Composite Deck Boards Manufacturer & Factory

First-generation composite decking features uncapped exposed wood fibers on the surface, leaving boards vulnerable to atmospheric humidity, mold colonization, deep oil staining, and color oxidation within 12–24 months. Forestar manufactures second- and third-generation capped co-extrusion boards featuring a 360-degree high-density polymer shell. This impenetrable cap seals the inner wood-polymer matrix against moisture, completely repels barbecue grease, wine, and food spills, and shields pigments from UV degradation.

Our material engineers utilize precision-graded reclaimed hardwood timber fibers compounded with recycled post-consumer and post-industrial high-density polyethylene (HDPE). Through twin-screw high-torque extrusion and proprietary coupling compatibilizers (maleic anhydride grafted polyethylene), the wood fiber achieves molecular bonding with the polymer melt. This creates a dense, reinforced composite structure delivering flexural strength surpassing 32 MPa and exceeding the load ratings of pressure-treated softwoods.

For residential deck installations, a joist center-to-center spacing of 350mm to 400mm (14 to 16 inches) perpendicular to the boards is recommended. For high-traffic commercial installations or diagonal (45-degree) deck board layouts, joist spacing should be reduced to 300mm (12 inches) on-center. Boards must be secured using our stainless steel hidden fastener clips to maintain automatic 4-6mm thermal expansion gaps and allow unhindered drainage. Critical substructure ground clearance of at least 100mm must be maintained to ensure proper sub-deck cross-ventilation.

Yes. Forestar provides comprehensive OEM/ODM manufacturing. Our internal tooling center can design and mill custom profile extrusion dies within 20 to 30 days. We offer customized 3D deep-embossed woodgrain patterns, dual-tone chromatic color blending, custom board lengths up to 5.8m (optimized for standard 20ft and 40ft shipping containers), and private-label packaging with customer-specific branding, labels, and barcodes.

Every export container is backed by a batch test certificate issued by our on-site quality assurance laboratory. Tests evaluate water immersion absorption, flexural modulus, color variance (Delta E < 1.0), and dimensional tolerances. Forestar operations are certified to ISO 9001 and ISO 14001, and our composite decking products hold CE certifications, SGS test reports verifying ASTM compliance, REACH environmental safety clearance, and European fire rating certifications (EN 13501-1 Class Bfl/Cfl).

Importers and project contractors can request physical architectural sample binders directly through our portal. Sample packages include cut board samples representing our full color palette, surface texture variants (brushed, grooved, 3D embossed woodgrain), hidden fixing clip hardware, and comprehensive technical data sheets. Samples are dispatched via DHL/FedEx air express within 48 hours for local light and thermal evaluation.