NyloDeck – High-Performance Decking from Recycled Carpet

NyloDeck is made from 100% recycled carpet and a water-blown polyurethane binder. Photo: Nyloboard. Click on image to enlarge.

The U.S. throws away a lot of carpet. According to the Product Stewardship Institute, approximately 2.7 million tons (5.4 billion pounds) of carpet enter the waste stream each year in the U.S., roughly 1.2% of all municipal solid waste. Some of this waste is burned to generate electricity, but much is landfilled. Now there's a better use for recycled carpet: decking.

Nyloboard, a six-year-old company that has been producing various rot-resistant products, including soffit and fascia boards and sheet goods, has just introduced a highly durable decking product. NyloDeckwas launched in mid-September at DeckExpo 2010, and introduced to the green building community at West Coast Green last week. Currently, NyloDeck is made primarily from nylon derived from post-industrial recycled carpet, but the company is expecting to be using 100% post-consumer recycled carpet as its feedstock by the end of this year, according to Tom Heimke, the facilities and production manager at Nyloboard, whom I spoke with at West Coast Green. In addition to the recycled nylon from carpet face fiber, NyloDeck contains a VOC-free, water-blown polyurethane binder. The decking contains no harmful heavy metals, as do most pressure-treated wood products.

NyloDeck in American Gray. Photo: Nyloboard. Click on image to enlarge.

The resultant decking is impervious to moisture, termites, mold, and mildew. Termite resistance achieves a 10-out-of-10 rating (AWPA E1-97); mold resistance achieves a 10-out-of-10 rating (ASTM D-3274); and fungal resistance testing showed "no decay" (ASTM D-1413). Screw retention is rated at 747 pounds-force (ASTM D-1037). The product carries a 30-year warranty.

The decking has a three-dimensional wood-grain surface texture and is available in three colors: Caramel, American Gray, and Cocoa. The boards have uniform color throughout and UV protection. Unlike some recycled-plastic and wood-plastic composite decking, NyloDeck can also be painted or stained to meet specific design needs.

Two thicknesses of the decking boards are available: 7/8", which can span 16" on-center; and 1-1/8", which can span up to 24" on-center. All of the decking is 5-1/2" wide and lighter-weight than wood-plastic composite materials.

NyloDeck in Cocoa. Photo: Nyloboard. Click on image to enlarge.

NyloDeck is installed with standard tools. Galvanized or stainless-steel exterior-grade deck screws are recommended, though hidden fastener systems can also be used. Decking should be spaced 1/4" apart with 1/16" end-to-end gaps.

The retail cost of the 7/8" decking is in the range of $2.50 to $2.75 per lineal foot, according to Heimke, while the thicker decking sells for $2.75 to $3.00 per lineal foot. Lengths from 8' to 24' are available. The material is being distributed nationally; contact the company to track down a local dealer.

For more information:

Nyloboard
Covington, Georgia
877-695-6909, 770-385-6168
www.nyloboard.com

See more on this product in the GreenSpec Guide

Alex Wilson is the executive editor of Environmental Building News and founder of BuildingGreen, LLC. In addition to this product-of-the week blog, he writes the weekly Energy Solutions blog. To keep up with his latest articles and musings, you can sign up for his Twitter feeds.