Cornwood deck underlayment rusting

[SiamSam]

Does anyone have a suggestion, looks like the underlayment was not steel. The deck is 10 years old, not in the tain too much.

 

[Stoneyluv]

Does anyone have a suggestion, looks like the underlayment was not steel. The deck is 10 years old, not in the tain too much.View attachment 65041View attachment 65040

i don't think there's much left you can do with that other than replace it. it's so thin you can't even scab it with other metal. maybe find some kind of resin material or plastic to replace it with so it doesn't keep happening.

 

[SiamSam]

Thanks Stoney, yes it is looking pretty far gone under that part. What kind of resin material ( know there's a lot of resin here on Budbuilders) or plastics are you talking about. I can take the picture to the hardware store and ask them what they think, which is always interesting. I thought about blowing a bunch of foam underneath and just screwing the board on top, but that's not a very elegant solution....

 

[Stoneyluv]

Thanks Stoney, yes it is looking pretty far gone under that part. What kind of resin material ( know there's a lot of resin here on Budbuilders) or plastics are you talking about. I can take the picture to the hardware store and ask them what they think, which is always interesting. I thought about blowing a bunch of foam underneath and just screwing the board on top, but that's not a very elegant solution....

man if you could get the foam even that would work well... you could even make disposable forms so you wouldn't have to use so much. in the states we have a product called polywood and it's lumber in common sizes extruded from plastic. people on the water make docks from it and it lasts for like 30 years.

i like your foam idea if you can make forms and shave the top even it could work.

 

[SiamSam]

When you said 'disposable forms' 🛎🛎🛎 the little bell went off in my brain. WHAT about putting sand (got lots) inside of 10 ltr vinegar plastic bottles as underlayment -- and putting in some steel (have) under the new boards? My thought is cut one more board so it is easier to work around the area. You can see it is likely weak all down that stretch. I also am thinking how lucky I am to have friends that I have never seen care enough to offer their ideas and encouragement.

 

[Stoneyluv]

When you said 'disposable forms' 🛎🛎🛎 the little bell went off in my brain. WHAT about putting sand (got lots) inside of 10 ltr vinegar plastic bottles as underlayment -- and putting in some steel (have) under the new boards? My thought is cut one more board so it is easier to work around the area. You can see it is likely weak all down that stretch. I also am thinking how lucky I am to have friends that I have never seen care enough to offer their ideas and encouragement.

working with what ya got, there's no better feeling when it works!!!

sure won't rot away.. and if you already have some support metal to span in between it should last you quite a few years before you need to deal with it again at least.

i couldn't even count the things i've made with trees and rocks... it's what i have the most of so gotta use it somehow!

still looks like hard work though!

 

[SiamSam]

When you said 'disposable forms' 🛎🛎🛎 the little bell went off in my brain. WHAT about putting sand (got lots) inside of 10 ltr vinegar plastic bottles as underlayment -- and putting in some steel (have) under the new boards? My thought is cut one more board so it is easier to work around the area. You can see it is likely weak all down that stretch. I also am thinking how lucky I am to have friends that I have never seen care enough to offer their ideas and encouragement.

 

[Stoneyluv]

i'm sure that plastic will break down over time but i bet it last longer than steel!!! hopefully it keeps its shape. if so you got a quick and ez fix..

 

[SiamSam]

i'm sure that plastic will break down over time but i bet it last longer than steel!!! hopefully it keeps its shape. if so you got a quick and ez fix..

Satisfaction in knowing I can drill down and spray more foam in other potential trouble spots. Included some more bamboo, sand, styrofoam and a turboencabulator with gasket glue. We'll see tomorrow what is what, but for now happy as Larry.

 

[Stoneyluv]

i have a love hate relationship with styrofoam... fun fact about me.. in my adult life i have never thrown away styrofoam in he trash. i had it stashed up at one point almost an entire shed full!!! then i stuffed every single piece of it in the ceiling of my garage to insulate it!!! sounds ridiculous but it was free and not kernel of it went to the landfill!!!

