Why Choose Ipe Plugs for Face-Fastened Decking?
Ipe plugs are small, cylindrical pieces of Ipe wood designed to fit precisely into counter-sunk holes above face fasteners. Their primary purpose is to hide screw heads, resulting in a cleaner, more sophisticated deck surface.
Beyond aesthetics, using Ipe plugs can contribute to the overall finished appearance by reducing visible metal components. This method is particularly popular for high-end decks, outdoor living spaces, and any project where a pristine wood surface is a priority. It allows the natural grain and color of the Ipe to be the focal point, rather than the fastening hardware.
Ipe wood is known for its durability and natural resistance to rot, insects, and mold, making it a benchmark hardwood for outdoor applications. A face-fastened installation with plugs leverages these properties while enhancing the visual appeal of the finished deck. (S1)
Understanding Ipe Color Variation and Plug Matching
Ipe lumber naturally exhibits a range of colors, from reddish-brown to olive-brown. This variation is part of its appeal, offering a unique character to each board. When using Ipe plugs, it's important to acknowledge that perfect color matching between a plug and the specific board it's placed in may not always be achievable.
Plugs are typically cut from various sections of Ipe, and just like full-length boards, they will display natural color differences. While manufacturers strive for consistency, slight variations in hue and grain are inherent to natural wood products. These differences can become more noticeable over time as the deck weathers or as finishes are applied.
For a more uniform appearance, some homeowners choose to select plugs that are generally darker than the average deck board color, as this can help them blend in more discreetly. Alternatively, embracing the subtle variations can add to the natural charm of the Ipe deck. It's recommended to order a sufficient quantity of plugs and sort them on-site to find the best matches for each location.
Installation Process: Counter-Sinking and Plugging
The installation of Ipe plugs requires careful execution. First, the Ipe deck boards are face-fastened using screws. Due to Ipe's density, pilot holes are essential to prevent splitting. (S1)
After the pilot holes are drilled, a specialized counter-sink bit is used to create a wider, shallow hole at the surface of the board, deep enough to fully recess the screw head and allow for the plug. The screws are then driven in, ensuring they are flush or slightly below the bottom of the counter-sunk hole.
Once the screws are in place, the Ipe plugs are inserted into the counter-sunk holes. A waterproof exterior-grade adhesive is typically applied to the plug before insertion. The plugs should be tapped gently into place, ensuring a snug fit. After the adhesive cures, the excess plug material, which will protrude slightly, is carefully trimmed flush with the deck surface and sanded smooth. This final step is crucial for achieving a seamless finish.
Worked Example: Estimating Ipe Plugs for a Deck Project
Let's consider a hypothetical deck project measuring 12 feet by 16 feet, using 1x6 Ipe decking boards. We'll assume the deck boards run the 16-foot length.
First, calculate the number of deck board rows. A 1x6 board has an actual width of approximately 5.5 inches. For a 12-foot (144-inch) width, you'll need 144 inches / 5.5 inches/board = approximately 26.18 boards.
Next, determine the number of joists.
Each board will have 13 fastening points. Therefore, you would need at least 702 Ipe plugs.
It is always advisable to order an additional 10-15% of plugs to account for potential damage during installation, miscuts, or to provide extra plugs for future repairs and for sorting for best color match. For this example, ordering around 800-850 plugs would be a prudent quantity.
Finishing and Maintenance with Ipe Plugs
Once the Ipe plugs are installed and sanded flush, the deck surface is ready for finishing. Ipe can be left untreated to weather to a silvery-gray patina, or it can be sealed with a UV-blocking oil to maintain its original reddish-brown to olive-brown hues. (S1)
If a finish is applied, it will cover both the deck boards and the plugs, helping to further integrate the plugs into the overall appearance. Regular cleaning and reapplication of finish (if desired) are part of Ipe deck maintenance. Ensure any cleaning or finishing products are compatible with both the Ipe wood and the adhesive used for the plugs.
Over time, Ipe's natural oils protect it from cracking or warping, contributing to its low maintenance profile. However, periodic inspection of the plugs can help identify any that may come loose due to extreme weather or movement, allowing for timely re-gluing or replacement. (S1)
Before you order
- Confirm face-fastening is the desired method for your Ipe deck.
- Verify the specific Ipe board dimensions to calculate fastening points.
- Determine joist spacing to calculate the number of screws per board.
- Calculate the total number of plugs needed, adding 10-15% for waste and sorting.
- Consider the natural color variation of Ipe when ordering plugs.
- Plan for the necessary tools: drill, pilot bit, counter-sink bit, and trimming tools.
- Select a high-quality, exterior-grade waterproof adhesive for plug installation.
- Decide on the desired finish (natural weathering or oiled) and its compatibility with plugs and adhesive.
- Factor in the time required for precise plug installation, trimming, and sanding.
Confirm installation details, approved uses and warranty terms in the current instructions for the exact product and profile. Your installer should verify the substrate, structure and applicable project requirements.
Questions to help you decide
Can Ipe plugs be used with any type of screw?
Ipe plugs are designed for use with face-fastened screws that can be counter-sunk. The specific counter-sink bit used must match the diameter of the plug to ensure a tight, secure fit. Always use stainless steel screws appropriate for exterior hardwood applications to prevent corrosion and staining.
How do I ensure the Ipe plugs are flush with the deck surface?
After inserting the plugs with adhesive, allow the adhesive to cure fully. Then, use a sharp chisel, flush-cut saw, or a specialized plug cutter tool to carefully trim the protruding portion of the plug flush with the deck board. Finish by sanding the area smooth to blend it seamlessly with the surrounding wood.
Will Ipe plugs change color like the rest of the deck?
Yes, as Ipe is a natural wood, the plugs will react to UV exposure and weathering in the same way as the deck boards. If the deck is left untreated, both the boards and plugs will eventually weather to a silvery-gray patina. If a UV-blocking finish is applied, it will help maintain the original color of both the plugs and the boards.
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Ready to enhance your outdoor space with durable and beautiful Ipe decking? Contact us for a material quote. Provide your project dimensions, desired Ipe profile, and ZIP code to confirm current availability and service options for Ipe decking and matching plugs. Start your project with Lumber Plus today.
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