This guide provides instructions for installing prefabricated Deckfab panels
Laying your Deckfab panels with the adhesive provided is a straightforward process. The following is a step-by-step guide.
1. Surface Preparation
It is important to remember that lasting adhesion depends on the integrity of the surface beneath. For example, if you have a painted deck, ensure that the paint is not likely to peel or lift. A clean, dry, and grease-free surface is essential
2. Dry Laying the Panels
The adhesive supplied allows some manoeuverability when laying. However, it is advisable to dry-lay the mats to ensure a good fit and get a feel for how they will go down once the adhesive has been applied to the deck.
3. Preparing the Surface for Adhesive
Take the panel up and prepare the surface for the adhesive. Thoroughly clean the area using a proprietary cleaner (and degreaser if required). Acetone can be used to clean the area; however, be careful to keep it away from the Deckfab panels and only apply the adhesive once the area has dried properly.
4. Applying the Adhesive
Once the surface is clean, dry, and grease-free, you are ready to apply the adhesive. It is recommended that masking tape is used to catch any excess adhesive and ensure the adhesive is applied to the edge of the panel area. Apply the adhesive over approximately 1m² at a time with a comb
The adhesive’s minimum working temperature is 5°C; however, 8-10°C is preferable. The maximum working temperature is 35°C
Using an applicator gun, apply to the area below the panel, being careful not to use too much; more can be added later if required. Using a spreader, apply evenly over the entire area, ensuring good coverage and aiming for approx 3mm grooves at right angles to the run of the main plank area, as this will ensure effective adhesion.
5. Positioning the Panel
Take hold of the panel and position the first edge into place, then slowly roll it out over the adhesive, applying even pressure as you go. The unique ‘keyhole grooving system’ provides maximum contact between the panel and adhesive, so ensure that no air is trapped below the mat. If necessary, it is possible to reposition the panel by sliding it smoothly as required.
6. Applying Pressure
Once the panel is in the correct position, use the roller to apply strong, even pressure over the panel, pushing out any build-up of adhesive and removing any trapped air. As a final check for raised areas, run a hand over the panel feeling for any unevenness and rolling out these areas as required.
7. Final Adjustments and Cleaning
Check the positioning again and make any adjustments as required. Carefully clean away any excess adhesive that may be around the margin edge of the panel. White spirit is an effective cleaner for the adhesive but is not recommended for use on the panel itself.
8. Edge Sealing (If Necessary)
To ensure a clean and smart finish, it may be necessary to run a line of adhesive around the edge of the panel if there is any gap between the material and the deck surface. It is also advisable around curved corners where a king plank has been used. This is best achieved by applying masking tape to the edge of the material and also to the deck and running a bead of adhesive into the gap. Smooth this off and leave to dry for 24 hours before removing the masking tape. Gently sand the panel edges to restore the wood effect if required.
9. Weighing Down the Panels
It is advisable to weigh down the panels with tubs or containers filled with sand or water and use wood planking to spread the weight as required over larger areas.
Note: Be careful if using water – although the adhesive is moisture curing, it is best left for a couple of days before getting really wet.
Image Suggestion: A photo showing weights (sandbags or water containers) distributed evenly over the newly installed Deckfab panels.
10. Curing Time
The adhesive takes approximately 24 hrs to cure at 24°C, but this is dependent on operating conditions. A good rule of thumb is to leave it for a minimum of 3 days before reinstalling any equipment and using your deck as normal. It should be OK to walk across as necessary, but try to keep off as much as possible.