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Options for New Surface Over Plywood Deck

barshfield | Posted in Construction Techniques on April 16, 2015 06:55am

I live in the Pacific Northwest in a 1960s home that has a wraparound deck with a plywood surface.  I want to replace the indoor outdoor carpet that the previous owner installed on the deck.  I already know I will have to replace several areas where the plywood has rotted through – so the underlying deck surface will be a combination of new plywood and old plywood. Part of the deck is open to the outside underneath and part of it forms the roof over part of a garage/workspace. 

What are my best options for a waterproof walking surface over this deck?  I considered an epoxy stone application, but the surface look stoo glossy for my taste.  I am considering an application of material like that used in truck beds (Rhino, Line-X, etc.) but it seems a bit spendy. I have also considered what looks to me like sheet vinyl, a 60 mil thick product (EPDM?) that the representative at the home remodeling show told me is like a roofing product.  However, I am (at some level) put off by the thought of laying plastic on my deck –  I may need to get over that.

So, back to my question: what do all of you think are my best options for a waterproof surface over my plywood deck?   No need to consider my personal taste (or lack of it) in your answers. Thanks. 

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Replies

  1. User avater
    deadnuts | Apr 16, 2015 09:26pm | #1

    Your best options are designing a surface that drains well and using exposed material that won't prematurely rot.

    1. barshfield | Apr 16, 2015 10:14pm | #2

      Looking for Product Options

      I know I've got to ensure at least some sort of slope for the new plywood, and to do something to ensure a slope exists in the old (I'm not so sure it has any slope at all).  So, assuming I can do that, I'm looking for recommendations for the surface, either in a treatment or a material.  Thanks.

      1. User avater
        deadnuts | Apr 17, 2015 10:21am | #5

        TPO

        1. barshfield | Apr 17, 2015 12:17pm | #9

          TPO

          Would that be the only layer to be applied over the plywood?

          1. User avater
            deadnuts | Apr 18, 2015 11:57pm | #13

            Generally, No. You mentioned pavers as your possible wear surface.

            For single waterproofing and wear surface you may want to consider Duradek. http://www.duradek.com/vinyl-decking/

  2. User avater
    MarkH | Apr 17, 2015 07:04am | #3

    Back in the day (long long time ago) canvas was used. It was painted with (lead based) porch paint. I'm not sure how it was attached to the deck though, but a glue like titebond etc would work. I read that #4 duck was used.

    1. barshfield | Apr 17, 2015 12:19pm | #10

      Back in the day (long long

      Thanks for the comment.  I'm just trying to make it back to today myself.  (My house already has a lot of "back in the day" type installations, many of which are far past their prime).

  3. mark122 | Apr 17, 2015 07:19am | #4

    EPDM would be a good choice for a water proof underlayment but i would not use it as the only layer. 

    From the sounds of your situation i would EPDM and scab over it allowing you to do any flooring you want.

    1. barshfield | Apr 17, 2015 12:16pm | #8

      EPDM would be a good choice

      Okay.  But when you say "scab over it," what do you mean? 

      1. mark122 | Apr 19, 2015 09:48am | #14

        you would have a "sub floor"

        you would have a "sub floor" that is your main water barrier made up of decking covered by epdm. Over this covering you would place either rips of pt lumber or something like that over your floor joist that would give you a nailing or screwing surface for whatever floor covering you want to use. 

        1. barshfield | Apr 19, 2015 11:00am | #15

          you would have a "sub floor"

          Thanks for the explanation.  I've got that in mind for another area, so thanks for the confirmation on that project as well.

        2. barshfield | Apr 19, 2015 11:01am | #16

          you would have a "sub floor"

          Thanks for the explanation.  I've got that in mind for another area, so thanks for the confirmation on that project as well.

        3. barshfield | Apr 19, 2015 11:01am | #17

          you would have a "sub floor"

          Thanks for the explanation.  I've got that in mind for another area, so thanks for the confirmation on that project as well.

        4. barshfield | Apr 19, 2015 11:01am | #18

          you would have a "sub floor"

          Thanks for the explanation.  I've got that in mind for another area, so thanks for the confirmation on that project as well.

        5. barshfield | Apr 19, 2015 11:01am | #19

          you would have a "sub floor"

          Thanks for the explanation.  I've got that in mind for another area, so thanks for the confirmation on that project as well.

          1. DanH | Apr 19, 2015 02:16pm | #20

            You can say that again!

  4. User avater
    Mike_Mahan | Apr 17, 2015 11:23am | #6

    Deck covering.

    I've been using Westcoat products for about 8 years now. For me the company is local and has provided excellent support. I don't know about availiability in your area. 

    This is a product recomendation based on experience, not spam.

    http://www.westcoat.com/alx-p-6.html

    1. barshfield | Apr 17, 2015 12:12pm | #7

      Deck covering.

      Thanks for this.  It looks like I would probably be able to get the product, but would it require a specially qualified contractor to install/apply? 

      1. User avater
        Mike_Mahan | Apr 17, 2015 03:53pm | #11

        You can do it yourself.

        The system you need will probably be the ALX. You can use it as a substrate for tile or with one of the Westcoat finishes. I've done both. Watch the training videos on the website and see if you would feel comfortable doing it yourself. You will need to be meticulous about following the instructions. Adequate sub structure is essential. Proper drainage and flashing is critical. Study the videos and literature and go for it.

        If you are a building professional you can add the system to what you can offer your clients.

        1. User avater
          Mike_Mahan | Apr 18, 2015 11:56am | #12

          Tools

          For the most part you don't need any special tools. But you do need a 1" crown pneumatic stapler. You can probably rent this.

  5. barshfield | Apr 20, 2015 12:03pm | #21

    You can say that again!

    Sorry about the multiple duplicate posts.  I was using a tablet and it didn't seem to be responding when I hit "post" (or so I thought).  Now I know.

  6. wmheinz | Apr 21, 2015 12:16pm | #22

    Separate the walking surface from the waterproofing

    First off...I'm an architect in the Seattle area...so I know the type of issues you are probably dealing with. 

    You could use Gaco Deck....been around forever as walking surface and waterpoofing.  Designed to do exactly what you are proposing.  Will require positive slope to drain.  Also, I have had clients punch holes through it with deck chairs and a dropped umbrella pipe.  Unfortunately, this kind of damage often goes unnoticed until rot sets in..

    Personally, I would separate the walking surface from the waterproofing. 

    Waterproofing:  "Old school" - could use a torch-down membrane.  Better to use pvc membrane...tough and can stand very low to no slopes.  The seams are all 'welded'.  Not a DIY product.  Carlisle is supplier, as well as others...

    Walking surface:  Would not recommend heavy concrete type paver....they weigh in at 20lbs per s.f. - not many remodels can support that extra weight.  There are other alternatives....there are wood deck "pavers" - installed look is like a big parquet floor.  Also, slate and procelain tile pavers with a reinforced backing to make a light weight paver...  company called Eco Paver has both, but there are many others as well.  Try their website for examples.  I would recommend this type of system because you can lift them up if you need to get to the surface below for cleaning or other maintenace.

  7. barshfield | Apr 21, 2015 03:25pm | #23

    Separate the walking surface from the waterproofing

    Thanks for the recommendations.  I'll first check out the waterproofing/underlayment for product and an installer.  The lightweight deck tiles sound like an attractive option.  Now if the nice weather would only stick around. . . .

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