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Plywood deck coating in Powell River with Ecodur

Plywood Deck Coating Ecodur_sm

Old plywood house decks abound throughout North America, but thousands have reached the end of their useful lives and have become hazardous as the plywood they were based on has deteriorated to the point where they will no longer carry the weight of occupants safely.

This was the case of an old home in Powell River on Vancouver Island in British Columbia with a deck area of just over 450 square feet.

Problem
In an era of low building costs, plywood was often the choice for decking with a layer of polyester mat and acrylic latex on top. This bonded well and, with a layer of latex acrylic, it was waterproof and the stipple effect provided a measure of grip for foot traffic.

In this case, decades of UV and foot pressure had weakened the protection layer and water had eventually got through the polyester to the substrate plywood, causing it to degrade to the point of serious weakness in several places.

The home owner did not want the major expense of a deck rebuild, so a protective coating was required that could resist UV, retain its flexibility and bond permanently to any remaining polyester and plywood.

Solution
VOC-free, non-toxic Ecodur was chosen for its exceptional adhesion with acrylic coatings, fiberglass and plywood. It not only has a lifetime of flexibility, it will also re-bond to original coats of Ecodur should repairs or modifications be required.

Ecodur also has a 25-year history of outdoor usage in sunny locations with no deterioration in its adhesion or breakdown of its waterproofing effectiveness.

Application Results
The preparation was rigorous given the condition of the old top coat, state of the Duradek which was 75% removed and the need to replace certain parts of the support plywood. A very strong degreasing agent, including sodium hydroxide, was used in order to make the final application surface clean. A coating of acrylic leveling compound with fiber was applied first.

Power River Deck Coating_sm

Two five-gallon buckets of Ecodur were manually applied next with extra attention and thickness to the flashing and post bases. An average of 30 mils coating thickness was achieved over central areas with thicker edge sections.

The air temperature was between 22 and 23 degrees Centigrade, but the deck was considerably warmer and probably contributed to the ‘tack free’ state being recorded at the 28 minute mark. The gray Ecodur coating, prior to going tack free, was sprinkled with decorative metallic, tope-colored, epoxy flakes.

Because of the temperature and repair areas, the applicator recommended the client staying off the deck for three days and no furniture placement for at least a total of seven days.