Duradek Case History #153: Restaurant Roof Deck

Project: Mother's Pizza Roof Deck, Halifax

Date: Winter 2012/2013

PROBLEM

After selecting a building for their new 'Mother's Pizza' location, the owners' mandate was to create a walkable roof upon which they could barbecue, entertain and grow fresh spices, herbs and vegetables to support their business model.

While the design called for a sloped roof to a center drainage trench, the bottom of the trench was level and lacked necessary drainage slope.

Mother's Pizza, Halifax - Roof Deck Construction.

The Duradek installers would first need to modify it by designing a metal trench and waterproof it in a manner that would permit drainage from two directions.

DURADEK SOLUTION

After designing the metal trench, they bent and shaped Duradek's PVC coated metal to fit into the trench to resolve drainage flow and added two Duradek approved drains. All PVC trench joints were sealed by welding 10" wide strips of Duradek vinyl onto the PVC coated metal. As a precaution in the event of overflow, a 4 ft. long by 6" wide diameter round scupper was constructed from the PVC coated metal and installed into the exterior wall.



Installation of Duradek vinyl membrane on roof deck.

Duradek Ultra Supreme Granite Chip vinyl provided a walkable flat roof and was also run 16" up the walls to prevent any possible moisture intrusion.



Mother's Pizza Roof Deck finished with
Duradek Ultra Supreme Chip vinyl membrane.

JOB NOTES

Full of technical challenges, this 2200 sq. ft. roof deck was taken on during December and January in Nova Scotia. The key to winter Duradek installations is to make maximum use of tarps and any and all weather 'windows of opportunity'.

The success of this project required not only the proficient skills South Shore Custom decks is known for, but also detailed coordinating with other tradesmen and the support and cooperation of the project manager and owners.

View or download the .pdf version of Case History #153 for the complete case history with installer details and before and images.

Duradek Case History #152: Residential Deck Renovation

Project: Residential Deck Renovation, Boise, ID

Date: April 2013

PROBLEM

This residential deck is situated in an ideal location fro enjoying the vista and relaxing. The owner of the home had felt that waterproofing the deck was something he could easily complete, which he attempted by applying a liquid coating. Unfortunately the liquid system failed and the homeowner once again invested his time and money into protecting the deck with the same ineffective liquid coating system. After the coating started to show cracking after the second attempt, the homeowner decided to look for other waterproofing options to surface his deck.



The liquid coating failed twice...notice the cracking (behind
the shadow from the railings) that allowed water infiltration.

DURADEK SOLUTION

The local Duradek Dealer was called to assess the deck. The failure of the existing coating had allowed enough water to get underneath to the substrate to cause damage. While sometimes sanding the failed coating down is adequate for the application of Duradek vinyl, in this case to finish the job safely and professionally a new substrate was recommended before installing Duradek Ultra Heritage Sunrise. The basket style picket railing from Durarail is a powder coated aluminum and offers the same low maintenance benefits as the Duradek vinyl...no recoating required!



Duradek and Durarail make a beautiful, low maintenance deck.

JOB NOTES

In addition to the waterproofing longevity that Duradek vinyl membranes offer, the application is a much less intrusive process and allows you to enjoy your deck right away. While liquid coating systems require time to dry, often with multiple coats being applied, Duradek's single ply system allows you to use the deck immediately after Duradek vinyl has been applied. No drying or curing time....no reapplication. Just a beautifully protected deck.

View or download the .pdf version of Case History #152 for the complete case history with installer details and before and images.

Duradek Case History #151: Residential Deck Repair

Project: Residential Deck Repair, Albany, OR

Date: July 2013

PROBLEM

The small second floor balcony on this home experienced a water damage problem that is unfortunately common and stresses the importance of doing it right the first time with detailed attention to proper waterproofing.

The contractor who installed the previous waterproof membrane neglected to run the waterproofing membrane up under the siding of the house, which left gaps between the waterproof membrane and the flashing details along the perimeter.

When proper installation details are not applied at the perimeter,
moisture can get past the membrane and cause irreversible damage.

