3 year old Westcoat deck coating CRACKS

[adrenalinejeeper]

I'm looking for some advice before I seek out bids to get this re-coated, I'm hoping some of the pros or vendors on here can chime in...

We have a plywood based deck surrounding the second floor of our new build. A local installer did what I believe is a Westcoat ALX system on it, I have a photo of the bag for the concrete base coat but no record I can find of what top coat it is.


October 2019 - I recall they added some kind of felty tape to the plywood seams, flashed everything, laid down a metal lath, then a base/scratch coat. They paused at this point until siding and paint were done.


January 2020 - They added the texture coat and "epoxy" color top coat. I don't know what it was exactly, but it is epoxy like.



Everything was fine until recently, we noticed some cracks.




Westcoat says the system requires a maintenance top coat every 2-4 years, which seems like an expensive system to me. I'm at 3, apparently I waited too long? Is there a better way to top coat this so it doesn't require so much maintenance? Or should I have the original installer, or a different installer, add a maintenance top coat now?

 

[Qwertyyqwertyyy177]

Have westcoat been shown these pics and they just suggested recoat?

 

[American Locomotive]

It seems like a very unusual system to use on a residential build. I'm pretty sure those cracks go all the way through - not just through the top coat.

If you look, you can see a whole bunch of cracks forming all in a line, which seems to indicate to me the structure is settling, causing the cement base coats to crack. It's something that seems nearly inevitable to me placing a thin cement layer over flexible plywood.

Maybe Westcoat will have some suggestions, but my gut feeling is its going to continue to crack forever.

 

[adrenalinejeeper]

I haven't bothered to try contacting Westcoat as their 5 year warranty states:
"The Westcoat ALX system requires a maintenance topcoat with WESTCOAT ACRYLIC TOPCOAT (or Westcoat Sealer) specified by a factory representative, every three to five years (depending on ultraviolet exposure and/or traffic) as determined by a Westcoat QCA OR authorized inspector. Inspections are required one year after installation and every two years thereafter by a Westcoat QCA or an authorized inspector. The record of the inspection must be kept in writing and entitlement to the benefits of this warranty require the purchaser to show proof of purchase of the materials and the record of inspection(s)."

This requirement for yearly inspections ($$$) was never made clear to me, so I know I wouldn't be able to make a warranty claim. However, they may have input as to the best way to repair it. Thanks for making me think of that, maybe I will reach out to them.

This is the system, it is designed to go on plywood and it is used often around here on residential projects where a weatherproof decking system is needed. It is most often seen on apartment/office building walkways and balconies.
https://www.westcoat.com/systems/alx/

This house is WAY over-engineered and over-framed. There has been minimal settling on the rest of the house, no drywall cracks or floor creaks of anything of that sort. However, that said, we have had an abnormally cold and wet winter for Southern California so it is not out of the realm of possibilities.

Here is a little peak at what is underneath. Check out my build thread for more.

 

[JRoach]

I'm looking for some advice before I seek out bids to get this re-coated, I'm hoping some of the pros or vendors on here can chime in...

We have a plywood based deck surrounding the second floor of our new build. A local installer did what I believe is a Westcoat ALX system on it, I have a photo of the bag for the concrete base coat but no record I can find of what top coat it is.


October 2019 - I recall they added some kind of felty tape to the plywood seams, flashed everything, laid down a metal lath, then a base/scratch coat. They paused at this point until siding and paint were done.


January 2020 - They added the texture coat and "epoxy" color top coat. I don't know what it was exactly, but it is epoxy like.



Everything was fine until recently, we noticed some cracks.




Westcoat says the system requires a maintenance top coat every 2-4 years, which seems like an expensive system to me. I'm at 3, apparently I waited too long? Is there a better way to top coat this so it doesn't require so much maintenance? Or should I have the original installer, or a different installer, add a maintenance top coat now?

Good evening, i work for Westcoat in NorCal but i would be happy to discuss your project if you have not reached out already

 

[JRoach]

Good evening, i work for Westcoat in NorCal but i would be happy to discuss your project if you have not reached out already

Please contact me directly at 408-479-1917
Joanne