Installation Information for the Deck-Max ™ Proprietary System

• Installation of the Deck-Max ™ system will involve a few simple decision's you will be asked to make Like

• What joist structure do you have  - e.g. Timber or Metal

• What screw type is then decided by - if you choose Metal joists then we have a specific self Drilling Screw for this application.

• If you are using timber joists then - What type e.g. Treated Pine OR Hardwood Then for both joist materials you will have a choice of either Gal coat class 3 wood screw OR 316 Stainless Steel [marine grade] screws.
  

• So now as you can see based on this information you will set up for all the correct products for your particular installation.

• HOW TO CHOOSE THE CORRECT BISCUIT GO TO>>

Using Quick set floor clamps

• It is an ideal tool to retain the board down and in to the joist while you are fitting the screw & biscuit. Simply keeps the boards in position while your hands are free to fasten the screw.

• This also stops the board from rising when pulling the boards in to your set gap prior to fixing the screw. Will pull 180 kg

In the process of setting the clamps - Tap boards in as below.			The DM 600 will pull the decking boards together and the 450 clamp will retain the board to the joist while fixing.

Choosing the Decking Material

The sub – structure of the deck is as per your engineer’s specification. Joists are normally set at between 300 mm to 500 mm centres, standard in most areas is 450 mm. When the deck exceeds 1200 mm off ground cross braces on posts are recommended – check building codes for confirmation.

Always use the BUILDING standards AND CODES for Construction, moisture content, tolerances and timber grades for outdoor decking guidelines.

Acclimatization of floor boards is advisable when installing in seasonal extremes of weather, experienced during summer or winter. The moisture content of the floor boards should always be checked with a moisture meter prior to purchase and prior to installation. Ambient Moisture content is the standard.

Decking

The specification for each biscuit [Original" OR The "Pro Biscuit"] will vary but the groove for each style of biscuit is the same for any board thicknesses. [Meaning that the groove height off bottom of board is the same for a 19mm board as it is for a 25mm board] The bottom is Datum point.

Suitable board sizes vary from 90mm wide x 19mm up to 140mm wide x 25mm t maximum thickness. Ideal size is 110mm wide x 19mm thick.

• Do not fit damaged boards      

• Do not fit warped boards

You should be sure to choose only quality kiln dried hardwood boards and check timber specifications prior to any fixing. If the timber you choose is going to shrink or expand by more than the standard allowed then an alternative fixing should be chosen.

Check the recommended moisture content average for your geographic area.

It is recommended that you obtain…

• ·   Certificate of moisture content from supplier

• ·   Certificate of proof that the boards are kiln dried from supplier

You will have two options of board preparation to suit two different styles of Biscuits…

"Original Biscuit"	"Pro Biscuit"

The “Original Biscuit”..

that can be pre grooved or biscuit cut a kerf on site. as shown in these photo's.....

The Deck-Max Pro biscuit..

this biscuit requires specially grooved decking from our Deck-Max Licensed companies to supply the decking for this biscuit. This is the fastest of the two options to install due to it’s engineered design. 

Firstly ask your timber supplier to pre groove both sides of the board – ask Deck-Max™ for specifications and suppliers. We also have companies that carry pre grooved decking ready to go for the Deck-Max Pro Biscuit.

Do not accept grooved decking from an UN LICENSED  profiler. If in doubt please call Deck-Max to confirm. 

Secondly prepare the grooves manually to each board with a biscuit cutter – this choice can only be applied when using the “Original Biscuit”.

3.The Deck-Max™ biscuit fits into a lateral cut to each board and is screw fixed to each joist – the Deck-Max™ biscuit provides a fixed minimum 3mm spacing for the boards, However this can vary out to 6 mm by simply using a spacer to match your preferred spacing – like a floor or wall tile packer.

 

Choose a timber the thickness required - say 5mm	Or use one of the biscuits - 4mm

STARTING

Choose the straightest long stick of timber and decide to start either at the wall / house or from the outside edge and work back – Once decided set a string line parallel to the finishing point and set your first board.

Clamp into position be sure it is set straight – then prepare a CounterBore hole using the Deck-Max DM 110 tool then fix with the screw from the Deck-Max wood plug and screw kit – DM 114. Fasten screw into the bottom of the hole then insert the wooden plug – it will sit a little proud then just shave off the top flush to the deck using a wide sharp chisel. Repeat this process on the last board.