This mistake allowed moisture to make its way through and eventually rot everything. The deck was literally crumbling and provided perfect breeding ground for mould and mushrooms.

 

When moisture is able to get to the deck substrate,
it is just a matter of time until rot weakens it beyond repair.

DURADEK SOLUTION

The rotted plywood substrate had to be completely replaced while the supporting joists were treated with Terminate to keep the rot from spreading further. Once the plywood was laid and flashing installed, it was prepped with a filler along the flashing edges, the plywood joints and screw holes; sanded smooth and swept clean to be in perfect condition for the application of the Duradek vinyl membrane.

Duradek's trained installers know that inside perimeter details require
running the membrane up and under the siding of the home.

Duradek Okanagan Linen was installed with the proper attention to detail that included running the membrane up and under the siding of the house for a watertight inside perimeter. The outer perimeter was finished with drip edge flashing and a pvc clip to securely fasten the membrane and ensure water that flows off the deck is routed away from the house.

 

Duradek Okanagan Linen proves an attractive AND
reliably waterproofed deck surface.

JOB NOTES

This is a very common scenario of unnecessary repairs due to failures resulting from inadequate waterproofing. Once the rotted wood is removed and the deck substrate is properly prepared for the application of the Duradek vinyl membrane, your Duradek can ususally be installed and used in the same day. There is no time required for drying or curing.

View or download the .pdf version of Case History #151 for the complete case history with installer details and before and images.

Duradek Case History #150: Commercial Residential Decks

Project: Corsica Villas, Newport Beach, CA
Date: October, 2012

Problem:

This commercial property situated in the desirable Back Bay area near Fashion Island was in need of some maintenance. Since wrought iron railings are typically not suitable for salty, coastal areas and can easily rust, it was evident that the wrought iron railings needed to be replaced on all 37 decks.

Coastal air can take a toll on wrought iron railings.

The deck surfaces were a common liquid applied system (polyurethane and sand) that require yearly reapplication to avoid falling prey to water damage. While the building maintenance management had stayed on top of the reapplication of this liquid coating system, the flashing details around the deck perimeters had become soft and were lifting. Both the flashing and the weathered, vulnerable railings made the decks unsightly and unsafe.

Duradek Solution:

Duradek / Durarail systems Inc. removed the deteriorated railings and prepared the substrate by sanding and cleaning. Then they applied Duradek Ultra Tiledek to completely waterproof the deck structures and protect the living area below. The troublesome perimeter flashing details that are so vulnerable to the high salt content in the coastal air was effectively solved by using Duradek's PVC coated flashing, enabling the flashing to be heat welded directly to the Tiledek membrane. The Tiledek then received an acrylic hydraulic setting fortified cement overlay with a spatter coat, and knock-down texture was applied.

Heat welding Duradek's PVC coated flashing to the Tiledek membrane.

The deteriorated wrought iron was replaced with Durarail black picket powder coated aluminum railing with custom details. Its durability and 20 year limited warranty is the perfect solution for the salty air.

Durarail powder coated aluminum railings can
withstand the elements for long lasting performance.

Job Notes:

Originally, Duradek / Durarail Systems was only asked to quote on the replacement of the railing system, however the issue of taking off old railing and installing new could create waterproofing issues if separate contractors were responsible for each phase, as well as complicating the warranty by having more than one contractor responsible for the deck. Duradek / Durarail Systems was able to convey to the owners that using one contractor, one supplier and one warranty was the best way to protect their investment and they were awarded the contract for both railing and waterproofing.

View or download the .pdf version of Case History #150 for the complete case history with installer details and before and images.

Duradek Case History #149: Private Residence

Project: Private Residence, Swannee, GA
Date: September 2012

Problem:

Over 20 years ago, an additional room on this home was built with the desirable feature of a roof deck.

Originally, the deck was waterproofed with a tar and bitumen and covered with an overlay product that was not entirely compatible with the bitumen.

Another problematic area was the perimeter flashing details which failed an resulted in the edges of the deck weakened due to water infiltration. Additionally, some of the supporting joists were bowing. the homeowner wisely decided it was time to have the deck resurfaced and avoid more costly damage.

