Dealing with the Deck

On the May long weekend as I was checking on various cottage systems during the opening process I noticed a problem with our deck. A fairly significant issue where wood rot on one of the beams is causing it to collapse.

This issue is at the front (lake side) left corner of the deck that wraps around the entire cottage. This is also the point where the cottage and deck are highest off the ground as the ground is sloping downwards to the lake quite rapidly in this area.

I wasn’t around when the deck was being built and my dad and his friends did it all. There were some interesting decisions made in places and this is one of them. The ground right under this corner of the deck is quite uneven and has some large vertical rocks right where you would normally have the post to support the corner. A decision was made to insert two posts away from this corner and cantilever the deck out away from these two posts.

So the plan I came up with is to build a temporary beam, support the beam on several temporary posts and to use the temporary beam and jacks to lift the deck a bit and cut out the damaged beam. A new permanent beam would be inserted into place onto some new posts and improved footings. The temporary beam would be lowered and removed to complete the repair.

Step one was to tackle the far corner where there is currently is no post by pouring a concrete footing over the vertical rock structure using the rock to anchor the concrete.

The area is pressure washed and as much loose material as possible is removed. Then a sono tube is customized to fit over and around the rock.

One thing I didn’t anticipate was that cutting the sono tube like this (above) on both sides weakened the structural integrity of the tube. As the concrete was added the weight caused the bottom of the tube to flair out. Several rocks were used to hold it together preventing a blowout.

The resulting shape is a little interesting but it should do the job.

The new temporary beam is quite an engineering feat that I’m hoping will do the job. The main piece is a 2×10 – 12’ with a 2×6 – 6’ stacked on the front end to account for lack of joists in this area because of the direction of the deck boards across the front. A notch is cut in the 2×12 to allow it to fit into some other deck members.

As I’m working alone getting this 2×10-12’ up in the air about 8’ at the far end is a bit of a challenge. I create some slings from some wire and attach the sling to the deck boards above. This way I can lift one end at a time into the slings and then tighten them up to bring the beam up to the underside of the deck. With the temporary beam hanging in it’s rough position I create several footings and posts with jacks on top in preparation for lifting the deck. Did I mention this is a two story deck?

Temporary posts are installed and braced and some existing bracing is repaired on a few other near by posts. 40+ years is tough on the wood that is exposed to the elements.

The beam being replaced is 16’, my temporary is 12’, what to do? Making good use of various bits and pieces of lumber that have accumulated around the cottage from other building projects I manage to extend the 12’ by an additional 4’. I use two 2×6-6’ and a 2×6-4’ to scab onto the 12’

All of this so far has taken four days. Not exactly full working days as I start between 9 and 10am by fogging for mosquitoes, applying insect repellent and gathering the tools. I work straight through until 2-3 pm when the insect repellant is wearing off and the mosquitoes are becoming annoying and I’m getting tired. 😊 Things are slow as the ground is quite uneven and you’re always hunched over under the deck. With extra beams, posts, bracing etc. it’s getting to be quite the obstacle course and I’ve still managed to bang my head on various things several times.

At this point I’m ready to cut all the nails holding the old beam in place and start to lift the deck to free the old beam.

Part 2.