Zero Maintenance Azek Composite Deck
Filed Under Fine Decks · Tagged: azek, azek composite deck, composite decking, deckmaster hidden bracket, decks, hidden brackets, railing design
We used Azek Brownstone Composite Decking and Fortress tempered glass balusters to create a zero maintenance deck nestled in this hilltop oak grove in Santa Rosa, California. Our retired clients wanted a deck that would never need more work.
Azek decking repels stains and never fades. Of course we used Deckmaster Hidden Brackets. With decking this good, who wants to see screw heads? In the few areas where we couldn’t use Deckmaster we used Cortex screws and plugs that match the Azek perfectly. You have to look really closely to see the plugs.
The railing design was a unique blend of materials using Azek for the rails and cap, painted redwood posts, and Fortress Pure View bronze tinted tempered glass balusters. The color worked perfectly, tying together the Azek Brownstone and the dark stain of the redwood siding on the house.
This huge deck took over three months to build. Not only was the site was quite challenging but there were also a variety of complicated areas that needed fussing. The crew took all the challenges in stride and the results are immaculate. The angled stairway was particularly problematic and Miguel really showed an artists touch in the way he fanned the deck boards on the landing.
The Santa Rosa building inspector gave us a great compliment on this project. He said that if everybody built decks like ours, we wouldn’t need building departments! Coming from a guy who has seen hundreds of decks we really appreciated the compliment.
Miguel Flores – Foreman
Alberto Curcio – Head Carpenter
Eli Jacobs – Carpenter
Paul Klawiter – Carpenter’s Apprentice
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Hidden Fastener Article
Filed Under Hidden Fasteners · Tagged:
This article appeared in the Professional Deck Builder Magazine, and features Weston Leavens’ invention of the Deckmaster Hidden Fastener. Please click on the image below to read the article.
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Mill Valley, California, Furniture Grade Deck
Filed Under Fine Decks · Tagged: building decks, cable rail, deck, deck builder, deckmaster hidden bracket, furniture grade deck, ipe hardwood, mill valley deck
The view of San Francisco Bay is the prime feature of this Mill Valley (Marin County) location and we wanted it to be as unobstructed as possible. We ruled out tempered glass which requires regular cleaning and Cable Rail seemed like the best option. Our client initially wanted a composite deck but after he saw ipe he realized that the stunning appearance of this exotic hardwood could not be passed up.
Built with Ipe Hardwood
Ipe is in my opinion, among the best deck woods in the world. It comes from South America, is highly rot resistant, and is 80% harder than oak. Ipe is also one of the most expensive deck materials both to purchase and install. Building a deck with Ipe is literally like building a large piece of furniture. It takes about twice as long to install a deck with ipe versus redwood or composite decking.
Every Screw Hidden
With wood this beautiful, the last things we wanted to see were screw holes in the floor. Of course we used the Deckmaster Hidden Bracket in most locations. However, due to the design of the understructure, many deck boards sat directly on top of beams which left no access for Deckmaster Brackets. There were also many areas on the rail that needed screws. In all these areas we elected to hide our screws using ipe plugs. This is quite time consuming because we had to pre-drill, countersink, drive the screw and then glue in the plug. The results however were well worth the effort.
Custom Notching Around Posts
Building with ipe requires every cut to be precise. It really tests the skill of the builder to notch around posts and other obstructions. Some of the deck boards on this project took three hours to cut and install. We just had to keep fussing until they came out right.
Stainless Steel Cable Rail Ices the Cake
There are a number of Cable Rail manufacturers. We selected a product by Feeney (http://www.cablerail.com/) because it seemed to be the most complete system and readily available at our local lumber yards. They start with marine grade stainless steel and include all the components required to make installation simple. Simple does not mean easy though, especially when building with ipe. Just drilling through the 4×4 posts gave us fits. Several drill bits ended up looking like ornate pieces of pasta after the ipe twisted them up.
There has been some controversy about how to make cable rails comply with building code regulations. The cable must be 1/8” diameter and spaced no more than 3” apart. When a 50 pound weight is hung from the cable, the space between cables may not exceed 4” at any point.
One thing I really like about ipe is that there are several styles of shaped rail caps available. They look and feel like fine furniture and nobody can resist reaching out and their hands along the cap.