This process is also used for steps, step risers etc.

 Do not over tighten screw in the bottom of hole. This is a two step process (read installation instruction for details).

TIPS

Using the wide range of speciality tools and accessories make the job very easy - GO TO>> Product range in Brief

Maintain pressure while fixing screw so you do not bush the square drive / recess. Choose the Deck-Max part # DM 108 – contains 2 x 100mm No. 2 square drive bits.

Do not fix screw at high speed

Fix screw with a light torque setting on a cordless. Check to suit before commencing.

Should you find the joist material too hard – run a pilot hole to suit the screw [diameter & depth]. Use the Deck-Max part # DM 106 this includes a 100mm x 3mm long shank drill bit which is perfect for the Deck-Max screws.

It is recommended that an exterior construction adhesive is laid on the joist prior to fixing the board – exterior grade polyurethane adhesive. (Must be certified for this application by manufacturer).

Bostik Ultra set is recommended by manufacturer laid up with 90% cover. Do not lay glue to wet / moist joists or dirty metal joists.

This process is part of the Deck-Max™ proprietary system.

When applying to steel galvanized floor joists – prepare the surface of the joist with N40 Primer [Bostik]. See manufacturers specifications.

Lay 5mm to 10mm bead of adhesive over top of joist in a thick bead to achieve minimum 90% cover. You should end up with a small bead visible from the underside of the decking board on both sides after fixing.

Adhesive is included in  Deck-Max™ as a fully packaged kit.

COVERAGE

Deck-Max Kits -  These estimates are approximate only and all quantities are based on the design of the area and the shape - these will vary the coverage and estimates of cover. Coverage assumptions are based on the joists set @ 450 mm centers and using 90mm to 140mm decking boards. Each pack of Deck-Max™ will show coverage per pack so you can estimate for your bill of quantities.

Boards up to a maximum size 140 mm wide and 25 mm thick and of specific kiln dried species to meet the industry standards are suitable for the Deck-Max ™ biscuit fixing.

When using boards under 70 mm wide – check with manufacturer for specification prior to purchase.

This fixing can also be used in the fixing of some specific synthetic composite decking boards / materials – check with Deck-Max™ for details.

A Kerf – is a lateral cut to the side of the decking board made by using a biscuit cutter.

SCREWS

 Our standard range of screws are designed to self drill into three floor joist types

=

• Timber Screw           Type 17 tip – class 3 corrosion rated.
• 316 Stainless            Type 17 tip – class 4 corrosion rated – Marine Grade Stainless Steel
• Metal self drilling       Self Drilling tip – class 3 corrosion rated – max wall thickness is 3mm.

The screw has a square drive recess for the most positive drive – you must retain pressure while driving so as to avoid any burring or bushing.

In some case self drilling screws may encounter extreme hardness of the joist material – if so run pilot holes as required; see photo >

Special Stainless Steel Screw fix - A pilot hole [using a long series drill bit] the pilot hole should be drilled through the hole in the biscuit while holding the biscuit into position - Deck-Max part No. DM 106  must be drilled at a slight angle back toward the previous board [say 10 degrees] prior to fixing the screw in position. If you do not pre drill, the screw will be over stressed and can bend or break under heat and pressure. Pre drilling also minimizes splitting of the sub structure joists. Note: Follow the angle of the pre drilled hole when fixing the screw.

Fixing into hardwood joists pre drill with 3mm long series drill bit Deck-Max Part No. DM 106 – run a test prior to commencing.

Fixing into treated pine joists pre drill with drill bit Deck-Max Part No. DM 106 long series drill bit –

Fixing into steel joist – some steel used in construction will exceed the normal tensile rating of a “C” section and or wall thickness over 3mm.

Check with manufacturer of Deck-Max™ prior to choosing a compatible metal joist material.

All butt joints should have an exterior water proofing product glue wiped over each face prior to fixing. All joints must have an exterior construction adhesive inserted to each kerf / lateral cut, prior to inserting the butt joint biscuit [part ref. DM-J10] Butt joints should always be set on joists

Clean off excess glue as soon as the joint is closed up. Bostik do have a special wipe available for this.

Fixing over Concrete

Pack Batten off concrete so the batten does not absorb moisture. Ideal to lay Ultra Set between the concrete and the bottom of the batten.

Be sure all water can escape from deck area - you may require some drainage pits installed. Prepare notches on bottom of battens to allow water to run off.