 

[Bandit420]

i have a love hate relationship with styrofoam... fun fact about me.. in my adult life i have never thrown away styrofoam in he trash. i had it stashed up at one point almost an entire shed full!!! then i stuffed every single piece of it in the ceiling of my garage to insulate it!!! sounds ridiculous but it was free and not kernel of it went to the landfill!!!

Luckily the city takes that stuff in the recycling bin so I don't have to stockpile but I do find these videos of cutting styrofoam strangely therapeutic.

 

[SiamSam]

Satisfaction in knowing I can drill down and spray more foam in other potential trouble spots. Included some more bamboo, sand, styrofoam and a turboencabulator with gasket glue. We'll see tomorrow what is what, but for now happy as Larry.

View attachment 20240711_074916.mp4

 

[Stoneyluv]

Luckily the city takes that stuff in the recycling bin so I don't have to stockpile but I do find these videos of cutting styrofoam strangely therapeutic.

i can't speak for your city at all man but mine is trash.. literally.. ever since china stopped buying the recycling from the US my local company stopped separating it. they now just bring one truck around to pick up everything and it all goes to the local landfill. plastic, styrofoam.. all of it!!! our landfill is kinda close i can't smell it or anything but it's in my township and i can get there in less than a ten minute ride down the highway. you can dump anything you want there as long as you pay money and have a yellow vest to wear!

you know i'm not a fan of wasting anything at all so it's a touchy subject for me. i'm not sure if there are any recycling plants other than separators and packers here in the states.. i believe all places actually using those old plastics are in other countries where all the manufacturing is done. can't remember the last time i saw a plastic bottle made in the usa..

i'm sure there are a few in the usa that recycle materials but sadly not around me...

View attachment 65236

man it is raining sidewayz!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

 

[SiamSam]

Might as well reinforce some of the future problem areas and give it 1 good coat of Berger stain

 

[Pipecarver]

View attachment 65146

Depending on how far back the damage goes you can scab a piece on both sides and hold the beam in place. I thinks its called a hardback patch

 

[Pipecarver]

Depending on how far back the damage goes you can scab a piece on both sides and hold the beam in place. I thinks its called a hardback patchView attachment 65732

Stiff back

 

[willie]

Does anyone have a suggestion, looks like the underlayment was not steel. The deck is 10 years old, not in the tain too much.View attachment 65041View attachment 65040

Are you looking for ideas just to fix this one area? If so, I would cut some 2x pressure treated....2x6 would be nice but, 2x4 if there is not enough room. Cut these pieces so they will span 5 deck boards. Then slip them in so they cover the 2 deck boards on either side of the one that's removed.
Use a lever and some pressure and pry up one end...... to the underside of decking. Drive a screw thru the top side of decking into that 2x.....then do the other side. Then screw it off. Do that at every steel member that's there. Then take some concrete mix and make that pt wood be supported. Close it back up.

 

[Rootsruler]

If you plan on staying there for any length of time, if it was me, I would pull up all the floor boards and rebuild the entire supporting frame. Even with the temporary fixes you're going to run into the same problem as the other areas rot away over time.

It could be just that area is bad but my experience with rust and metal is that the dime size spot of rust you see is probably a foot in diameter if you remove the coating. Your rust issue is considerably bigger.

 

[SiamSam]

Well, wife and I talked about it but neither one of us wanted to get that medievil yet. When you ask 'how long' are you going to be there....IDK is my best guess....10 years? Lets see how this patch goes and then circle the wagons. Thanks for your input and vote for the 'right' way. You are of course Mr 'right' --) just not 'right' now.

