Fiber reinforced plastic (FRP) composite structural system for decks, docks, boardwalks, walkways, spa decks, hot tub decks and gazebos and components therefore and method of making same

This invention to a decking system for use as a residential or commercial deck is manufactured from an extruded fiber reinforced plastic (FRP) material known as pultruded FRP and assembled using a combination of corrosion resistant hardware and/or adhesives. The invention is assembled from FRP pultruded components comprising several systems which included a weight bearing support system, flooring system, safety system, roofing system, and decorative system. The systems described herein can be used to assemble not only decks but also docks, boardwalks, walkways, gazebos, spa and hot tub decks. The FRP material is pultruded from a choice of resin systems with UV inhibitors such as isophtalic polyester flame-retardant, vinyl ester flame-retardant, or the like, such that the decking material is maintenance-free, strong, light in weight, resistant to rotting, corrosion and weathering. However, many other resin systems are available and, therefore, this invention shall not be limited to a specific resin system. The FRP material is pultruded from a choice of fiber reinforcement systems, the most common of which is fiberglass, however many other fiber types are available and, therefore, this invention shall not be limited to a specific type. In this disclosure, it will be understood that the FRP pultrusion decking system of this invention may have many uses such as a decks, docks, walkways, boardwalks, gazebos, hot tub decks, spa decks, etc. and can be extended. However, for the sake of simplicity, the primary applications discussed herein will be in the context of a deck, dock, and boardwalk, and shall not be limited by this disclosure. An entire structure utilizing fiber reinforced plastic (FRP) pultruded structural shapes is provided for use in decks, docks, and boardwalks. This deck system for building decking, docks, boardwalks, walkways, gazebos, hot tub decks and spas can be built either to and extending from the exterior side of residential or commercial structures or as an independent, freestanding structure. The invention is assembled from FRP pultruded components comprising several systems which include a weight bearing support system, flooring system, safety system, roofing system, and decorative system. Components of the invention including but not limited to vertical support posts, horizontal decking, railing, stairs, gates, doors, frames and supporting members will be manufactured from FRP pultrusion structural shapes and composite sections using co