When building a deck, one of the most important decisions is choosing the deck boards. The length of the deck boards impacts the look, durability, and cost of the deck. In general, longer deck boards require fewer seams, create a more seamless appearance, and speed up installation time. So what is the longest deck board currently available? Let’s take a closer look at deck board lengths and options for maximizing board length.
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Standard Deck Board Lengths
The most common deck board lengths available are:
- 12 feet
- 16 feet
- 20 feet
12 foot boards are the shortest option and are readily available at most home improvement stores. They provide enough length to span several deck joists while still being manageable to transport and work with. 12 foot boards are a versatile option suitable for most residential deck projects.
16 foot deck boards provide a longer span and require fewer seams for a cleaner look. They are still relatively easy to work with compared to longer lengths. 16 foot boards are a nice step up in length while still being realistic for DIY builders to handle.
20 foot decking boards are on the longer end of standard sizes. They allow installers to minimize seams and speed up the installation process. 20 foot planks are more difficult to transport and maneuver into place than shorter boards. Using them typically requires two people and some specialized equipment. But the longer lengths provide a premium aesthetic.
Special Order Long Deck Boards
While 12, 16, and 20 feet are the most common sizes, some deck builders want to push the limits and maximize board lengths. Many decking manufacturers can supply special order boards longer than 20 feet upon request. Here are some of the longest deck board sizes available by custom order:
- 24 feet
- 30 feet
- 40 feet
24 foot deck boards provide a huge leap in length over standard sizes. They can span nearly the full width of the average residential deck with a single board. But handling 24 foot planks requires special equipment and skills. Their length makes them challenging to carry and position during installation.
30 foot deck boards take length to the extreme. At this point the planks are so long and heavy that installation requires multiple workers, lifting equipment, and very careful maneuvering. But for decks with adequate structural support, 30 footers create a beautiful seamless appearance.
40 foot deck boards are at the upper limit of length. There are very few residential applications where boards this long are necessary or practical. Handling and installing boards this big takes a commercial level crew. But for the right oversized deck project, 40 foot planks can deliver a spectacular seamless hardwood look.
Maximizing Deck Board Lengths
Here are some tips to maximize deck board lengths on your project:
- Check manufacturer size capabilities – boards over 20 feet will need to be custom ordered
- Evaluate deck size and layout – make sure the structure can support long spans
- Consider equipment needs – long boards may require special lifts, trucks, cranes
- Factor in labor – extra workers will be required to install oversized planks
- Allow for overhang – order boards slightly longer than the deck area
- Inspect boards for defects – carefully check long boards for any damage
By keeping these considerations in mind, you can maximize deck board lengths to achieve the seamless upscale look you desire.
Longest Deck Board Options by Material
Let’s take a look at some of the longest deck board sizes available for the most popular decking materials:
Wood
For traditional wood decking, cedar and redwood boards up to 40 feet are possible. Treated pine, a more affordable wood option, is available up to 30 feet. Keep in mind the longer the wood board, the higher likelihood of warping and twisting over time.
Composites
Wood-plastic and other composite decking brands can also be ordered in lengths over 20 feet. Trex, TimberTech, and other composite companies typically offer custom boards up to 40 feet. Composite boards resist warping better than solid wood.
PVC
PVC decking such as AZEK can be made in extra long boards thanks to its highly uniform manufacturing process. Expect to pay a premium for huge PVC boards up to 40 feet long, but they deliver unrivaled durability and consistency.
Aluminum
Aluminum decking is capped at around 20 foot board lengths. The metal contraction and expansion properties of aluminum make it very difficult to work with in longer spans.
In summary, wood, composites, and PVC offer the most options for oversized deck boards over 20 feet. Aluminum has more limited size capabilities. Always check with the manufacturer first about maximum board lengths when planning an exotic large plank deck.
Cost Considerations
There are some notable cost tradeoffs to using long deck boards:
- Oversized boards can cost two to three times more than standard lengths
- Special delivery fees may apply for lengths over 20 feet
- Professional installation is highly recommended, adding labor costs
- Longer boards mean fewer total boards are needed for the deck
- Far fewer seams and faster installation balance some cost increases
In most cases, the appearance and enjoyment enhancement from longer deck boards outweighs the added upfront investment. The boosted resale value and curb appeal for your home is also a significant benefit.
Appearance Benefits
Here are some of the appearance benefits that come with specifying the longest deck boards possible:
- Minimized seams for more seamless look
- Enhanced hardwood floor visual
- Larger uninterrupted plank appearance
- More distinctive high-end aesthetic
- Consistent grain patterns with fewer seams
- Allows for dramatic herringbone or chevron deck designs (using appropriate substructure)
- Showcases the natural beauty of wood or luxury composite decking
The reduced seams and continuous plank visual made possible by long boards can completely transform the look of a deck. Many homeowners feel the dramatic appearance is worth the higher costs.
Durability Considerations
Using the longest deck boards that your project can accommodate also provides some potential durability benefits:
- Fewer seams means fewer opportunities for splits and cracks over time
- Minimizing seams leads to less chance of moisture seeping in between boards
- Proper gapping retained better with fewer seams
- Careful installation and limited seams reduces future maintenance
- Easier to refinish decking with long continuous boards
Of course proper installation and maintenance practices are still critical for deck longevity. But enhancing the seamless visual with long boards also improves deck function and lifespan.
Conclusion
When designing and building a new deck or replacing decking boards, using the longest boards possible provides appearance, function, and durability benefits. While specialized labor and equipment may be required for lengths over 20 feet, the outcome is well worth the investment for most homeowners. Be sure to check with manufacturers about specific maximum board lengths when planning your project. With smart planning and strategic layout, you can take advantage of the longest deck boards available to achieve a truly seamless, spectacular deck surface.