Metal balusters in salt air

3588 Views 32 Replies 12 Participants Last post by Calidecks, May 14, 2014

CarpenterSFO

Discussion Starter · May 11, 2014

Does anyone have any good recommendations for metal rails and balusters in salt air? I am proposing a deck project within a block or so of the ocean, and the owner wants metal railings. I may suggest custom welded, galvanized, and painted, but I'd appreciate any leads to manufactured options. Fortress? Powder coated? Painted? Steel? Aluminum?

1 - 20 of 33 Posts

griz

· #2 · May 11, 2014

CarpenterSFO said:
Does anyone have any good recommendations for metal rails and balusters in salt air? I am proposing a deck project within a block or so of the ocean, and the owner wants metal railings. I may suggest custom welded, galvanized, and painted, but I'd appreciate any leads to manufactured options. Fortress? Powder coated? Painted? Steel? Aluminum?

From experience, do not waste your time or money on ANYTHING but stainless or aluminum.

I live two blocks from the ocean and nothing but stainless & aluminum works.

DO NOT buy in to the galvanized sales speel, nor anything with that powder coat chit....

Copper is another good choice.

Reactions: 5

ohiohomedoctor

· #3 · May 11, 2014

Fortress rusts in Ohio. Not been overly impressed with them.

Reactions: 1

John Hyatt

· #4 · May 11, 2014

I vote Copper.

Plumbing supply house buy 20' lengths. Get the drain stock it's less money and works just fine.

I do this on a regular when building high end decks. I cut the pipe for size on my compound miter and make connectors on the drill press using a hole saw bit . Set the drill press so you don't go through the stock then run it by the table saw. Clean the red markings off with lacquer thinner.

Little trick > TWP 100 series will keep the copper from going green <
I like anything that won't go green I hate the green mafia. :laughing:

It takes a while for the finish to set up on copper so its better to put it on after install. I used 2'' copper in the deck behind my beloved Butler Manor over 15 years ago still no sign of green, no pealing, no lifting after 5 coats or so. I put a coat on the copper balusters every time I refinish the South American decking.

Altogether its close to three times more money than powder coat alum balusters but looks 1000 times better.

JonMon

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Reactions: 1

RobertCDF

· #5 · May 11, 2014

2 inch copper? I bet that looks real nice! Did you install them horizontally?

John Hyatt

· #6 · May 11, 2014

I did.

On that one I drilled holes in ipe 1x4s and installed the detail as a unit to the posts.

J.

EthanB

· #7 · May 11, 2014

I've been looking for a solution and I found two suppliers that have a nice coated aluminum rail. Fortress's new aluminum system looks sharp.

Reactions: 1

parkers5150

· #8 · May 11, 2014

i've used copper on a few projects as well and Jon is correct in that it looks $1,000.00 times better. I usually can sell with"you'll never have to touch it". I on the other hand, don't mind the patina and on some cases encourage it:thumbsup:

Reactions: 1

deckman22

· #9 · May 11, 2014

I haven't tried the copper pipe thing yet but can say for sure galv. or powder coated steel does not hold up well on the Texas cost. I've even seen stainless steel have rust spots on it.

Reactions: 1

CarpenterSFO

Discussion Starter · #10 · May 11, 2014 (Edited)

John Hyatt said:
I vote Copper.
....
I cut the pipe for size on my compound miter and make connectors on the drill press using a hole saw bit . Set the drill press so you don't go through the stock then run it by the table saw. Clean the red markings off with lacquer thinner.

JonMon

Thanks, John. Copper would look nice for them; they have copper gutters and flashings already, and would get the value. They have a rustic/woodsy vibe, and copper would look better than stainless.

Connectors - I may be missing it completely, but you're talking about custom wood dowels as connectors?

- Bob

John Hyatt

· #11 · May 11, 2014

If you look at standard alum balusters on line. They sell Connectors as well for their product.

Picture a cylinder with a hole going through it. Screw the cylinder to the top and bottom rail, slip the pipe into both of them. Bang Bang install the detail as a unit.

I make these connectors on the drill press . Several advantages exist including being able to glue them in, the factory ones are a plastic compound, and of course the price. These I fabricate from clear pt stock, it's pretty easy to select a knot free section from most any pt 2x6 I have them laying around all over my shop.

Or, I could make them for you exacting a small fee.

JonMon

Reactions: 1

Deckhead

· #12 · May 11, 2014

I'll post a picture of the disaster that is galvanized rails at a job im going to this week. Its was failing so they epoxy coated. That's failing too so they just want me to replace it.

parkers5150

· #13 · May 11, 2014 (Edited)

you can also drill holes in your top and bottom rails to receive the tubing... just remember that you need weep hole on the bottom rail:thumbsup: if you take a look at my website, the first pic under decks is this very application at a golf course install

Reactions: 1

CarpenterSFO

Discussion Starter · #14 · May 11, 2014 (Edited)

...

CarpenterSFO

Discussion Starter · #15 · May 11, 2014

Deckhead said:
I'll post a picture of the disaster that is galvanized rails at a job im going to this week. Its was failing so they epoxy coated. That's failing too so they just want me to replace it.

If I went with galvanized, it would be full-on welded railings, double dipped as a full unit. We've installed plenty of those railings with success.

I just e-mailed the proposal, pricing copper.

-- Bob

Reactions: 1

John Hyatt

· #16 · May 11, 2014

CarpenterSFO said:
If you'll make me just a few free samples - let's say 300 - I'll test them out and decide whether to give you an order.

Forget You, Man

If I have to explain Connectors to you I figured you could use some more help.

Fool

J.

CarpenterSFO

Discussion Starter · #17 · May 11, 2014 (Edited)

Mis-post

CarpenterSFO

Discussion Starter · #18 · May 11, 2014 (Edited)

John Hyatt said:
Forget You, Man

If I have to explain Connectors to you I figured you could use some more help.

Fool

J.

John:

My bad, somehow I completely missed or completely mis-read one of your earlier posts, thought I was being funny - apparently not. :sad:

I appreciate any help, whenever and wherever I get it.

- Bob

Reactions: 1

redwood

· #19 · May 11, 2014

I've used copper balusters before and they look nice, but never the frame. There are lot's of companies out there that make aluminum rails. I'm sure there are stainless steel rails as well, but really costly.

Reactions: 1

Deckhead

· #20 · May 11, 2014

CarpenterSFO said:
If I went with galvanized, it would be full-on welded railings, double dipped as a full unit. We've installed plenty of those railings with success.

I just e-mailed the proposal, pricing copper.

-- Bob

I meant no harm and I don't doubt it, I'm just saying almost all the jobs I do are on or near the beach and even stainless will rust in certain applications. Galvanized is a huge hassle and ultimately can't hold up even with maintenance.

You chose one of the best options, my go to for metal is usually powder coated aluminum.

Reactions: 1

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