Building a Solid Wooden Deck: Step-by-Step Guide for a Sturdy Base
Building a solid wooden deck is essential to ensure the stability and durability of any structure, especially for projects like geodesic domes or elevated rural constructions. In this detailed guide, we explore the step-by-step process, from leveling the posts to installing the phenolic floor, ensuring a strong and reliable result. Additionally, we provide tips on exterior deck installation, wooden floor installation, and how to choose materials like iroko decking, sucupira decking, or junckers decking for specific projects.
Design and Materials for the Deck
The deck design is based on a structure of strategically placed wooden beams to evenly distribute the load. Below are the materials used in this construction:
- 11 phenolic sheets (18mm thick) – for the floor surface.
- 4 beams 3″x6″ (2 to 2.5m long)
- 8 beams 3″x6″ (3m long)
- 26 beams 2×4″ (3m long)
- 14 beams 2×4″ (2.4m long)
If you’re looking for wooden decks near me or deck manufacturers, make sure to choose high-quality materials like gamiz decks and parquets or junckers decking to ensure durability.
Design in Adobe Illustrator: Precision Planning for the Deck
For the structural planning of the deck, Adobe Illustrator was used, a fundamental tool for vector design and digital modeling. This software allowed precise definition of the beam and post distribution, ensuring a stable base for the dome construction. In this digital layout, the main beams (in orange) are clearly identified, strategically placed every 2 meters on the posts with precise cuts for secure fitting.
The 2″x4″ cross beams were installed approximately every 55 cm, reinforcing the structure and providing uniform support for the floor installation. The pink circle marks the area where the dome will be placed, ensuring its structure rests correctly on the deck. The design optimizes load distribution, maximizing stability and strength.
Preparing the Posts for the Deck
Before installing the deck, it is essential to ensure the posts are properly leveled and prepared to receive the beam structure. The following procedure was followed:
1. Leveling the Posts
- A guide string was used to mark the height at which all posts should be cut.
- To ensure precise leveling, in addition to the guide string, a transparent water hose was used. This method allows verifying that all posts are at the same height in a simple and effective way.
- The cuts were made with a chainsaw, ensuring an even and stable surface.
- To learn more about using a transparent hose for leveling, you can check this article, which includes a section with more details on its application.
2. U-Shaped Cut Technique for Beam Support
To improve the stability of the structure, a U-shaped cut was made at the top of each post. This cut allows the main beams to fit and rest securely, reducing the risk of slipping and improving weight distribution.
- The cut was made at an angle to facilitate beam fitting.
- The 3″x6″ beams were secured to this support with 4″ spiral nails.
Assembling the Beam Structure
Once the posts were prepared, the main beam structure was installed. This step is crucial for the deck’s strength.
1. Installing the Main Beams
The correct installation of the main beams is fundamental to ensure the deck’s strength and stability. The following steps were followed:
Placement on Supports
- The 3″x6″ beams were placed on the cuts made in the posts.
Diagonal Splice Technique
- In areas where two beams needed to be joined, a diagonal cut was made using a chainsaw and handsaw. This cut facilitates structural joining, better load distribution, and improved integration between wooden pieces.
- Beam alignment was verified before final fixation.
Beam Fixation
- 4-inch spiral nails were used to secure each beam to the posts and adjacent beams.
- Additional nails were added to reinforce the diagonal splice area.
Leveling and Final Adjustment
- Leveling was verified using a long ruler and bubble level at various points on the structure.
- Minor adjustments were made if necessary, ensuring the base was completely even and without unwanted inclinations.
This assembly system not only reinforces the structure but also optimizes load distribution and improves resistance to natural ground movements or changes in weather conditions.
2. Reinforcement with Secondary Beams
- 📐 Installation of secondary beams: The 2″x4″ beams were spaced approximately every 55 cm, providing structural reinforcement and floor support.
- 🔨 Notching the primary beam: To improve stability and fixation of the secondary beams, a notch was made in the primary beam, allowing each beam to fit correctly in place.
- 🔩 Fixation with nails: 4-inch spiral nails were used to ensure the secondary beams were securely attached to the main structure.
Installation of the Phenolic Floor
With the deck ready, the floor was installed using 18mm phenolic sheets. To plan the distribution of the sheets and ensure they covered the entire area of the 6-meter-diameter geodesic dome, Adobe Illustrator was used again. This tool allowed for visualizing how to efficiently place the 11 phenolic sheets, covering most of the space without wasting material.
In a small section where the dome would not fully cover, a leftover piece of phenolic from another part of the project was used. This allowed for material optimization and minimized waste. Once all the sheets were laid out and marked, the 6-meter-diameter circle defining the dome’s area was traced.
To trace the circle accurately, a sturdy string was tied to a central point, and at the other end, a pencil was marked at 3 meters (half the diameter). Using this method, the perimeter of the circle was marked, which would later be covered by the 15 wooden boards provided by Acidome. The wooden boards were cut using a Bremen handsaw, as there was no electricity available at the time, and precision was required for the cuts.
The rest of the deck was covered with wooden decking, allowing for comfortable walking, enjoying the outdoor space, and facilitating rainwater drainage, preventing pooling and contributing to a more durable surface.
- 🛠️ The sheets were aligned and fixed with self-tapping screws.
- 🏠 Insulation and the final wooden floor were installed after the dome was enclosed, as the structure would be exposed to impacts, moisture, dirt, and constant traffic during the construction process.
Final Tips and Common Mistakes
- 🛠️ Application of asphalt paint: All primary and secondary beams received a first coat of asphalt paint diluted with 50% paint and 50% mineral spirits, followed by a second coat with a more concentrated mix of 80% paint and 20% mineral spirits. This treatment helps protect the wood from moisture and extends its lifespan.
- 🪵 Choosing the right wood: It is recommended to use beams that are as straight and dry as possible. Moisture in the wood can cause deformations over time, affecting the deck’s leveling.
- 🔩 Checking the level of each beam before fixing: It is crucial to ensure each beam is properly aligned and leveled before final nailing or screwing.
- 🎨 Asphalt paint on phenolic: Asphalt paint was not applied to the phenolic, as a layer of insulation and wooden flooring was later added. However, if no top coating is planned, it is recommended to seal it to prevent moisture damage.
- 🏠 Considering exterior insulation: In this case, since the dome is 26m², no insulation was added under the phenolic. For larger domes, it might be advisable to add a layer of styrofoam, fiberglass, or other thermal insulation under the deck to improve thermal efficiency.
- 🛋️ Impact of floor type on the dome: Floor choice is key for thermal comfort. With only phenolic as a base, cold or moisture can transfer more easily. In this project, this was resolved by adding 10mm insulation and a wooden floor on top, improving thermal protection.
Next Steps
In the next article, the construction of the dome’s skeleton will be explored, detailing the materials, techniques, and assembly of the main structure. Don’t miss it!
Need More Information or Personalized Advice?
If you have questions about how to build your wooden deck, need specific material recommendations, or simply want to know more details about this project, don’t hesitate to contact us! We’re here to help you every step of the way. Write to us through our contact form or leave us a message on our social media. Your wooden deck project is just a click away!
