Zero Maintenance Azek Composite Deck

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

Tags: azek, azek composite deck, composite decking, deckmaster hidden bracket, decks, hidden brackets, railing design

Windsor, California Deck and Patio Cover (Sonoma County)

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

Tags: backyard deck, hidden brackets, patio cover, sonoma deck builder, windsor california deck builder

Redwood Association Deck Contest Winner

Weston Leavens and his company, Deckmaster Fine Decks, added to their list of honors and awards in October, 2008 by winning the “Build a Deck, Win a Deck” contest sponsored by the California Redwood Association and Mead Clark Lumber.

The winning entry was an impeccably crafted Clear Heart Redwood deck in Graton, (near Sebastopol) California. “We selected the best vertical grain and quarter sawn clear redwood we could find for the decking and attached it from below using Deckmaster Hidden Brackets. That way the floor surface is unmarred by unsightly nails or screws” said Leavens who invented and patented the Deckmaster system. “We also, notched the posts to receive the 2×4 rails which gives the deck a furniture grade appearance.” he continued.

Redwood built Green

A longtime environmentalist, Leavens employed a number of Green building techniques and products in this project starting with the demolition of the old deck. Instead of chopping up the old deck and throwing it into a landfill, each board was carefully removed and de-nailed. An ad on Craigslist located a company that re-uses redwood for deck and fence repairs. “One of the beauties of redwood is that even after the deck has worn out, many of the deck boards are still sound and can find new life in other applications” said Leavens.

Built to last for generations

The best way to build a “green” deck is to make it last longer. Decks in Northern California usually fail and need replacing when they are between 20 and 30 years old. However, Leavens is confident that decks built today using top quality materials and construction techniques may easily last 100 years or more.

There are many reasons that decks fail but the most common problems are

1) water penetration into the joists through surface nail holes and

2) rot along the ledger attachment to the house. The Deckmaster Hidden Bracket avoids the first problem by attaching the deck boards from below. The second problem is solved by using “Deck to Wall” spacers. These plastic spacers (invented by a Petaluma deck builder) hold the ledger ½” away from the house wall and prevent rot due to water accumulation.

The winning deck also employed Ground Contact Rated Pressure Treated Douglas fir understructure. All hardware was heavily galvanized, powder coated or otherwise ACQ compliant to hold up to the chemicals in the wood and the worst elements that Mother Nature can throw at it. The finish was SuperDeck Natural deck stain which protects against UV radiation and gives the wood a tougher surface to help withstand driving rain.

All Screw Construction

There were no nails used in the construction of this deck. When wood dries and shrinks, nails loosen and lose their ability to hold. Good quality screws offer much more permanent holding power. “The image of a deck builder swinging a hammer does not apply to us. Our hammers mostly gather dust while our screw guns work all day long” Leavens explained.

Finishing Touches

In order to hide the treated understructure and avoid seeing the end grain of decking, this deck has 2×12 vertical fascia mitered at the corners. “The quick and easy way to finish a deck is to overhang the deck boards and leave the ends exposed. Adding mitered fascia takes time and skill but the results are worth it” added Leavens.

No stranger to the winner’s circle

While pleased to receive local recognition, Weston Leavens has a long history of besting the competition. In his 25 years as a deck specialist, Leavens was a winner in the National Redwood Deck Contest (also sponsored by the California Redwood Association) and won numerous awards at the Del Mar Fair in San Diego County. His invention, the Deckmaster Hidden Bracket spawned the whole hidden fastener revolution in deck building. Deckmaster Fine Decks is located in Sebastopol, California and builds projects throughout the North Bay and Wine Country.

Tags: california redwood association, deck builder, heart redwood, hidden brackets, redwood deck, sebastopol california

National Award Winning 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