When TTJ did its first-ever Sector Focus on wood-plastic composites last year – concentrating mainly on the decking sector – there was immense interest in the product and the market.
It’s fair to say not everyone in the timber sector was happy about the coverage because the product is not wholly timber (usually 50-75% wood content) but the market has continued to grow and most timber product distributors and merchants now offer at least one WPC decking brand as an option in their decking businesses.
Assessing WPC’s share of the new decking market is difficult because of the lack of reliable data. When the next Timber Decking and Cladding Association (TDCA) survey is completed soon we may know more, but looking at the growth since TTJ’s report a year ago, it is likely that the product has broken through the 10% volume market share point.
Some senior timber trade executives have confessed to installing WPC decking in their own gardens, while major British sawmiller BSW Timber last summer acquired a Welsh WPC manufacturer Alvic Plastics.
In our interviews, we’ve learnt that some regional merchanting chains are investing more than £1m in stocks of WPC and other (non-wood) composite decking.
Imports make up the greater share of WPC decking, with products being shipped in from China, the US, Germany, France and Finland. But several British-made products are also active.
NEW TDCA SCHEME
The TDCA has had many discussions with its members in the last 12 months, the result of which will see a new TDCA product approval scheme approved at its board meeting this month.
The scheme is open to manufacturers, importers and distributors, with applicants needing to meet the requirements of BS EN 15534 (composites made from cellulose-based materials and thermoplastics). The standard defines test methods for characterisation of compounds and products, as well as specifications for WPCs in decking, cladding and fencing.
“To get the accreditation companies will have to prove that they have done the research on their products and that they work,” said Janet Sycamore, TDCA head of operations.
Only companies with products containing wood fibre content can seek the TDCA accreditation, ruling out UK composite decking market leader Millboard, a USmade product which uses PU resin, mineral stone flour and glass fibres. And recognised independent accreditation agencies will need to be used.
The TDCA has been working with Bangor University’s Biocomposites Centre on the project.
“I think the market needs something like this because there is such a mix of products and different qualities out there,” said Ms Sycamore.
“Practically all of our members are either already offering the products or thinking about doing it. Those that originally had reservations now realise that WPC is part of the market and have accepted it.
“But timber is still an important part of the structure supporting a WPC deck. While WPC will have a good place in the market, timber decking remains a good option and is the most economical.”
Ms Sycamore estimated that 2018 had probably seen the biggest annual WPC deck growth in the UK so far.
Chinese-made Saige Longlife Decking has been on the UK and Irish markets for the past eight years.
“Sales have again started off well for 2019 and we are hoping for continued healthy growth this year,” said Harriet Keohane, Saige director.
“We do feel that Brexit is impacting on some of our landscaping customers dealing direct with home owners, with people wanting to hold off on spending money on their gardens until after this period of uncertainty passes. But commercial and housing markets seem to be unaffected in our opinion.”
Saige has added a new colour – Coffee – to its range and is expanding into fencing with its Composite Fences, incorporating composite balustrade options and a gate.
The balustrade, gates and fences have no visible fixings and have a patent pending. The whole system will be launched towards the end of this month, with fences already in stock.
“We believe it is a natural progression for the WPC landscaping industry and is a great opportunity for us,” added Ms Keohane. “We do get asked for composite balustrades in particular and we like to react to our customer’s requirements. Past options for composite balustrades have been large and unsightly, with a need for plastic covered posts, however, we feel we have now been able to design and produce a sleek looking solution.”
MADE IN GERMANY
Michael Stubbs and Roger Summer, UK sales agents for Germany’s Novo-Tech – the manufacturer of the Megawood and EasyDeck WPC brands, say WPC had grown again in 2018.
“There has been quite significant growth in composites actually,” said Mr Stubbs.
He knew of two regional merchanting groups that had each invested over £1m in just one composite decking brand. “There is an undercurrent of residential decking demand, bolstered by commercial jobs. You can see the trend of composite decking and cladding, it’s just happening. “It’s now virtually accepted that most merchants or distributors will have a minimum of two composite decking brands. The switch from softwood to hardwood to WPC decking is massive but it’s now getting to be par for the course.”
Novo-Tech’s Megawood and EasyDeck brands claim to have the largest range of WPC products on the market, with a significant choice of profiles and colours, with some products that can be installed on 500-600m centres.