Roof Deck Before

Duradek Solution:

The original material was quite difficult to remove, but eventually it was cleared off the deck to allow access to the substrate. the bowing joist were lowered to allow for an even surface.

Most of the substrate was able to be saved, however se tionsw along the perimeter could not be salvaged and wad replaced with 3/4" plywood.

Duradek Ultra Granite Chip vinyl was installed and proper flashing details added to all of the perimeter of the deck to ensure the substrate stays fully protected.

Roof Deck After

Job Notes:

When doing deck renovations, it is often difficult for contractors to fully identify the extent of possible water infiltration and damage until the old waterproofing system has been removed and they can conduct a full assessment of the structure below.

Sometimes on roof decks, the water damage is so bad that even vertical walls require replacement, while in other cases, like this one, water damage only affected a limited area of the existing substrate.

View or download the full Duradek Case History #149 .pdf

Duradek Case History #148: Residential Balcony Renovation

Project:
Private Residential Balcony Renovation
Date:
May, 2012

Problem

There were several issues with this existing deck. The prior owner had done repairs around the parapet wall which compromised the perimeter seal of the waterproofing. Rather than replace all of the vinyl, a vinyl border/extension was glued to the existing vinyl around the perimeter and up the parapet wall to keep the waterproofing function of the vinyl surface intact and also serve as a decorative border.
The wall was then finished with stucco, and both the original vinyl and the border layer were eventually covered with a deck paint.

After many, many years it is time to replace this painted-over vinyl.

The seams where the border layer met the original layer were lifting, so the vinyl had to be removed and replaced, but the project could become very costly if the (relatively) recently stuccoed parapet walls and balcony door had to be removed to complete it, which normally is standard for guaranteed waterproof performance.

Duradek Solution

The old vinyl was cut around the perimeter, leaving the original vinyl tucked up under the stucco wall with about an inch extending from beneath it. The old vinyl was removed from the deck surface and while some delamination of the plywood occurred, with some filling and sanding the plywood was able to be re-used.  (For specific details, see Duradek's Substrate and Edge Trims).

Duradek Forest Floor Birch
A fresh new look and waterproof protection.

New Duradek Forest Floor Birch was applied and the seams were properly welded to provide a waterproof layer, with special care given to where the new vinyl was carefully welded directly to the old vinyl that was left tucked up under the stucco and threshold, eliminating the need to remove the stucco or the balcony door. A mechanical fastener was also used to ensure the old and new vinyl will remain securely in place up the vertical perimeters, and to prevent any possible shrinkage at the deck/wall intersection.

Job Notes

Although this was not the ideal way of waterproofing the deck area, it was an adequate solution to the homeowners problem, taking their budget into account.
Ideally, removal of the stucco from the base of the wall would have been the preferred method of waterproofing the deck area, but that would have at least doubled the cost of the repair.
To complete an installation like this requires a very patient, meticulous and experienced installer.



What a difference a day makes!

View or download the full Duradek Case History #148 .pdf

Duradek Case History #147: New Deck

Project:
Private Residence Roof Deck, Atlanta, GA
Date:
May 2012

Problem

The owners of this home really know how to maximize space! Having personally considered every detail, the architectural plans included building vertically to make the most use of their real estate and to  take advantage of he fantastic view by  including a roof top deck.

They wanted the deck to have an attractive finish, but one that would not require ongoing maintenance to keep it looking good. Most importantly though, they wanted to use a product that would provide reliable waterproof protection for their new home.

Beautiful and functional!

Duradek Solution

The Duradek installers take every detail of deck waterproofing into consideration and were able to ensure proper water routing was in place and that the substrate was correctly prepared. Then, Duradek Ultra Cork Macchiato vinyl was laid, guaranteeing waterproof protection for the living space below.

Durarail Panorama Post topless-glass railing system was added to finish the view inspired deck. this powder-coated aluminum and glass system paired with the Duradek vinyl membrane provides the homeowners with the elegant, low maintenance deck they had desired.

A perfect leisure area for outdoor living at home.

