Dock Construction from Start to Finish
Repairing a dock begins with demolition and inspection of the entire dock and piles.
We work from a float constructed from three large laminated beams which have been bolted together. The float allows us to access the sides and bottom of the dock.
With the old dock removed and disposed of, we're ready to start the fun part -- rebuilding the new dock.
We use a crane to remove the old dock's deck and framing section by section, then place them on the debris barge destined for an approved upland disposal site. Now that the piles are exposed, we can verify which ones need repair.
Steel collars are preserved with two-part epoxy and fastened with galvanized steel bolts and hardware, securely fastening the old and new pile sections together.
To begin, we cut the pile below the low lake water level. This is where the wood hasn't been exposed to oxygen and is as good as the day it was installed. Then we attach a new treated douglas fir pile stub that matches the cut pile's diameter. The old and new piles are then bolted together with two steel collars. Finally, we epoxy coat the collars to blend in with the surrounding lake.
Repairing rotten piles requires air tools connected to a large compressor on a nearby barge. The new pile stub is craned into position and lowered into the water. The diver then secures it to the existing pile with two epoxy coated steel collars and six bolts.
We use galvanized steel bolts and fasteners to provide a secure attachment and years of life.
After the rotten piles have been repaired, we shoot the level of the new dock using a laser set on solid ground on the beach. This allows us to cut the piles to an exact height to create a level structure, no matter how long the dock is.
Some docks are constructed with piles that extend above the dock. These are bolted to the new dock pile separately for a perfect finish.
With the piles repaired, we're ready to attach the new pile caps. Due to the harsh lake environment, we use only the finest timber -- douglas fir treated with chemonite (ACZA) -- to provide a secure foundation and a long life.
With the new pile caps attached, we're ready to frame the dock. This consists of setting and attaching new 4" x 8" douglas fir stringers treated with chemonite. We also use 4" stringers, instead of 2", to provide a solid foundation that won't bounce or sway. The stringers are precisely spaced to accommodate the new grated deck surface.
We frame the dock with treated douglas fir stringers to support the grating and provide a stable foundation for mooring boats and enjoying water recreation.
The final grated deck is a plastic molded product which requires a substantial foundation to keep it from sagging under your feet, so we carefully locate and place the stringers to ensure the dock is framed and square.
The platform or ELL at the end of the dock is squared to each side to ensure the edges of the dock are set at a true 90 degree angle.
As the stringers are set, the grating is placed and aligned with the edge of the dock.
The grating is screwed to the stringers with stainless steel screws to provide a secure attachment and long life.
As the grating is completed, we're ready for the finishing touches. We install two rows of 2" x 8" treated douglas fir exterior fascia to cover the stringers and pile caps.
The grating comes with a non-skid surface, is kid and pet friendly, doesn't get hot in the summer and can be cleaned with a garden hose. Fantastic!
The dock is completed to the beach and almost ready for another summer of fun.
The grated deck provides a stable platform for accessing your boat and participating in water activities.
The new pier is not only functional and attractive, but complements the entire waterfront property.
In most cases, we can leave the boat on the boatlift while working through the repair and rebuild process.
The fascia around the dock provides a handsome and durable finish.
We aren't finished until you tell us we've exceeded your expectations. Contact us today to repair or replace your dock.