Mr Stubbs has noticed a move towards the more competitive products and EasyDeck sales have started to outshine Megawood because of its lower price point. “We’re seeing this market still being driven by price.”
He also cited a move towards a wider range of profiles, smooth boards and more different colours. Megawood will launch a stone colour soon for use in tandem with paving slabs. “Composites are coming to the fencing market, there’s no doubt about that but I believe composite cladding will be a big area,” added Mr Stubbs.
Megawood will be launching a WPC cladding product this year after customer demand for the product.
SAWMILLER’S WPC MOVE
The UK’s largest sawmiller BSW Group made a major move in WPCs last summer when it acquired Alvic Plastics Ltd following a longstanding relationship with the company. BSW had already launched a WPC mono deck board in partnership with Alvic earlier in 2018, which it said had been a huge success with existing customers.
The partnership provides BSW with the opportunity to distribute WPC products along with timber deliveries nationwide.
“Alvic joining the BSW Group is a fantastic opportunity for us to revolutionise wood plastic composite products in the UK, utilising Alvic’s extensive production knowledge and capability along with our own wide-spread customer base and national distribution,” said BSW CEO Tony Hackney, speaking at the time of the Alvic acquisition (TTJ September 2018). The companies have been working on new WPC products to offer the market in 2019.
Meanwhile, the largest UK volume sales WPC decking brand Trex is made in the US and distributed by Arbor Forest Products. This year it has responded to demand for a less costly WPC deck option in the wake of a wave of new lower priced Chinese-made imports. So, Trex and Arbor are launching two new collections to compete in this segment but with the same Trex guarantee.
These are the Trex Enhance Naturals and Trex Enhance Basics collections, both of which are solid boards capped on three sides. The main differences of the new ranges with its existing premium Transcend product are that Trex Enhance boards are lighter due to a scalloped core, and the shell is made differently.
“The expanded Trex range is about increasing homeowners’ and installers’ options when it comes to Trex decking – giving them the choice of more products and more colours with price points to suit any household,” said Arbor Forest Products’ Trex product manager, Sarah Francis.
COMPOSITE PRIME JOINS TTF
Fast-expanding WPC decking importer Composite Prime has become a member of the Timber Trade Federation (TTF), becoming the first-ever member of the industry-leading body that solely supplies composite materials. The company has high profile distribution partnership agreements for its ranges with the likes of Arnold Laver, Taylor Maxwell and Timbmet, along with GAP, a leading supplier to builders and installers in the UK PVCu market.
Made from a combination of FSC-certified wood and recycled plastics, the firm estimates its luxury garden and landscaping products have saved the equivalent of 25 million plastic bottle tops from going to landfill over the last six months alone.
Meanwhile, Compass Forest Products – part of Consolidated Timber Holdings which also includes MBM Forest Products – is offering Novo-Tech products, but using its own brand name.
Compass’ Marc Foster said the company had wanted to offer something different in the composite decking market.
“Now you walk into every single merchant and you are met with lots of different options on composite decking, with point of sale displays. The products are usually 135mm- 140mm wide boards and often capped products [top plastic wear layer].”
“We did not want a plastic wrap because we are a timber company and when you walk on a capped product, ultimately you are walking on plastic.”
CTH will offer a product in a 16x193mm solid profile in two colours – silver ash and woodland brown.
This year it is officially launching on the market and will push the product, with stockholding at Tilbury. It intends to emphasise the “Made in Germany” angle, telling customers the close proximity of the factory meant it could source new shipments within a week.
Mr Foster said a wide profile board not only looked different but he said also averaged about 30% quicker to install. It is offering a 10-year warranty, including a promise to meet full remedial costs in the first five years should there be a problem with the installation.
The long-term goal is to offer the product across the CTH Group.
But Mr Foster says softwood decking is still here to stay because of its price point, but thinks hardwood decking could see reductions in the coming years. “Low maintenance products are still a massive driver for consumers.”
He also thinks further development of WPCs will see their appearance looking more natural.
To summarise, WPC decking growth is set to continue, with WPCs also expanding into cladding and high-end fencing, Product understanding and knowledge throughout the supply chain and among installers is key, especially due to the plethora of brands and varying qualities.
If the TDCA approval scheme catches on, it could be the answer and the peace of mind that people need, as well as benefitting those accredited suppliers with an additional marketing tool.
