Unveiling ExaDeck – The Pioneering Porcelain Decking

Transcending the limitations of conventional materials like wood, resin, or plastic, this innovative deck board offers unparalleled suitability, particularly in scenarios where moisture poses a significant challenge and crucially for fire-rated projects at height, such as raised access floor applications.

Robust Composition and Superior Strength

At the core of ExaDeck’s prowess lies its robust porcelain composition, purposefully crafted to withstand the rigours of outdoor conditions. Boasting an impressive Class A fire rating, this decking system exemplifies uncompromising safety and performance. Its high mechanical strength, substantial breaking capacity, and exceptional resistance to abrasion render it an optimal choice for areas subjected to heavy foot traffic.

Frost and Temperature Resilience

ExaDeck’s minimal water absorption characteristics imbue it with an extraordinary ability to withstand the harshest climatic conditions. Its resilience against frost and ice, coupled with its capacity to endure temperature fluctuations over a prolonged passage of time, safeguards the system from expansion-induced deformities and cracking, ensuring long-lasting structural integrity, high performance and aesthetic appeal.

Rectification

Unlike most porcelain deck boards and tiles, ExaDeck goes through a double rectification process during manufacture. The edges of the boards and the side fixing detail are trimmed to become dead straight and dead flat so that completely flat lines are created across large sections of decking and the W Clip hidden fixings are securely and exactly fastened, avoiding any risk of movement or insecurity.

Crucially, the boards are also rectified – this is a process that occurs when the porcelain is being baked and is not fully hardened and also after it has been fully kilned and hardened – along the upper and lower surfaces. It is vital that the top and underside are dead flat since many boards can display a slightly convex profile which will make the boards rock when fixed to the substructure rail/joist and lead to rocking and potentially cracking over time.

This risk is avoided by the double rectification process and is unique to ExaDeck.

Hygiene and Safety: Paramount Priorities

In the realm of UK construction, hygiene and safety take centre stage, and ExaDeck excels in both domains. Its easy-to-clean surface and barefoot-friendly design, complemented by an almost zero water absorption rate, create an environment that prioritises cleanliness and user comfort.

Sustainability

ExaDeck is manufactured in the most sustainable way. As well the factory is powered by renewable energy via solar panels on the roofs of the factory itself, all the water used during production is recycled multiple times through a series of filters and storage tanks. Every ingredient is 100% recyclable; and both the clay and the mineral components used within the ExaDeck boards are sourced from fully recycled sources, being the waste elements from other quarrying and production processes.

Many companies and product brands may claim that they are sustainable and that their products are sustainable without providing evidence of such sustainable credentials. ExaDEck can back up all our claims, just ask us.

Meticulously Engineered Components

ExaDeck Board

The ExaDeck Board, the cornerstone of this innovative system, boasts meticulous engineering and stringent quality control. Meticulously crafted with dimensions of 26mm (H) x 141mm (D) x 1,217mm (L), these boards undergo rigorous testing, including crucially rectifying the boards twice,to ensure uncompromising performance across a range of critical parameters.

Aluminium Box Rails and I-Plus Joists

Complementing the ExaDeck Board, the system incorporates meticulously designed aluminium components, including Box Rails and I-Plus Joists. These components, being made from aluminium, are clearly and unequivocally rated Class A1 according to both EC Decision 96, DCLG (as renamed after the General Election before going to press) regulations and BS EN 13501-1 2018, further reinforcing the system’s commitment to safety.

These lightweight but extremely strong support rails ensure complete stability and strength for the decking system.

Independent Testing and Validation

ExaDeck’s exceptional performance is backed by rigorous independent testing, conducted by renowned organisations like Specialist Technical Services (U.K) Limited (STS-Group). These comprehensive evaluations validate the system’s weight tolerance, load-bearing capacity, wind uplift resistance, fore rating and overall structural integrity, ensuring that the system meets and exceeds industry standards and regulatory requirements.

Pedestal Placement and Load Testing: Box Rails

The Wallbarn Aluminium Box Rails/Joists have undergone stringent testing to determine their weight tolerance and load-bearing capabilities. Conducted in accordance with BS 8579:2020 and BS 8527:2020, these tests targeted a load resulting in a 5mm deflection, providing valuable insights into the recommended pedestal placement for optimal weight distribution and reduced point loading.

Wallbarn tested all six of its aluminium rail products, both the low-profile box section versions and also the very heavy-duty I Plus version.

Furthermore, the Box Rails/Joists were subjected to destructive load testing, where 2-metre lengths were clamped at each end, and a vertical compressive load was applied to the centre. Remarkably, even these very low profile rails, under a force of approximately 107kg (1.05kN), exhibited significant resilience, bending over 64mm without breaking and regaining their original shape after the test concluded.

Pedestal Placement and Load Testing: I-Plus Rails

The very heavy-duty Wallbarn Aluminium I-Plus Rails/Joists, designed for heavier loads and longer spans, underwent similar rigorous testing by STS-Group. The tests, conducted in accordance with BS 8579:2020 and BS 8527:2020, provided valuable insights into the recommended pedestal placement for optimal weight distribution and reduced point loading.

Additionally, destructive load testing was performed on 2-meter lengths of the I-Plus Rails/Joists, with the rails clamped at each end and a vertical compressive load applied to the centre. The table below displays the remarkable force applied and the corresponding deflection achieved prior to failure, further attesting to the system’s exceptional load-bearing capabilities.

In conclusion, the weight tolerance of the entire range of aluminium rails is clearly demonstrated as exceptional.