Build access panels to all service points including the drainage points.

 

Preparation before	Finished product	Fix biscuit when ever it intersects with a joist

 

Maintenance

 A decking oil treatment and maintenance program is essential and should be applied and monitored for the preservation of the decking.

Deck coatings – refer to the manufacturers specifications for their each product.

Follow all manufacturers’ specification and recommendations.

Specifications are updated on a regular basis. All changes take precedence over previous specifi

cations.

Deck-Max Key Features

• UV stable
• Chemical Resistant to oxalic acids
• 7 year warranty on the biscuits
• Polyurethane Adhesives Bostik ULTRASET SF
  
• Screw specifications
• Biscuit design options
• Mitered corners
• End joints / butt joins
• Eliminate Cupping
  

Bostik ULTRASET SF Adhesive

Bostik ULTRASET SF is a Polyurethane adhesive – This item will provide an ACOUSTIC  membrane between the joists and the decking boards

• Ultra set remains flexible

• This will eliminate squeaky or rattley boards.

• Provides a secondary fixing

• Available in  300ml cartridge

• Be sure top of joists are dry.

• Coverage – allow approx. one 300ml cartridge per 5sq.m. of decking.

Application – lay up a 5mm to 10mm bead [90% coverage] for a visual reference when the board is fixed you should have a small bead coming out both [under] sides of the joist.

 

See from under as minimum requirement	Thick Bead application	Apply to joists one board at a time

 

NOTE:

Cupping is minimized by using Deck-max as a fixing which retains the board on the outside and applying downward pressure to a spot that is not retained by surface fix screw or nail.

Full control of cupping is based on the selection of kiln dried timber to a local ambient moisture content – timbers of larger size should be allowed extra space in the gap to facilitate moisture uptake and timber drying out.

Use packers as in tiling to set your desired space between the decking boards.

Cupping is caused by the underside of the board having a higher moisture content than the surface – too close to ground, poor air flow, laid too close to clay type soils – too close to concrete with no drainage, incorrect preparation of ground under deck, failure to follow manufacturers specification.

Cupping may have occurred prior to installation - always check your decking before you lay. see photo below.

 

This board had cupped before installation.

 

 

TEST RESULTS    - Go To STRENGTH PAGE

Testing is an on going feature of the Deck-Max philosophy to ensure the product will meet all expectations and exceed them when it come to the choice of any of the Deck-Max  products.

The industry has one only reference for the measure / performance in the decking industry and it is referred to as the “Withdrawal Test” meaning that when a certain amount of pressure – measure in K/n and Kg force the decking board will pull from the nominated sub structure.

Testing has been undertaken for this test  and reports written to establish some bench marks that we will use as reference points.

Reference document – Deck Nail Withdrawal Test  “FWPRDC project No. 02.1209 undertaken by the Australian government “ Forest and Wood Products Research and Development Corporation and Queensland Government Department of Primary Industries and fisheries March 2005.

The test involved a series of nails and screws fastened into both treated pine and hardwood joists.

e.g. machine nail – screw dome SS 50 x 2.5 into pine  achieved an average failure at 1.6 k/n.

Always ask your supplier or Competitor what was the “Withdrawal test results” for their product – we tested a competitor of secret fixing methoid and it failed at 0.8 k/n half that of the nail measure above.

TEST WERE RUN IN FACILITIES UNDER STRICT ISO GUIDE LINES.

• batten material used was MGP 12  70mm x 35mm

• as a reference we did compare and used 50mm x 125mm hardwood

• the decking boards varied from 140mm x 19mm up to 140mm x 25mm Merbau and spotted gum.

• Boards were fixed with a variety of our screws using 316 stainless steel & our standard class 3 wood screw.

• Best performance achieved an amazing 8.12 k/n and still we could not break the deck-max part

• It was an incredible sight to see when 100% of the time of failure was the decking board.

• Not one test of 20 test run could we break the biscuit or the screw.

.

This makes the deck-max biscuit over 5 times stronger that a dome head nail fix and simply the strongest deck fixing in the World.

 

Proud to be a member of ATFA association

 PDF files available by log in.

• Fixing into metal Joists     
  
• Fixing into Wood              
  
• Fixing with the “Original Biscuit” 
  
• Fixing with the Deck-Max PRO biscuit 
  
• Fixing OVER Concrete   
  
• Biscuit cutter