Job Notes

A previously built deck on one of the lower levels was constructed perfectly level and water routing was overlooked. Adding in the proper slope and drainage was a challenge.

In this case, the large double doors accessing the deck had to be raised 3" in order for a new sub floor to be added to accommodate proper water routing.

Duradek president, John Ogilvie, takes interest in ensuring each and every Duradek installation performs as intended and made a personal visit to this project himself.

Duradek president, John Ogilvie inspecting details at the job site.

View or download the full case history #147 .pdf

Duradek Case History #146: Residential Roof Deck Repair

Project
Private Residential Roof Deck Repair
Date
July 2012

Problem

The previous waterproofing system on this roof deck appeared to be a fiberglass-like surface without the proper flashing, and it had not aged well.
There was insufficient slope to the porch and the main leak seemed to be located at the door. There was softness to the plywood in this area due to the accumulation of moisture over time where the water had been getting underneath the old membrane. The customers used a tarp as a temporary measure to keep water from leaking into the sun room below.

Duradek Solution

Once the old membrane was removed, the slope of the deck was corrected and  new plywood was put down. The customer chose Duradek Ultra Cork Macchiato for their finish.
While solving the main leak, the 3 ft. swinging door was removed and was upgraded to an 8 ft. sliding door. With the Duradek Ultra vinyl brought into the door opening, and then the drain pan laid in place on top, this trouble area was professionally repaired for a water-tight roof deck and a dry room below.

Job Notes

With the professional waterproofing details provided by the Duradek installers, there have been no further leaks from this deck. Even after hurricane Sandy battered the area, there were no calls for repairs!

Download the pdf of Case History #146

Job Contact:
Delmarva Roofing and Coating
Noah Spence
noah@delmarvaroofing.com
www.delmarvaroofing.com


Applicating Contractor:
Chelsea Builders
Mike Eline
meline@ezy.net

Duradek Case History #145: Estate Pool House New Roof Deck

Project: Estate Home - New Pool House Roof Deck
Date: June 2012

PROBLEM

The owner of this estate home wanted to have an elevated deck near the pool so that there could be a lounging area to enjoy the view of the lake.
The existing pool house had a regular, sloped roof. Rather than build a new structure, the decision was made to re-model the pool house to accommodate a roof deck that could be surfaced with exterior tile and accessed from a spiral stair case.
Since there was a full bar/kitchen underneath, it was critical that the roof deck provide reliable waterproof protection.

DURADEK SOLUTION

The old roof had to be removed and a new roof completely reconstructed to accommodate a walkable surface with adequate water routing.
The Duradek installer prepared the plywood substrate by fastening a cement board to which he then adhered the Duradek Ultra Tiledek membrane.
Once the roof deck of the pool house was finished with the same beautiful tiles as the rest of the pool area, black Durarail powder-coated railings with glass inserts was installed to complete the low maintenance deck that was designed specifically to enjoy the view.

JOB NOTES

With a fully operational kitchen in the bar underneath the pool house deck, there was no room for error in the waterproofing performance on the deck above.
Duradek Ultra Tiledek was able to provide waterproof protection that is guaranteed for 10-years. Even if one of the surface tiles was damaged and needed replacing, the waterproofing underneath remains intact.

View or download the .pdf version of Case History #145 for the complete case history with installer details and images.

Job Contact:
Duradek Georgia Representative
Norm Shafer
770-842-8218
nshafer@bellshouth.net

Applicating Contractor:
Duradek of Georgia
R.L. Hayes
770-667-4988
royce@rlhayesinc.com

Duradek Case History #144: New Roof Top Deck

Project: New Residence (Henry Walker Homes),
Salt Lake County, UT
Date: July 2012

Problem:

This new home project developed by Henry Walker Homes, based out of Utah, included a roof top deck. Being a developer that takes pride in quality craftsmanship, when they realized that the waterproofing coating they had planned to use was not a roofing product, they immediately began to look for approved roofing grade options.

It was important for this builder of new homes to provide reliability and attention to detail in the desirable feature of a roof top deck.