MetalPad Ex Pedestal: A Sturdy Foundation

The MetalPad Ex Pedestal, a crucial component of the ExaDeck System, is meticulously crafted from mild steel conforming to EN 10152 standards. Being made from steel, they are clearly and unequivocally Class A. They are covered with a special  Zintec 200 anti-corrosion protective coating to ensure the pedestals are ideally suited for external applications. The Zintec 200 material has been physically fire-tested by independent testing institute Warrington Fire and is certified to be Class A.

Coating the steel pedestals with Zintec 200 also ensures that there is no reaction between the steel and the aluminium rails.

The pedestals are designed to ensure seamless integration with the aluminium components of the system by hand via wing nuts and clips.

Secure Connections and Seamless Integration

To ensure a cohesive and robust installation, the ExaDeck System incorporates a range of specialised brackets and fasteners designed to facilitate secure connections between the various components.

Brackets/Connections for Aluminium Box Rail

The Aluminium Box Rail can be securely joined end-to-end or at right angles using specialised brackets and stainless steel screws supplied by Wallbarn.

Brackets/Connections for Aluminium I-Plus Rail

The I-Plus Rails/Joists offer two connection options: a self-tapping screw for secure mechanical fixing or a Wing Nut/Bolt Kit for hand-tied fixing. The latter option allows for initial loose assembly, enabling precise alignment before final tightening, ensuring a well-fitted and stable construction.

Deckboard fixings

Deckboards and a full decking system are only as secure as the decking fixings. Wallbarn has designed developed and manufactured a bespoke decking fixing called W Clip.

W Clip is made from aluminium and is electro-plated, not powder coated, black. They are made coloured black in order to avoid any of the shiny silver colour from the aluminium rail showing between the decking boards. Wallbarn got feedback from our clients and this was a real issue for their clients, so we acted and produced our own bespoke clip to address this issue.

W Clip comes in two sizes, a 60mm wide clip to fit completely across the 60mm wide rails/joists; and a 30mm version for cost savings.

Always drill a pilot hole into the aluminium rails/joists before attempting to fix decking clips.

The clips are designed to fit perfectly into the side milling profile of the ExaDeck boards (remember what we said about rectified boards being completely straight at the edges and completely flat on the underside?) and come with screws already partially fitted into them, to prevent them slipping out during fixing. This speeds up and makes significantly easier the full installation process.

Cutting and Drilling: Precision and Safety

When cutting or drilling the metal components of the ExaDeck System, it is recommended to utilise premium blades and tools specifically designed for working with porcelain and metal. This approach minimises the generation of sparks and reduces the risk of damaging the extruded profiles, ensuring seamless integration with pedestals and headpieces. It will also ensure truly straight and neat cuts and lines on the decking boards themselves.

Long-lasting Performance and Limited Warranty

Wallbarn’s complete Class A ExaDeck System, when properly installed and maintained, boasts an impressive expected lifespan of up to 50 years. To ensure optimal performance and take full advantage of the warranty, it is highly recommended to use the complete system with all components supplied by Wallbarn, as outlined in the installation guide.

The system is backed by Wallbarn’s standard Limited Warranty of 15 years, covering all components on the condition that the Installation and Care & Maintenance Instructions are followed, and the system is installed according to Wallbarn Ltd guidelines.

Low Maintenance

While the ExaDeck System requires relatively low maintenance, it is crucial to ensure the proper functioning of the drainage system on the sub-deck where the rails/joists are installed. Regular checks and maintenance of the drainage channels or outlets are necessary to prevent water pooling, which can potentially lead to material damage, rust, or corrosion over time.

The beauty of this system is that sections can be removed for inspection fairly easily and with no damage to or destruction of the materials.

By prioritising the maintenance of drainage in the installation area, you can help ensure the longevity and optimal performance of the ExaDeck System, minimising the risk of deterioration caused by excessive water exposure.

Fire Safety and Disposal Considerations

The ExaDeck System achieves a remarkable fire resistance Class A1 according to the BS EN 3501-01: 2018 standard, posing no fire risk and allowing for safe installation in high-rise applications. In the event of a fire, use extinguishing media appropriate for the surrounding conditions.

Despite this system being recognised as being Class A according to DCLG regulations and EC Decision 96; some specifiers still ask for a physical fire test. Although this seems bizarre and is completely unnecessary, Wallbarn is currently engaging with an independent testing institute to conduct a full system fire test and certification. This will show that the system, being made up of Class A-rated components, is Class A.

At the end of the system’s life cycle, recycling the aluminium and steel components is strongly recommended to conserve resources and reduce environmental impact. To reinforce, every element within this system can be fully recycled. Alternatively, the system can be disposed of at an approved solid waste disposal site, adhering to local or national regulations to ensure responsible waste management and minimise environmental impact.

Conclusion

The ExaDeck Porcelain Decking System stands as a testament to innovation, durability, testing and unwavering commitment to safety and performance. With its robust porcelain composition, exceptional strength, and resilience against various environmental challenges, this system redefines the possibilities of outdoor decking solutions.

Backed by rigorous independent testing and validation, ExaDeck offers construction professionals a trusted and reliable choice for projects demanding the highest standards of quality, longevity, and fire resistance. Whether in residential, commercial, or public settings and especially at high rise, this pioneering system promises to elevate outdoor spaces with its seamless integration, low maintenance requirements, and a commitment to sustainability through recycling and responsible disposal practices.

Embrace the future of decking solutions with ExaDeck, where exceptional engineering meets uncompromising performance, creating outdoor environments that transcend expectations.