Application Instructions

60 mil Vinyl Installation Instructions

READ ALL DIRECTIONS BEFORE BEGINNING

IMPORTANT: In inclement conditions, the plywood must be kept dry. Make a barrier by suspending a tarp at lease 24" from the deck surface. Hint: Use the roof fascia.

IMPORTANT: Do not apply adhesive when the deck is hot to the touch from direct sunlight. Ducan does not warranty Dek-Master® on stairs.
Do not install Ducan Dek-Master® vinyl sheeting on pressure treated lumber. K-3 board, particle board and OSB are not recognized as suitable exterior sub-floor materials.

Installation
	1.	Carefully sweep off the deck surface and make sure it is free of all debris. Any imperfections will telegraph through.
	2.	Install galvanized metal cant strip at the house to deck interface or if running vinyl sheet up the wall, install 2" x 4" galvanized metal flashing at the house to deck interface. This will act as an attachment transition between the deck surface and the house. Note: It is always preferable to run the vinyl up the cant strip or flashing and under the siding and tar paper.
	3.	Install galvanized metal flashing to protect the edges of the plywood from moisture and to act as an attachment area for the vinyl. Install 2" non-return flashing around the perimeter of the deck surface 1/4" away from the edge of the plywood using 1 1/4" galvanized ring nails, starting from the center and working your way out to the ends.
	4.	Once cant strip and non-return drip flashing have been nailed to the deck, fill all joints and surface imperfections with Dek-Master® Dek-Patch joint filler and patching compound. Follow mixing instructions on the label. Fill all joints, screw indentations, surface imperfections and transition of cant strip and flashing to the deck surface. It is important when leveling out the flashing or cant strip edge that the Dek-Patch doesn't build up on the top surface. To avoid grinding or sanding, just before the Dek-Patch hardens scrape off excess with the trowel. IMPORTANT: Do not allow the Dek-Patch to freeze for 24 hours. DO NOT ALLOW DEK-PATCH TO GET WET.
		Your surface is not prepared and you are ready to install your waterproof Dek-Master® sheet vinyl. Do a review of the video, brochure and web site before proceeding. Tip: To be sure the vinyl is square on the deck draw a chalk line in pencil so that when you unroll the vinyl you can be sure that the sheets are square on the deck surface.
	5.	The pattern of the vinyl is directional. Lay each sheet in the same direction. Lay out Dek-Master® vinyl to ensure the fewest possible seams. Start from the furthest point from the wall and allow 1" to 2" of vinyl to go over the flashing and 1" for up and over the cant strip or 6" for up the wall. Adjust the vinyl sheet to ensure it is parallel to the wall and/or deck edge. Tack within 1" of upper edge to hold in place temporarily. The seam area will be Hot Air Welded so putting a tack or staple in this area is safe. IMPORTANT: Colour variances from roll to roll are common. Ducan will not be responsible for any material applied from two separate rolls.
	6.	Fold vinyl sheet back half its width (as shown at left) and first apply Dek-Master® Pro Contact Adhesive to the deck surface, secondly to the back side (fuzzy side) of the vinyl. IMPORTANT: Both surfaces must have a complete even coat of Pro Contact Adhesive. (Pro Water Based Adhesive is a trowel on product that goes on the plywood surface only.)
	7.	Both surfaces must have a complete even coat of adhesive (Pro Solvent Based Adhesive). Let the adhesive dry until tacky. Test the tack by placing your finger to the adhesive coated back side (fuzzy side) of the vinyl. Adhesive should be stringy between your finger and back side of the vinyl .
	8.	Push adhesive coated vinyl sheet down onto the deck surface by working with your hands from the middle point to the edge of the deck, then outwards to the ends. (If using Pro Water Based Adhesive you must use more pressure to push the vinyl into the glue.) IMPORTANT: Ducan recommends using your hands to smooth the vinyl down. If an air bubble forms in the vinyl, smooth it out with your palms to remove it. If you find you are acquiring air bubbles under the vinyl this could be from temperature or too much adhesive. Push the bubbles down. Most likely after a few days they will go down and stay down on their own. Note: Use of a roller or rolling pin can cause stretching of the vinyl. DO NOT USE. WHEN TO APPLY: Temperatures between 12°C/54°F and 32°C/90°F are best. The plywood surface must be clean and dry, with no more than 12% moisture content. Do not apply to pressure treated lumber.
	9.	Remove tacks or staples and fold the vinyl sheet back as shown at left. Apply Dek-Master® Pro Contact Adhesive to the back of the vinyl first (fuzzy side), then to the deck surface. IMPORTANT: Both surfaces must have a complete, even coat of Pro Contact Adhesive.