Duradek Solution:

Duradek also believes that installation details are important and on this project the extra care went into details such as planing the plywood before the vinyl membrane was installed to ensure the drip edge was flush with the surface.



Duradek Installers take care of every intricate detail!

The Duradek Ultra Heritage Sienna vinyl was installed using the heat-welded system and the roof top entertainment area of this new home development now has guaranteed waterproof protection for its new owner for the next 10 years.



The fully waterproofed roof deck is now ready to enjoy.

Job Notes:

The developer was concerned about the $2 per square foot price difference between the coating they had planned on using and the guaranteed waterproof protection of Duradek. The Duradek installer explained that with coating systems, they must be re-coated every one to three years, while Duradek is installed only once and simply requires seasonal washing for maintenance...a more cost-effective solution overall!

Download the .pdf of case history #144

Job Contact:
Duradek of Utah / Dekmax
Matt McClure
801-390-9600
matt@dekmax.com

Applicating Contractor:
Lonestar Builders Inc.
Dallas Hakes
801-489-6188
dallas@lonestarbuildersinc.com

Duradek Case History #143: Custom Tile Roof Deck

Project: New Private Residence, Cumming, GA
Date: May 2012

Problem:

Along the shores of beautiful Lake Lanier, this exquisite new building is a private residence with detailed architectural elements often reserved for high-end markets. When the owners decided they wanted outdoor tiles on their deck surface, the contractor was both concerned and challenged with the task of proper waterproofing since the deck is curved and acts as a roof to the patio area below. After a tile contractor was retained to complete the challenging task, he immediately contacted his local Duradek distributor.


Every detail is carefully considered with
Duradek's professional installers.

Duradek Solution:

The Duradek installer carefully assessed the project and he knew to do the job properly, the lower level of brick on the vertical surfaces adjacent to the deck surface had to be removed, allowing him to apply the Ultra Tiledek membrane a few inches vertically for proper waterproofing at the deck perimeters. Although the project contractor would have preferred to avoid the extra cost, Duradek installers believe in doing it right the first time, so he would not install the membrane at all unless it could be done properly. The tile contractor agreed, the bricks were removed and the membrane was installed correctly.

Job Notes:

When it comes to waterproofing, it's all in the details and with this project that fact was not overlooked. When it came down to the flashing details on the perimeter, the elegant tile look was extended to this feature by taking Duradek's PVC Coated Drip Edge to a metal fabricator to customize it. They successfully adhered the exterior tile to the pvc coated drip edge and gave the project a sophisticated and elegant finishing touch.

Applicating Contractor:
Advanced Duradek Systems of Georgia / R.A. Maner Construction
Roger Maner
404-557-1061
ramanerconstruction@yahoo.com

Job Contact:
Duradek of Georgia / R.L. Hayes Construction Inc.
Royce Hayes
404-402-3251
royce@rlhayesinc.com

Duradek Case History #142

Project: New Private Residential Deck

Date: April 2012

Problem:

Finding a good contractor can sometimes be difficult in the best of circumstances, but when the project is an hour and a half outside of the nearest town in the wilderness of Northern Alberta it is an even bigger challenge.
Besides retaining the services of a good installer for waterproofing specialties, this project required a product that will stand up to the extreme elements that can wreak havoc in a cold northern winter. And with the decking project requiring roofing grade protection, the waterproofing element was critical.

In the process of waterproofing a new deck with Duradek

Duradek Solution:

The professional commitment of our Duradek installers was demonstrated when David from Koala-Tee Renovations made the long trek to the wilderness to bring his waterproofing expertise to this new home.
With a good sized upper deck over top of a lower level deck, Duradek Ultra Cork Macchiato was the perfect choice to compliment the style of the home. The new home owners now have a beautiful and low-maintenance deck, as well as a completely dry area for the lower level below.

This second level deck is now waterproofed with
roof-grade protection with Duradek

Job Notes:

The general contractor for this job had never worked with Duradek before. After seeing the completed job, he was so impressed with the Duradek Ultra vinyl membrane that he asked David from Koala-Tee Renovations to do his own home deck too!