Stone Decks: 2M+ Sq Ft Installed | F&D Mastery Podcast #69

Bart invented the Stone Deck system (originally the Silca grate) in 2007 after a friend suggested a product to make stone-over-wood decks last; it is now installed across more than 2 million square feet in the market.

The core product is a honeycomb-structured engineered-polymer grate (16 by 18 inches, sized for 16-inch on-center joists) that screws onto the joists as a subfloor, made from roughly 90%+ recycled material, and rated to hold over a ton per square foot while deflecting less than 5/16 of an inch.

Almost any stone can go on top (concrete pavers, porcelain, granite, marble, slate, brick) in 3/4-inch to 3-inch thickness, and because it is a subfloor, a homeowner can swap the stone or change colors later without rebuilding the deck.

Installation is fast (the record for laying a grate is 17 seconds) but the real learning curve is that cutting stone requires a diamond blade and a slower finishing cut than wood; some larger contractors hire hardscapers for the stone while their carpenters build the frame.

Stone decks appeal to homeowners tired of staining, painting, and hot composite boards, add resale value to the home, and price competitively head-to-head with high-end composites like TimberTech, though not with pressure-treated lumber.

Pairing the grate with a metal joist system creates what Bart calls a 'forever deck' since nothing rots, and the system also works on porches, docks, bridges, balconies, countertops, and around fire pits (with an insert), in both new construction and remodel drop-in configurations.

Bart just sold his plastic injection molding business to focus full-time on Stone Decks, holds a patent for a commercial rooftop uplift solution (aimed at Dade County hurricane requirements), and urges contractors to embrace change to differentiate themselves as the first in their local market.