Author Topic: My deck replacement project  (Read 817 times)

zolotiyeruki

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My deck replacement project
« on: July 19, 2017, 09:15:43 AM »
There's this thing attached to the back of our house.  The original builder tacked it on.  I think they wanted to call it a deck, but it's the sorriest excuse for a deck I've ever seen.  All pressure-treated wood, wasn't maintained, tiny, and useless.  A piece of junk.  So here, I will chronicle our adventures in replacing it.


(I had already cut back some of the bushes to make digging them out easier)


Time for it to go.  DW and I have been talking about getting rid of it for a long time, and my sister's visit (with her two strapping sons) prompted us to go ahead, make the design, and pull the permit.

Step 1: demolition.  I let the teenager do this one.  The 20-something and I worked on rooting out the bushes.  They had a rapt audience :)



All done with the deck.  Still some mature, deep-rooted bushes to go, though.  It looks like the sheathing is in pretty bad shape where the deck was attached to the house, so we will likely strip back more of the siding and replace the rotted sheathing.



Next steps:
--finish removing bushes
--purchase sonotubes
--rent augur
--dig holes and insert sonotubes and backfill and call the city for a hole inspection

zolotiyeruki

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Re: My deck replacement project
« Reply #1 on: July 20, 2017, 09:37:49 AM »
Day 2: 
--Bought the sonotubes.
--Removed all but 1 bush
--Rented augur
--Dug 1.25 holes.  Stupid rocks.  It was quite a workout to wrestle the augur around.  The massive thunderstorm that rolled through this morning was the last straw.

No pictures yet--I'll post when I can.  When I have the chance, I'm going to rent the larger, towable augur.  I wish I had opted for that one first--it's only a few bucks more expensive than the 2-man model.

zolotiyeruki

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Re: My deck replacement project
« Reply #2 on: July 24, 2017, 02:01:13 PM »
Day...I'm not sure what.  Saturday, we rented the towable augur from HD.  It worked great, until a shear pin broke.  Turns out some previous renter broke the original, and replaced it with a smaller pin.  I replaced the broken, smaller pin with a properly-sized bolt.  Finally got the holes dug.

And then Mother Nature promptly dumped about 6 inches of rain on us.

Also completed:
--stripped siding where the new ledger will be
--cut all joists to length
--put up new housewrap and tape where the old ledger was
--temporarily attached new ledger.  It's clear that my level isn't exactly level--across the 16' length of the ledger, it was a good 3/4" off.  Ugh.

Next steps:
--pass hole inspection tomorrow morning
--pour concrete and attach post base plates
--permanently attach new ledger
--mount flashing for the ledger

lisa_mustache

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Re: My deck replacement project
« Reply #3 on: July 24, 2017, 05:46:26 PM »
I'm following along!  We're about to start building a deck in our backyard, so this is of timely interest to me.  I wish you luck!

zolotiyeruki

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Re: My deck replacement project
« Reply #4 on: July 25, 2017, 10:13:53 AM »
Day 5:
--Got ledger properly fastened with 1/2" lag screws.
--Got all the muck and water out of the holes we worked so hard to dig
--Installed flashing over the ledger
--Salvaged the post supports from the old deck.  This will be like $85 saved :)
--Finished breaking apart the old wood from the deck.  Put about half out for garbage collection.
--Pulled a bunch of 2x8 stuff from the old wood that I'm hoping to salvage for blocking in the new deck. It's in good shape.
--Passed inspection on the holes!  Woot!  The inspector walked around back, took a look, said "looks good" and handed me the sticker.


craiglepaige

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Re: My deck replacement project
« Reply #5 on: July 25, 2017, 11:36:06 AM »
Nice work ;)

Those two man augers are useless unless you are using them in soft sand.
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zolotiyeruki

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Re: My deck replacement project
« Reply #6 on: July 26, 2017, 08:45:45 AM »
Day 6: we got the concrete poured!

(sorry, no pictures for now--it was dark when we finished, and I had no time this morning).

I learned something interesting the other day:  a 10" sonotube (cylindrical cardboard concrete form) actually comes in two sizes, one slightly smaller than the other, so that they pack better on the truck and on the shelves.  I did the math, and realized that the smaller tube will take 10% less concrete.  I also did the math to figure out that a 48"x10" tube will take 4.4 60# bags of cement mix to fill.  So I opted for the smaller tubes, in the hopes that I could use four bags per hole.  It came out to be the perfect quantity.

We made the unpleasant discovery that one of our four holes was 6" off from where it should be.  Fortunately, it wasn't too hard to lengthen the hole so that the footing would be in the right place.  I'm really glad we used the 12" augur when digging the holes, because it allowed me to align the forms with their intended locations.

I think I've salvaged enough 2x8's from the old deck that most if not all my blocking can come from them.

Next steps:
--Wait.  :)  I'm out of town for a few days on a business trip, which will give the concrete time to set
--Install post supports, align them perfectly, and snug them down
--Set up a string marking where the top of the posts will be
--Purchase 6x6 posts, mark them for length and cut
--Nail 6x6 posts to their supports
--Attach beam to posts

This is where it starts getting more fun :)

zolotiyeruki

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Re: My deck replacement project
« Reply #7 on: August 08, 2017, 09:51:17 AM »
Finally, an update!  The footings turned out nearly perfect--within 1/4" in all cases.



I got the posts, propped up the beam, and installed the first couple joists.




At that point, I realized that the posts weren't exactly vertical.  After a bit more measuring, I discovered that the outside of the sheathing was a full 1.5" further out from the foundation than I thought.  So I recut all of the joists, and things look much better.

Next steps:
--perfectly align the bottoms of the posts, install a nut to hold them down
--cut and install the remaining two posts
--install the remaining joists

After that:
--install tie-backs (connect deck joists to the interior floor joists through the ledger)
--cut the stringers
--install lots of blocking
--install posts for hand/guard rails

oneday

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Re: My deck replacement project
« Reply #8 on: August 08, 2017, 11:04:04 PM »
Lookin' good!  I know what most of the terms mean, except beam. Is the beam the one going between the two posts, perpendicular to the joists?
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gooki

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Re: My deck replacement project
« Reply #9 on: August 09, 2017, 02:51:06 AM »
Omg how on earth could they have built that pitiful set of steps. That's the perfect spot for a big ass deck. Should give the back of your house some shape as well.
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zolotiyeruki

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Re: My deck replacement project
« Reply #10 on: August 09, 2017, 09:14:27 AM »
Lookin' good!  I know what most of the terms mean, except beam. Is the beam the one going between the two posts, perpendicular to the joists?
Yes, the beam runs parallel to the house, and rests on the posts.  The joists hang from the ledger (attached to the house) and the beam.