rays and extreme weather conditions. Visit www.zar.com.
BUY IT
BOWRENCH
Got bent boards? The BoWrench decking tool is a time-saving installation device. Made with heavy-gauge steel, the BoWrench provides a fast, one-person method to straighten deck boards, which are often warped. To operate the BoWrench, simply fit the tool on a joist and swing the lever arm to pull or push the boards into alignment. When the handle is perpendicular, the tool locks in place, holding the board securely and leaving your hands free to drive in nails or screws. With the BoWrench, you’ll save time, create a long-lasting surface and maximize your materials. Visit www.cepcotool.com.
DECK DEFENSE ONE-COAT WOOD FINISH
Deck Defense has been reengineered with a new formula for better performance, longer life, and easierapplication. Although it is a totally waterborne product,Deck Defense has penetrating properties like oil finishes, but unlike oil-based products, it hardens into a lattice-like coating, supporting and strengthening the natural wood fibers from the inside out. Your wooddeck will be protected from the natural damaging effects of sun, wind and water. Available in seven colors, Deck Defense is easy to apply and maintain, and is ideal for coating decks, fences, railings and other horizontal surfaces. Visit www.permachink.com.