	10.	Push adhesive coated vinyl sheet down onto the deck surface by working from the middle point to the edge of the deck, then outwards to the ends. Important: Ducan recommends using your hands to smooth the vinyl down. If an air bubble forms in the vinyl, smooth it out with your palms to remove it. If you find you are acquiring air bubbles under the vinyl this could be from temperature or too much adhesive. Push the bubbles down. Most likely after a few days they will go down and stay down on their own. Note: Be careful walking on the vinyl, avoid twisting too fast as the adhesive may not be completely set. Use of a rolling pin can cause stretching fo the vinyl. Do Not Use.
	11.	Subsequent vinyl sheets must be overlapped 1" to the adhered vinyl sheets. To prepare subsequent sheets, place a piece of 1" masking tape to the underside edge (fuzzy side) where the overlap will be. It is necessary to follow this step to ensure the Adhesive does not interfere with the Hot Air Welding process. This tape will be removed prior to completion of the Hot Air Welding.
	12.	Install 1" masking tape on the edge of the first panel (patterned side). This will protect the vinyl against any adhesive that may end up on it. It will also act as a guide as you slide the corresponding sheet over to achieve the necessary 1" overlap. This tape will be removed prior to completion of the Hot Air Welding.
	13.	Follow the same procedure as you did for the first panel installation flipping the sheet over half way, adhering and then folding back the other half in the same way. Use waxed paper to protect the lower panel while gluing the second one. Do not try to glue the vinyl to the cant strip at the same time on your final sheet. The vinyl may try and pull away as it dries leaving a hollow area under it without being attached.
Finishing
	1.	Hot Air Welding Lap joints must be a minimum of 1" to 1 1/2" and be fully heat welded. Remove the temporary tacks or staples and the two strips of 1" masking tape and make sure there is no Pro Contact Adhesive residue in the overlap area before you proceed. Ducan offers the hot air welder along with a DVD for those wishing to rent the unit. Please contact your retailer or Ducan Customer Service at 1-800-943-8226 regarding the rental of this unit. IMPORTANT: Ducan strongly recommends repeated practice prior to working on the actual deck seams. The more practice the more professional the deck will look and the more water tight the seal. WARNING: Do not use excessive pressure with the seam roller as this could distort the vinyl layer. Hot air welding seams is an option for the 45 mil and is required for the 60 mil vinyl. Ducan offers the hot air welder along with a DVD for those wishing to rent the unit. Please contact your retailer or Ducan Customer Service at 1-800-943-8226 regarding the rental of this unit.
	2.	Finishing Now that your deck surface is completely sealed it's time to prepare for the vinyl for attachment to the flashings and cant strip.
	3.	Cant strip Finishing IMPORTANT: 60 mil must be installing up the wall and under the siding. It is too thick to bend over a cant strip. Installing up the wall adhere vinyl to the cant strip or flashing then up the wall 6 to 8". Vinyl can be stapled or tacked on the upper edge to keep it from moving when installing the siding. Tip: If Dek-Master Caulking is not available, an outdoor polyurethane caulking may be substituted. WARNING: Do not use silicone or latex based caulking as they are incompatible.
	4.	Finishing Flashings and outside corners With a razor knife, trim the vinyl flush with the edge of the flashing. At the corners, cut the vinyl from the outside edge to the deck corner in line with one edge. With a small brush suitable for enamel paints apply a coat of Dek-Master® Pro Contact Adhesive to the flashings and onto the back of the vinyl. Be sure to keep the adhesive off the corner areas where the hot air welding gun will be welding the corner flap. Tightly push the vinyl against the flashing to make sure it is well adhered. Fold the outside corner flap around the outside corner first, then pull the top flap over the first. Hot air weld the top flap to secure to the flap beneath. Install the Ultra U-Channel deck clips over the edge of the vinyl covered flashing to complete your Dek-Master 60 mil vinyl installation. Tip: Apply drops of Ducan Overlap Cement every 4" to 6" inside the Ultra U-Channel canal to chemically weld it to the vinyl covered flashing if desired.
	5.	Install the Ultra U-Channel deck clips over the edge of the vinyl covered flashing to complete your Dek-Master 60 mil vinyl installation. Tip: If desired, apply drops of Ducan Overlap Cement every 4" to 6" inside the Ultra U-Channel canal to chemically weld it to the vinyl covered flashing. This keeps it securely fastened to the flashing. Tip: From time to time you may run into a situation that is different from the instructions above. If in doubt, please call our technical support line at 1-800-943-8226.

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I can honestly recommend Ducan products and by doing it myself saved nearly $5000.00 on a 450 square foot deck! Steve Anthony, Okanagan Falls, BCread more »