Deck replacement

[twocutekelpies]

Doggo approved

Our back deck needed replacing, especially after part of it gave way under hubby's foot, thankfully he didn't fall through it.

We thought it would just be a matter of replacing the deck but we opened up a can of worms.

Materials

Merbau decking https://www.bunnings.com.au/specrite-90-x-19mm-merbau-pre-oiled-decking-random-lengths-90mm_p0200172

Protectadeck joist protection https://www.bunnings.com.au/protectadeck-45mm-x-50m-flexible-pvc-joist_p0910783

Joist hangers, 50mm climacoat decking screws (no longer sold by Bunnings due to supplier change)

Decking oil https://www.bunnings.com.au/timber-protect-4l-water-based-exterior-decking-oil_p1400470

Deck scrubbing brush https://www.bunnings.com.au/oates-long-handle-deck-scrub-brush_p4460246

Unipro jumbo deck brush https://www.bunnings.com.au/uni-pro-175mm-jumbo-deck-brush_p1662785

Tools

Prybar and hammer to remove

Mitre saw to cut to length

Multifunction tool to notch out posts and decking boards around posts

Drill, Impact driver

Steps

Step 1

We removed as much of the old decking as we could while still leaving a path for us to get up and down the stairs. This revealed every second joist needed replacing as well as most of the bearers. Two posts also needed replacing when we found them to be quite soft around the middle. 
Every second joist needed replacingSome areas flaked away2 posts needed replacing

Step 2

We removed sections at time to fix up or replace, I primed and painted the existing good hardwood joists as well as the new hardwood ones we bought from a local timber yard. I also primed and painted the new posts and bearers ready to go in. I'm afraid I didn't take many photos during the process. In reality this whole thing took over 6mths as we found it all quite daunting at first.
We still needed to keep a pathway so we removed the nails holding the deck to the bad joists and threaded the new ones underneath. We also had a temporary fence between posts to prevent dogs and grandkids from falling through the open deck area.

Removed and replaced sections at a timeReplaced all joists

Step 3

With the hardest part finally done, we were able to move onto laying the deck. We had bought the merbau months previously and had laid it out in the weather for a few weeks to remove most of the tannins etc so it didn't run all over the new paintwork. Some lengths were a little bowed so we used ratchet straps to pull lengths straight against deck spacers. 

Protectadeck stapled onSun and rain protection while workingFinally making some progress

Step 4

I have a new respect for deck layers, my back absolutely ached while laying this down. I had two drills and an impact driver set up, one with a drill bit, one with a countersink bit and the impact driver with a square drive bit in it. Hubby got hit with the flu just after starting and I couldn't just leave it so continued on my own. 

Working our way acrossSite fore-girl never far awayFinally made it across to the other side

Step 5

With the deck now laid, I gave it a good scrub with nappysan, rinsed and then applied 3 coats of Timber Protect Decking oil.
oiled and doggo approved

Step 6

Our deck only used less than a litre for 3 coats, so I took the remainder over to our daughter's deck, cleaned it up and it drank over 6 litres with 3 coats, hadn't been done in a long time. 

Scrub with Unipro deck wash, pressure washed3 coats

[JacobZ]

Hi @twocutekelpies,

Scary stuff. I'm glad your hubby wasn't injured when the decking board gave way. It almost looks like every second joist was replaced in the past leaving the ones that have subsequently rotted to the same fate. I'm glad you picked it up before further problems happened.

The new merbau decking looks great and I'm sure the Protectadeck 45mm x 50m Flexible PVC Joist will keep those joists strong and free from rot for a long time.

I'm glad to see your doggo approves. Great work and thank you for sharing.

Jacob

[Dave-1]

Afternoon @twocutekelpies 

I really am impressed with your deck, it looks like a professional job! Well wirth the effort!

Long live ratchet straps is all I can say They may be a pain to set up but are worth their weight in gold!

It would have been scary seeing the hole (and almost going through it) then uncovering the rest.... Makes me think its time to check my deck

Huge effort but the results speak for themselves!

Dave