Miguel Flores – Foreman
Alberto Curcio – Head Carpenter
Eli Jacobs – Carpenter
Paul Klawiter – Carpenter’s Apprentice
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The proud owner of this stunning deck was interviewed by the Prime Buyers Report and I was happy to receive the following email:
“Good afternoon Weston,
I just had a lovely chat with Bill Fxxx. He loves you and couldn’t say enough good things about your work. When he answered the phone, I told him you’d given me his name as a reference and I was wondering about his experience with Deckmaster Fine Decks. He said the truth is that your ego is completely wrapped up in the quality of your work. He raved about how he is thrilled with the deck, and he was blown away that you took time to cut out paper templates and even used scrap wood to cut exact pieces to ensure they’d fit before you cutting the ipe. He told me every contractor who comes to his house says “wow” and comments how great the deck is. He also said your work is flawless, and he told me that your background in furniture making makes a difference–nothing in his house looks as great as his deck. 
What a wonderful reference he is for you. You should be very proud your customers are so devoted to you and in love with your work. I’m so glad I had the chance to talk with you and share your information with the public. I hope we help find you many more thrilled customers.
Have a great day,
Lauren
Lauren Bongard Schwarz
Associate Editor
The Prime Buyer’s Report”
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Windsor, California Deck and Patio Cover (Sonoma County)
Filed Under Yard Decks · Tagged: backyard deck, hidden brackets, patio cover, sonoma deck builder, windsor california deck builder
This Sonoma County back yard was HOT!!! It literally cried out for a deck and patio cover. The western exposure meant that summer afternoon sun reflected off the wall of the house like a solar oven. The owner had to keep the shades drawn on the windows inside to keep the sun from overheating the house. The solution was to build this elegant patio cover which is architecturally pleasing and transforms the back yard into a comfortable and inviting living area.
The Design Challenge
One design challenge was that the house has a low eve in one area that we had to go under and a high attachment in another area. How were we to have two levels of roof with a graceful transition and a minimum of posts? We solved it by doubling the rafters and hanging a beam (using long bolts} and then hanging the rafters from the hanging beam. The whole patio cover only required three posts.
Because of the high attachment we decided to use large timbers. The beams are 6×10 and the rafters are 4×8 with nice custom corbels on the ends. We spaced the 2×4 slats close together so they let in light but not the excessive heat from the sun. The white color matched the house trim and gives the structure a light and airy feeling.
Decking Material and Construction With No Nails or Screws on Surface
The deck below was built with Evergrain Cherrywood decking. This is a very rich looking composite that wears like iron. Of course we installed the decking with Deckmaster Hidden Brackets so there are no nails or screws to mar the deck surface. The owner can use her soft hot tub without worrying about stubbing her toes on protruding nail heads. We added 12” fascia around the perimeter to hide the understructure and give the deck a finely finished appearance.
This was a very rewarding project because it completely transformed the backyard environment from being unusable on hot summer days to an inviting outdoor living area.
Miguel Flores – Foreman
Alberto Curcio – Head Carpenter
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Freestanding Arbors and Pergolas
Filed Under Arbors · Tagged: Arbors, backyard deck, landscaping, pergolas, rafters, timber
This beautiful backyard was designed by David Reed, ASLA and it is an impeccable example of inspired landscape design. All the elements from masonry to wood to plants work together in seamless harmony. We were excited to mount our overhead structures on massive masonry columns. The bulk of the columns required the use of heavy timber construction.
Free of Heart Center
The pergolas in the pictures were built with 6×12 beams and 4×8 rafters with custom designed curved corbels decorating the ends. Whenever we build with timbers we specify Appearance Grade, #1, FOHC (Free of Heart Center).
Not many people (even builders) are aware of the meaning of FOHC and why it is so important when building with exterior timbers. The easiest way to find a 6×12 timber is right from the center of a tree.
Unfortunately, if the timber contains the heart of the tree it will develop huge splits and will twist with enough force to pull out or break fasteners. The solution is to find a bigger tree and mill the whole timber from wood that is farther from the heart of the tree. This gives the timber nice even straight grain and much greater stability.
Notched Rafters
The standard easy way to install rafters onto a beam is to simply put them in place and hold them with toe nails or toe screws. We added strength and stability by notching our beams and rafters, then fitting them together. This is a time consuming method that tests the skill of the carpenter. One wrong cut and a very expensive timber can be ruined. However, the resulting look is very satisfying and much stronger over the long haul.