 

[SiamSam]

Could get an estimate on redoing the whole thing Wednesday from the contractor who previously looked at the roof. He is based 4 hours away and he'll hopefully get it redone. Can not DIY,too risky for sure. 16 sq mtr. Can those cement boards be reused? Sacks of SAKRETE here are $3 for some ballast. Add syrofoam blocks, make it super strong9

 

[Rootsruler]

If you have access to cement deck blocks you may want to consider them as a base to hold up the structure. Easier than having to dig post holes and not as permanent.

10-3/4 in. x 10-3/4 in. x 7-3/4 in. Concrete Deck Block 100002709 - The Home Depot

Produce a classic and marvelous look to various corners in your home with the selection of this Unbranded 73/103/103/ Concrete Deck Block.

www.homedepot.com

 

[SiamSam]

If you have access to cement deck blocks you may want to consider them as a base to hold up the structure. Easier than having to dig post holes and not as permanent.

10-3/4 in. x 10-3/4 in. x 7-3/4 in. Concrete Deck Block 100002709 - The Home Depot

Produce a classic and marvelous look to various corners in your home with the selection of this Unbranded 73/103/103/ Concrete Deck Block.

www.homedepot.com

Cool roots, will look for these -- havent seen them in our hardware stores, but could be at the pre-cast concrete places....

 

[Zen_seeker]

If you have access to cement deck blocks you may want to consider them as a base to hold up the structure. Easier than having to dig post holes and not as permanent.

10-3/4 in. x 10-3/4 in. x 7-3/4 in. Concrete Deck Block 100002709 - The Home Depot

Produce a classic and marvelous look to various corners in your home with the selection of this Unbranded 73/103/103/ Concrete Deck Block.

www.homedepot.com

They work great. For a deck I put down and level a 2x2 patio stone first.

I also use them to support waist high wooden fences. I use them to divide yards. Keep pets/kids in one area. Relocate as needed.

 

[Zen_seeker]

Cool roots, will look for these -- havent seen them in our hardware stores, but could be at the pre-cast concrete places....

All our hardware stores like homedepot or Lowe’s have them. Sometimes in the garden area as well as the fence/deck area.

If you need a lot they are easy to make and cheap. YouTube has videos.

 

[GoodShit97]

All our hardware stores like homedepot or Lowe’s have them. Sometimes in the garden area as well as the fence/deck area.

If you need a lot they are easy to make and cheap. YouTube has videos.

Don't forget he's in Thailand.
What's easy for us to get may not be easy for him to get

 

[SiamSam]

Don't forget he's in Thailand.
What's easy for us to get may not be easy for him to get

 

[SiamSam]

True that, ionized steel was a local's suggestion. Looked but didn't see the particular block. Contractor said he would come today. Mebbee he meant someday or Sunday..I've not had great luck with any of my contractors here, other than the electrician. People are leery of white devils and 98% speak no English. Will keep you posted.

 

[Zen_seeker]

Don't forget he's in Thailand.
What's easy for us to get may not be easy for him to get

I know, that’s why I said “our” and “like”. Was hoping they had something similar.

Making them is easy if you have the time. I’m lazy so just buy them.


They went up a couple of $.

 

[Rootsruler]

Cool roots, will look for these -- havent seen them in our hardware stores, but could be at the pre-cast concrete places....

Anything similar will work. Not sure how high your deck is but I did a single level deck using these for a client and it worked great. The blocks supported the floor joists which made the whole thing real solid. We used a local wood, Guancaste, for the floor joists. The work was in Costa Rica so the climate is probably similar to yours. Look for whatever material they use in your region that will resist the local weather and pests.

The one thing I will mention if you decide to do it yourself is to take your time prepping the footings that go under the blocks. I've had to repair footing work that contractors short cut. For a deck shortcutting the footings will usually result in the deck moving around or sink after a year or two.

 

[SiamSam]

Got much done today on the deck project, you can see what the ground prep. Tomorrow they will rip it all out and make it beautiful. Going with Synotex roof paint, mixed to match the deck sample and the fellow loaded it in the car. Because we're re-using so much of the old wood, there will be patches, no problem