Composite decking has become a popular choice for modern outdoor spaces. It’s strong, stylish, and easy to maintain. Many people choose it for patios, gardens, and pool areas. But have you ever wondered how it’s made?
Knowing what goes into composite decking helps you understand why it performs so well and lasts for years. Let’s take a closer look at its materials, the process behind it, and why it’s such a practical choice for homeowners.
What is Composite Decking?
Composite decking is a man-made material created to look like wood but perform better outdoors. It’s made from a mix of recycled plastic and wood fibres. This combination gives it the warmth of natural timber and the toughness of plastic.
Unlike traditional wood, it does not rot, splinter, or warp. It can handle rain, sun, and humidity without much change in shape or colour. That’s why it’s often preferred for long-lasting outdoor use.
What Materials Are Used in Composite Decking?
Composite decking is made from three main ingredients: wood fibres, recycled plastic, and additives. Each plays an important role in the board’s strength and look.
1. Wood Fibres
Wood fibres give composite decking its natural appearance. They help it look and feel like real timber. Most of these fibres come from recycled wood waste, such as sawdust from mills. Using this waste material helps reduce the need for new timber and supports eco-friendly manufacturing.
2. Recycled Plastic
Recycled plastic is what makes the decking tough and water-resistant. It binds with the wood fibres and protects them from moisture and decay. The plastic used is usually high-density polyethylene (HDPE) or polypropylene.
It also adds flexibility and helps the boards hold their shape in changing weather. Plus, using recycled plastic keeps waste out of landfills, making it a greener choice.
3. Additives and Binders
Additives are small but important. They help the decking last longer and look better. Colour pigments give the boards their tone. UV protectants keep them from fading in sunlight. Other additives improve grip and reduce scratching. Together, these elements create a strong and durable product.
How Composite Decking is Made
The process of making composite decking is precise and carefully managed. Here’s how it works from start to finish.
Step 1: Preparing the Materials
The process begins by preparing the wood fibres and plastic. The wood is ground into fine particles. The plastic is cleaned and shredded. Both materials are then dried to remove moisture. This step is vital because any leftover water can weaken the boards later.
Step 2: Mixing the Ingredients
Next, the wood fibres, plastic, and additives are mixed together. The mixture is heated until the plastic melts and covers the wood fibres. This creates a thick, even blend known as the composite mix.
Getting the ratio right is important. Too much wood can cause swelling, while too much plastic can make the boards brittle. A balanced mix ensures both strength and flexibility.
Step 3: Shaping the Boards
Once the mix is ready, it goes through an extrusion machine. This machine pushes the material through a mould that shapes it into long, uniform boards. The mould also gives the surface its texture — some smooth, some with a natural wood grain.
Step 4: Cooling and Cutting
After shaping, the boards are cooled slowly. This prevents warping and helps them set properly. When the boards are firm, they’re cut to standard lengths and checked for quality.
Step 5: Finishing Touches
The final stage adds protection and polish. Some boards are sanded or embossed for a more realistic look. Others go through a co-extrusion process, which adds a thin outer layer. This layer protects against stains, fading, and scratches, making the deck even more durable.
Traditional vs Co-Extruded Composite Decking
There are two common types of composite decking: traditional and co-extruded.
- Traditional composite decking is made from one blended layer of wood and plastic. It looks like wood and performs well but may fade a little over time.
- Co-extruded composite decking has a special outer shell that protects the inner layer. This makes it more resistant to sunlight, moisture, and everyday wear.
Both are strong and long-lasting. Co-extruded boards, however, need even less care and keep their colour longer.
Why This Process Makes Composite Decking Better
The materials and production process give composite decking several clear advantages:
- Durability: It resists cracking, warping, and rotting.
- Low Maintenance: It doesn’t need staining or sealing — just a quick clean.
- Eco-Friendly: It uses recycled materials and reduces waste.
- Attractive Design: Modern techniques create boards that look like real timber.
- Weather Resistance: It stays strong through rain, heat, and humidity.
Each benefit comes directly from the way the decking is made.
Caring for Composite Decking
Because of its design, composite decking is easy to look after. A few simple steps are enough to keep it in great condition.
- Clean regularly: Sweep away dirt and leaves to avoid stains.
- Wash gently: Use mild soap and water. Avoid harsh cleaners.
- Protect the surface: Use pads under furniture legs.
- Check for wear: Tighten fasteners or replace clips if needed.
Following these steps will keep your deck looking fresh and safe year after year.
Why Choose Composite Decking?
Composite decking is a practical and smart choice for homeowners. It combines the natural look of timber with the strength of modern materials. It’s long-lasting, easy to clean, and kind to the environment.
If you want a deck that looks elegant but needs little upkeep, composite decking is ideal. You can find a wide range of options and finishes at Super Deck.
Final Thoughts
The way composite decking is made is what makes it special. Every step — from using recycled materials to shaping and finishing — creates a product built to last. It’s a blend of innovation, sustainability, and style.
If you’re planning to upgrade your outdoor area, composite decking gives you the best of both worlds: the beauty of wood and the strength of modern engineering.