This landscape project was one of the best we have ever been involved with and we were proud to be selected to build the pergolas. As you can see from the night shot, we could not have asked for a more stunning showcase for our craftsmanship.
Tags: Arbors, backyard deck, landscaping, pergolas, rafters, timberRelated posts
Installing Patio Cover Makes Winery Deck Livable and Inviting
Filed Under Patio Covers · Tagged: decks, patio cover, redwood deck
Often a patio cover can make the difference in having a deck that’s basically useless transformed into an inviting living space. That’s what spelled success with this winery deck that was so drenched in sun that it wasn’t usable. At first glance, the solution didn’t appear to lend itself to an easy fix. It took some real design ingenuity to yield the ambience the space needed.
The Story Behind The La Vista Winery Deck
How do you take a complicated situation and make it look simple? That was the design challenge for the deck on my friend’s home winery. He had a small rectangular deck nobody used. Although it was a balcony deck, it was not inviting or easy to access. The sun cooked it on summer afternoons.
Here were the factors that made it tricky to design a good project:
1. The best view was to the northwest which meant that the deck needed to be built at a 45 degree angle from the house.
2. The area under the deck needed to be as open as possible for vehicles to load and for wine barrels to roll in and out. This span required a 6×12 beam.
3. The only possible attachment for the patio cover was under the eaves of the house. Putting the beam under the rafters would block the relaxing view of his pasture and pony and sunset over the western hills, so we put the beam on top and hung the rafters.
4. The owner had one major request. He needed to have a place to display his original sign with the winery name.
In the end this clear heart redwood deck became an inviting place to have a glass of wine while watching the sunset, even in the heat of summer . Mission accomplished!
Weston Leavens – Deckmaster Fine Decks
Tags: decks, patio cover, redwood deckRelated posts
National Award Winning Deck
Filed Under Pool Decks · Tagged: award winning deck design, california redwood association, deckmaster hidden bracket, hidden brackets, redwood deck
This beautiful deck around the pool and spa won the National Redwood Deck Contest sponsored by the California Redwood Association. I had received a call from David Reed, Landscape Architect, asking me to hurry over to see a client who needed his deck replaced. David said the client was considering a large retaining wall and a flagstone patio instead of a wood deck. David viewed this as a big mistake.
When I met the client, he showed me through his house which was furnished with an extraordinary collection of antique Japanese furniture and cabinetry. He then led me out to his expansive deck and said something that made a lasting impression on me. “I love wood and I love decks but this deck is only ten years old and in dire need of replacement. I can’t justify the expense of building another deck if it will have such a short lifespan.”
| Surface Fasteners Destroyed the Original Deck |
We looked at his deck and it was very well built with redwood decking and treated understructure. The redwood planks were in really good shape – except where the nails had been. Many of the nails had popped up and been replaced by screws which were now popping up as well. Most nail holes had a dime sized area of rot. His beautiful deck had been ruined by the fastening system.
| Deckmaster Brackets Solve the Problem |
I showed him a small model of my Deckmaster invention that was quite new at that time. He could see that the problem areas on his deck would be eliminated with my new system. David Reed proceeded to design him a beautiful deck which we then built. The deck was entered in the National Redwood Deck Contest which was sponsored by the California Redwood Association and Home Mechanix Magazine and won the second prize. It was the top professional entry that year.
When the magazine was writing the article about the deck, I got a call from the author asking if we had an 800 number. I said “no” and he suggested that we get one because he planned to feature the Deckmaster Bracket in his article. He had never heard of hidden fastening for decks and thought his readers might be interested. He turned out to be right. When the article came out the phone started ringing and never stopped.
The deck still looks good today and it is nearly twice as old as the deck it replaced! The Deckmaster Hidden Brackets made all the difference.
Tags: award winning deck design, california redwood association, deckmaster hidden bracket, hidden brackets, redwood deck
Weston Leavens and Master Deck Builder are synonymous. He brings decades of inventiveness and award winning perfection in design and construction to the deck building craft. If you're seeking eye appeal and lasting quality, you've come to the right place. Just looking at a few of the illustrations of Weston's work throughout this site cannot help but convince you.