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Post by Freeborn on Sept 19, 2022 7:22:31 GMT -6
My family has an old dock that historically we have used cedar decking on. We are wanting to upgrade the cedar to the new plastic type decking most docks are using today. To do this I need a center beam (1x1 or 2x1 square aluminum) added to the Top Rail center of the dock section. The dock is laid out in 48"x48" sections that a decking panel is laid on top of the aluminum frame. There are 16 frames on the dock we would need this square tubing added to just the top rail. I just got a quote from a local Brainerd welder (Brian's Welding) and they want $1,400 to for the welding and material, does this seem reasonable? Seems high to me considering there hourly on-site rate is $100. Material could be high as it would need approx. 62' of 1x1 or 2x1 square tubing. I would do this myself but I don't weld. Could a fastener work? Thanks!   |
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Post by terrifictom on Sept 19, 2022 7:55:09 GMT -6
Been a while since I retired but aluminum tubing isn't cheap. My guess is that the tubing for the project is probably over half the cost.
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Post by Catscratch on Sept 19, 2022 8:20:34 GMT -6
Everything looks flush to me. A center rail would create a hump? Do you not also need the side rails to be raised the same amount?
Not completely understanding what you are doing I'll throw this out there... Use steel, cut it to length and weld flanges to it that can be bolted to the aluminum cross members. Way cheaper materials and steel is probably something you are set up to weld.
Edit - just re-read your post and saw that you don't weld. I bet you have a friend that could weld on some flanges for next to nothing or let you use their welder.
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Post by Freeborn on Sept 19, 2022 8:38:59 GMT -6
Everything looks flush to me. A center rail would create a hump? Do you not also need the side rails to be raised the same amount? Not completely understanding what you are doing I'll throw this out there... Use steel, cut it to length and weld flanges to it that can be bolted to the aluminum cross members. Way cheaper materials and steel is probably something you are set up to weld. Edit - just re-read your post and saw that you don't weld. I bet you have a friend that could weld on some flanges for next to nothing or let you use their welder. Thanks Cat, Steel would be allot cheaper, I'll keep that in mind. The square tubing would butt-up against the existing frame and span between what you see is a 1x1 on one end and a 2x1 on the other. The added center tube would be flush with the side rail. Thanks! |
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Post by biglakebass on Sept 19, 2022 8:46:51 GMT -6
Steel would add significant weight potentially, depending how beefy it would need to be to stay rigid.
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Post by Foggy on Sept 19, 2022 8:52:47 GMT -6
If the dock is currently aluminum (I think it is?) then stay with aluminum all the way. Joining dissimilar metals could create an potential electrolysis problem for you with the catalyst (water) always present to corrode the frame over time. There is a dock guy at the north end of your lake on county road ?? that makes docks docks and does repairs. (Beach craft?....or some such name) They may be able to help you with the welding if that is the way you want to roll.
Not sure who your buying the plastic decking from.....but some of those guys may be able to do the job too. There is the dock company in Nisswa (D&H Dock) that welds aluminum and sells allot of docks and decking.....I'd ask them for a price. Then there is another dock company in Cross Lake (Waterfront services) whom could do the work too and sells decking etc. These two places have similar docks. (Brians is always kinda high priced IMO......but does good work). Both of those places said here sell plastic deck panels (Brock Dock panels)
You may be able to have aluminum tubes cut to 4 foot length and have an L shape welded to each end. Then screw, bolt, or rivet these to those cross members. that would be fairly easy solution.....and you would not have to transport the whole dock to have it welded. Tho.....I bet those suggestions above have portable welding equipment to do the job. I think the "bolt-on" suggestion is not going to be as strong over the long run. I would stay with a welded tube to unitize the dock and to allow the panels to fit correctly (flush) on the top.
If your buying dock panels from one of those guys.....I'd be they have done this before. Let them do a "package price" to convert you dock and provide the panels.......IMO>
Edit : looking at your pics again.....you may want them to cut out that !" crossmember and make it a 1x2" or have them weld another 1" section to it to beef that up. The plastic dock boards do not have enough rigidity to do the work of your old cedar deck. Let those dock companies tell you how to convert it. 2 cents.
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Post by Freeborn on Sept 19, 2022 9:00:39 GMT -6
If the dock is currently aluminum (I think it is?) then stay with aluminum all the way. Joining dissimilar metals could create an potential electrolysis problem for you with the catalyst (water) always present to corrode the frame over time. There is a dock guy at the north end of your lake on county road ?? that makes docks docks and does repairs. (Beach craft?....or some such name) They may be able to help you with the welding if that is the way you want to roll. Not sure who your buying the plastic decking from.....but some of those guys may be able to do the job too. There is the dock company in Nisswa (D&H Dock) that welds aluminum and sells allot of docks and decking.....I'd ask them for a price. Then there is another dock company in Cross Lake (Waterfront services) whom could do the work too and sells decking etc. These two places have similar docks. (Brians is always kinda high priced IMO......but does good work). Both of those places said here sell plastic deck panels (Brock Dock panels) You may be able to have aluminum tubes cut to 4 foot length and have an L shape welded to each end. Then screw, bolt, or rivet these to those cross members. that would be fairly easy solution.....and you would not have to transport the whole dock to have it welded. Tho.....I bet those suggestions above have portable welding equipment to do the job. I think the "bolt-on" suggestion is not going to be as strong over the long run. I would stay with a welded tube to unitize the dock and to allow the panels to fit correctly (flush) on the top. If your buying dock panels from one of those guys.....I'd be they have done this before. Let them do a "package price" to convert you dock and provide the panels.......IMO> Edit : looking at your pics again.....you may want them to cut out that !" crossmember and make it a 1x2" or have them weld another 1" section to it to beef that up. The plastic dock boards do not have enough rigidity to do the work of your old cedar deck. Let those dock companies tell you how to convert it. 2 cents. Thats probably the route to go, find a turnkey solution instead of chasing two different providers. Thanks! |
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Post by caveman on Sept 19, 2022 9:12:01 GMT -6
My family has an old dock that historically we have used cedar decking on. We are wanting to upgrade the cedar to the new plastic type decking most docks are using today. To do this I need a center beam (1x1 or 2x1 square aluminum) added to the Top Rail center of the dock section. The dock is laid out in 48"x48" sections that a decking panel is laid on top of the aluminum frame. There are 16 frames on the dock we would need this square tubing added to just the top rail. I just got a quote from a local Brainerd welder (Brian's Welding) and they want $1,400 to for the welding and material, does this seem reasonable? Seems high to me considering there hourly on-site rate is $100. Material could be high as it would need approx. 62' of 1x1 or 2x1 square tubing. I would do this myself but I don't weld. Could a fastener work? Thanks!
