Trex Company, Inc.

Trex Composite Decking

Trex is widely considered as one of the inventors of composite decking made from recyclable materials. The idea for a process and product created to maximize the use of materials that would otherwise wind up in landfills is credited to inventors Kjell-Ake Gustafsson, of Binghamton, NY; John J. Muller, of Winchester, VA; and Roger A. Wittenberg of Newton, PA.

Company Patent

The first patent for a “Method of Producing a Wood-Thermoplastic Composite Material” was filed as U.S. Patent number 5746958 in March 1995 and granted in May 1998. The Assignee was Trex Company LLC, operating in Winchester, VA. The process abstract for the creation of composite decking is: “A method for producing a wood-thermoplastic composite material using a high bulk density feedstock. Since the feedstock is easy to handle it provides manufacturers with lots of control over the process. Prompted by the prospect of environmental regulations mandating recycled materials, this process uses spent sawdust and plastic material rather than disposing of it.”

Manufacturing Processes

Trex continues to employ a process that combines different materials, mostly wood and plastic, that are formed to create a product that has the appearance of wood. The wood content in Trex products is largely wood byproducts like sawdust, wood pallets, wood chips and wood fiber. The polyethylene plastic continues to be mostly recycled materials from commonly discarded items like stretch wrap, packaging films, grocery and retail bags and case/carton/product overwraps. Trex uses about 100,000 tons of waste polyethylene film each year and claims to keep 200,000 tons of plastic and hardwood scraps out of American landfills each year. Over 120,000 pieces of post consumer film (packaging, bags, overwraps, etc.) can be used to create a 500-square-foot Trex deck. The components are mixed and a pigment and preservative are added during the process. The mixture is then heated, formed into a board shape, and cooled.

Transcend Decking

In 2009 Trex introduced a ‘Transcend’ line of decking that is a co-extruded composite decking product that includes a shell around the composite boards on three sides to protect the boards from staining, fading and scratching. The Trex Transcend line of decking claims a recycled content rate of 95.4%.

Products

Trex products include:

Environmental Record

Trex promotes an environmental stance as part of its commercial appeal in the marketplace. In public materials, Trex Company, Inc. cites that no trees are cut down to make Trex decking products; that the company uses vegetable-based oil hydraulics in transportation trailers; and that it recycles factory waste back into the manufacturing line.

Recycled Components

Trex composite decking contains 97% recycled content and offers verification by ICC-ES. In July 2010 Trex received a Verification of Attributes Report (VAR-1011) from the International Code Council Evaluation Service (ICC-ES) under the Sustainable Attributes Verification and Evaluation Program. The verification validates Trex’s wood-alternative products are manufactured with a minimum of 95.4% recycled content. Trex claims is the first composite decking manufacturer to obtain this certification.

Environmental Affiliations

Trex has been a member of the Green Building Council, a trade group promoting environmentally friendly building practices, (USGBC) since 2009. USGBC is best known for the widely recognized LEED program (Leadership in Energy & Environmental Design).

Through the LEED point-based system, the use of Trex decking and railing products add points based on the percentage of recycled product content.

Environmental Programs

Trex conducts and participates in eco-friendly educational and recycling programs in various parts of the United States. Since 2006, students at selected schools throughout the East Coast and Midwest have participated in a ‘Trex Plastic Bag Challenge’ (recently renamed ‘Plastic Film Recycling Challenge’ ). Students collect plastic bags in exchange for a gift of Trex benches to participating schools.

The company has also provided in-kind contributions, financial assistance and expertise to environmental projects around the country. These include:

Environmental Recognition

Trex corporate participation in environmental efforts, coupled with its eco-friendly product profile, has led to recognition by governments, publications and trade groups.

These include:

Industry Recognition

Controversy

Lawsuit: A manufacturing problem at the Trex manufacturing facility in Fernley, Nevada led to the production of some decking boards from 2002 to 2007 that were prone to surface flaking. These boards were sold throughout 16 Western states in the U.S. and resulted in a class action suit against the company. In a settlement approved in 2010 Trex agreed to replace any decking boards, including some resulting labor costs, for decking affected by surface flaking.