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