Local to me they get built as 4'x8' decks that lay on top of the framing. I believe they use 1" tall aluminum tubing for the framing under the poly decking (might be taller). : www.dockandlift.com/gallery?lightbox=dataItem-jbcj2wly7 For reference locally here a ThruFlu deck retails for double of a cedar deck.
My professional opinion is to stick with cedar. Ten years from now you can have decks that show ten years of wear or brand new decks.
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Post by Catscratch on Sept 19, 2022 9:21:50 GMT -6
If the dock is currently aluminum (I think it is?) then stay with aluminum all the way. Joining dissimilar metals could create an potential electrolysis problem for you with the catalyst (water) always present to corrode the frame over time. There is a dock guy at the north end of your lake on county road ?? that makes docks docks and does repairs. (Beach craft?....or some such name) They may be able to help you with the welding if that is the way you want to roll. Not sure who your buying the plastic decking from.....but some of those guys may be able to do the job too. There is the dock company in Nisswa (D&H Dock) that welds aluminum and sells allot of docks and decking.....I'd ask them for a price. Then there is another dock company in Cross Lake (Waterfront services) whom could do the work too and sells decking etc. These two places have similar docks. (Brians is always kinda high priced IMO......but does good work). Both of those places said here sell plastic deck panels (Brock Dock panels) You may be able to have aluminum tubes cut to 4 foot length and have an L shape welded to each end. Then screw, bolt, or rivet these to those cross members. that would be fairly easy solution.....and you would not have to transport the whole dock to have it welded. Tho.....I bet those suggestions above have portable welding equipment to do the job. I think the "bolt-on" suggestion is not going to be as strong over the long run. I would stay with a welded tube to unitize the dock and to allow the panels to fit correctly (flush) on the top. If your buying dock panels from one of those guys.....I'd be they have done this before. Let them do a "package price" to convert you dock and provide the panels.......IMO> Edit : looking at your pics again.....you may want them to cut out that !" crossmember and make it a 1x2" or have them weld another 1" section to it to beef that up. The plastic dock boards do not have enough rigidity to do the work of your old cedar deck. Let those dock companies tell you how to convert it. 2 cents. Thats probably the route to go, find a turnkey solution instead of chasing two different providers. Thanks! Foggy nailed the best way to do it. I was suggesting "cheaper". An sacrificial anode would prevent the corrosion but if you stick with welded aluminum you won't have to worry about it. |
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Post by Foggy on Sept 19, 2022 9:44:24 GMT -6
You got another issue that needs to be resolved.....and that is the poss on the "outside" of the frame instead of the inside. Not sure how they will tackle that....but there are solutions. It appear to me that your frame is a Port A Dock frame. They put the posts inside and had some plastic covers to trim the decking. A bit harder to do with your plastic deck panels....but it can be done.
FWIW.....I designed the aluminum decking for one of the aluminum Porta Dock products. I dont think this is it....but they fit the decking simiarly. You may have a Shoremaster or possibly a Hewitt....but I lean more to Porta Dock or Shoremaster. I may check with one of their dealers to see if they have done some conversions like this?
I have no experience with the flow-thru product Caveman said above. I think some like that product....just never had one.
I got a D&H dock.....and I have had some panels blow out in a big storm. If those Flow-thru panels would prevent that.....they would get my attention. Around here the Brock product seems to sell the best.
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Post by Tooln on Sept 20, 2022 7:45:17 GMT -6
Foggy hit the nail on the head. Aluminum tubing isn't cheap and it takes a skilled welder to weld aluminum. Good luck finding your best option.
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Post by MoBuckChaser on Sept 20, 2022 13:48:13 GMT -6
My family has an old dock that historically we have used cedar decking on. We are wanting to upgrade the cedar to the new plastic type decking most docks are using today. To do this I need a center beam (1x1 or 2x1 square aluminum) added to the Top Rail center of the dock section. The dock is laid out in 48"x48" sections that a decking panel is laid on top of the aluminum frame. There are 16 frames on the dock we would need this square tubing added to just the top rail. I just got a quote from a local Brainerd welder (Brian's Welding) and they want $1,400 to for the welding and material, does this seem reasonable? Seems high to me considering there hourly on-site rate is $100. Material could be high as it would need approx. 62' of 1x1 or 2x1 square tubing. I would do this myself but I don't weld. Could a fastener work? Thanks! Materials whether it be aluminum or steel are out of sight cost wise. $1400 may be a steal. |
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