Rooftop Decking Installation Using Thermo Bamboo – Ultra-Low Build-Up Solution

This residential roof deck project required a high-performance decking system within a strict height constraint. Wallbarn was approached to deliver a build-up that provided structural integrity and visual quality, all while remaining within a limited height threshold. The final system achieved an ultra-low build-up starting from just 60mm.

The solution centred around Wallbarn’s Mega Balance pedestals, which are fully adjustable and feature a self-levelling headpiece, ensuring a stable base even on falls and uneven surfaces. Onto these, the aluminium Box Rail joists were installed. At just 15mm high, the Box Rail is precision-engineered from premium extruded 6063 T6 aluminium, offering outstanding strength in a slim profile. This configuration enabled the necessary clearance to be maintained beneath the decking while maximising the finished floor level.

For the decking surface, Thermo Bamboo boards were selected for their durability, dimensional stability, and elegant aesthetic. These dense, compressed boards are made from steamed bamboo fibres, a process that removes sugars and moisture to eliminate fungal and bacterial activity. This method also significantly increases the material’s density and hardness, with Thermo Bamboo reaching a mass density of 1,200 kg/m³ — harder than most tropical hardwoods and exceptionally resistant to traffic damage, warping, or splitting over time.

Thermo Bamboo offers long-term performance with a rich brown finish that naturally weathers to a silvery tone. The boards carry a Class Bfl-s1 fire rating and are certified “Very Durable – Class 1” under EN350 / CEN/TS 15083-2. Additional certifications include Class 0 for blue stain fungal resistance (EN152) and Class 4 for external use (EN335). These properties make it suitable for both residential and commercial applications, especially where fire safety and sustainability are key project drivers.

The entire deck was installed with seamless integration around existing rooflights, thanks to the flexibility of the substructure and clean connection methods. The pedestals, aluminium joists and bamboo materials used in this system are not only rot-proof and low maintenance, but also align with sustainability goals — offering a low-carbon, environmentally responsible decking solution with a 25-year performance warranty.

This project demonstrates how Wallbarn’s modular components and premium-grade materials can solve height-restricted installations without compromising on compliance, durability or finish.