Hardware Store PVC Sheets as Deck Hardware Material

[southcoasting]

All,
I've been thinking about cheaper alternatives to G10 for backing material for all my deck hardware that I am about to put back on.

I just noticed the big box hardware store have PVC sheets in 3/8" and 1/2" thickness. I thought this might be better than just plain wood.

Any reservations on using PVC sheeting?

[scoob]

To brittle? Depending on the load it may want to split?

[CapnK]

If it's Azek brand or similar, it is actually a sheet form of PVC foam. Not super compressible, but definitely more so than G10. I'd do this:

Prep the backing pad by sanding, routing, or otherwise rounding corners and edges down to a radius appropriate for glass to easily adhere - say at a 45* angle so you won't need to fillet. Hot glue or 5-minute epoxy the backing pad in place, then glass over it, prior to drilling for the hardware, and use large washers. That should be rock solid.
Of course, if deck area over that pad is cored, do the usual "overdrill, backfill with thickened epoxy, and redrill" your mounting holes to prevent water intrusion. The PVC foam will not soak up water, you don't have to worry about it with regards to that.

I made a rooftop garden of 2' square x 16' and 20' length boxes for my sister probably over 15 years ago with Azek when it was a very new product. You could get boards and sheets of it then, special order from Home Depot in my case. Glued and screwed. It is still holding up great.

[rescuesailor02]

I have been buying HDPE plastic, (it is essentially the same as Starboard) from the internet. Mostly off of Ebay, look in the the search the entire site and don't search by the Starboard name. Its cheap, strong, rot proof, and does not really compress. It is easy to work as you can use any wood tool on it. I've had great luck and really have not complaints.

[mitiempo]

Starboard is a lousy backing plate material. It moves under load.

Best to use fiberglass epoxied to the underside of the deck.