Plastic lumber has proven itself to be extremely useful in a variety of applications over the last twenty years. There are two basic methods of manufacturing plastic lumber: Continuous extrusion and flow-mold. All of our products are individually flow-molded. Most of the time they are molded to the specific size required.

Whereas continuous extrusion can create nearly any length product, the process is limited to relatively thin profiles. The flow-mold process is capable of much larger profiles and accepts more sophisticated additives. We have molded structurally reinforced timbers that were true 11" x 11" inches and over twenty feet long weighing in excess of 1,000 pounds each. Our flow-mold process is limited to 1-1/2" - or larger in any shape.

• Wetlands walking paths
• Landscaping
• Decking
• Flooring
• Docks and Marine
• Lawn and Garden
• Boardwalks
• Terracing walls
• Parking barriers
• Sound Barriers
• Park signs
• Decks, Rails
• Equine Fencing
• Bollards
• Fence posts
• Sign posts
• Pergolas
• Planters
• Truck flooring
• Trailer flooring
• Municipal and private walkways

You might also want to find out more information about our UNIQUE NEW 2"x6" Tongue & Groove Planking with DeepV design.

“moldedCAST™,” our basic lumber formula, matches or exceeds the basic physical properties acceptable by the ASTM testing methods and is similar to other polyethylene products available on the market.

Our basic source of material is postindustrial, not curbside. Our products tend to be more dense than other manufacturers' (weighing more per foot). As result of our R & D efforts, we have made the decision to use less foam and more stabilizers and compatabilizers.

The texture and color of our product is more natural, i.e., pleasantly inconsistent. On occasion, there will appear multiple color flecks on the surface. This is a result of our mix containing materials that have different viscosities when they melt. The chemical composition and physical properties of the material match and bond together but the colors of the regrind used in our blend sometimes appear on the surface. If it is important to your project to have a uniform “plastic” look, please tell us and we will try to compromise our artistic urges and create a more uniform colored product just for you.

“fiberCAST™” is our basic reinforced lumber formula. Plastic lumber is an amorphous blend of olefin polymers that, by their nature, do not have a grain. This being said, it is possible to strengthen the bonds between the polymer molecules and simulate a grained-strength product. This product also meets or exceeds the basic physical properties offered by other plastic lumber manufacturers. Again, our product tends to be heavier per foot and occasionally have the inconsistent texture and multiple-colored fleck on the surface. We add compatabilizers, bonding agents, fiberglass, stabilizers, and other ingredients that increase our product's ability to hold the molecules together and thus achieve a more structural application.

Contractors take note:

If you are considering using a product like our for a project, there are several characteristics you must plan for:

Expansion/contraction co-efficient for any plastic is greater than wood.

This can be modified by increasing the percentage of “filler” in the formula selected for your product.

This must also be planned for
           by drilling slightly larger holes than usual
                 for that bolts and washers/nuts
           for lag/deck screw, always drill a larger pilot hole through the                  board and a smaller than usual pilot hole into the baseboard.

On larger timbers, we advise placing your fasteners about 1/3 of the distance in from either side so that you are drilling through solid plastic alongside the core and not directly into the core.

REMEMBER: this material expands and contracts around the hardware. If you leave expansion room, this project will be there for your great grandchildren.

Our CASTplastic™ lumber's strength is not in a natural grain (as in wood) but in the box-beam-like element produced by our flow-molding process. Looking at a cross-section of our material, you will see a “foamed” core surrounded by solid plastic, occasionally you will see small cavities within that core. These cavities have little to no effect on the performance of the product. The foam core helps to force the hot, fluid plastic into the shape of the mold and holds the outer planes parallel to each other after the cooling process. Technically, this core helps to “stress” the plastic as it is forming into the specified dimensions and adds more grain-like strength to the product.

WARNING: DO NOT TRY TO RIP A PIECE OF CASTplastic™ LENGTHWISE . If you try to “rip” a 2” x 6” into two 2” x 3” s the strength of the piece will be destroyed.

If you have an application that calls for a milled shape over the length of the lumber, we highly recommend that the shape be molded into the part.

FINAL WARNING: It is common practice in deck building to notch the support post to fit in rafters, rails, etc. DO NOT USE THIS TECHNIQUE WHEN USING OUR MATERIAL. AVOID NOTCHING! We are able to mold the shapes you need to build your deck project from structural reinforced posts and rafters to the deck, steps and newel post. If you notch into this core, you can loose up to 1/3 of the physical strength of the product.

Compounded/custom formulas

Plastic is one of the great marvels of the modern world. Through a variety of techniques of blending, cross blending, introduction of additives, etc., it is possible to modify the physical properties of the end product.

Like baking, using the same basic ingredients you can create a wide range of results. With the expert help of some of our local plastic compounders, we have learned that the physical properties of plastic lumber can also be modified.