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Baltimore remodeler Michael Humphey agrees. "There's no question that the stainless does a better job," says the owner of Great Bear Structures, who says he has never built a deck that collapsed. "I build relationships with my clients so they trust me. I recommend stainless, and they say OK."

Hardware became an acute issue for deck builders in 2004, when manufacturers replaced CCA (chromated copper arsenate), an arsenic–containing chemical wood preservative that wards off bugs, mold, and rot, with alkaline copper quat (ACQ) or copper azole for pressure–treated wood used in residential projects. They quickly learned that the new preservatives, because of their very high copper content, are about five times more corrosive to steel nails and other metal fasteners than CCA, according to the American Wood Preservers Association.

Now, most builders use hot–dip galvanized steel fasteners, which add a layer of zinc to screws and bolts to prevent the steel from touching the copper in deck lumber treated with copper–containing preservatives. Or they can use stainless steel, which can be up to three times as expensive.

Some manufacturers have added a polymer layer on top of the zinc for even more protection. USP Structural Connectors found in a test that fasteners with its polymer "barrier" coating over a zinc layer lost 3.2 percent of its material weight when exposed to ACQ–treated lumber, compared with 9.1 percent for fasteners with a galvanized coating alone. Stainless steel fasteners lost .02 percent.

The test was conducted in a corrosion chamber for 120 days. Still, Todd Grevious, engineering manager for USP's central region, says the manufacturer can't correlate that to an amount of time on an outdoor deck that is exposed to the weather.

Lesh quotes an old truism that he says applies to deck building: "Pick two: cheap, fast, good. You can have two of those things, but it's not going to be all three. It can be cheap and fast, but not good. Unfortunately in the States, we go for cheap and fast."

The solution, he offers home builders and remodelers: "Be right up front with people. Tell them that your deck is going to cost X number of dollars more because it's going to be quality. Eight of 10 people will go for the cheaper bid, but two will go for the quality work, and your reputation will grow."

In the end, Lesh says, code–defying deck builders and do–it–yourselfers are keeping him—and his fellow home inspectors—in business. "I make a living finding all of their problems," he says. Katwijk says he does, too: "The home builder might hire a framing crew [to build a deck] because they don't want to pay my price, but it's guaranteed work for me in about five years."

Code Changes

The International Code Council will base its 2008 guidelines for residential decks, in part, on these calculations from Virginia Tech and Washington State University. Calculated on-center spacing of fasteners (inches) for pressure preservative-treated hem-fir or Southern pine deck ledgers attached to spruce pine fir or a 1-inch-thick laminated veneer lumber band joist for residential deck joist spans with 40 per-square-foot live and 10 per-square-foot dead loads.

Joist Span (FT)	6	8	10	12	14	16	18
Connection Details	On-Center Spacing of Fasteners
1/2-inch lag screws with 15/32-inch sheathing	30	23	18	15	13	11	10
1/2-inch bolts with 15/32-inch sheathing	36*	36*	34	29	24	21	19
1/2-inch bolts with 15/32-inch sheathing and 1/2-inch stacked washers	36*	36*	29	24	21	18	16

*These spacings were limited by a consideration of the bending strength of a 2x8 (minimum) ledger
between the bolts or lag screws. Source: Virginia Tech

How To Sell Up

Convincing a homeowner to pay a few hundred extra dollars for top-of-the-line deck hardware can be a tough sell, but it could mean the difference between a safe deck and one that collapses without warning. Deck builders offer these tips for selling safety:

• If the deck is to be part of a new home, show the buyer how little (if any) difference the sturdier hardware will cost when it's amortized over 30 years as part of the home mortgage.
• Show the homeowner that the industry, academic researchers, and government experts agree that using quality fasteners prolongs the life of the deck.
• Educate the homeowner about the common causes of deck failures: nail connections rather than sturdier bolts or lag screws; improper or nonexistent flashing; and corrosion of hardware.
• Insist on getting a building permit specifically for the deck so a building inspector will double-check the connections. Encourage homeowners who want to build their own decks to get building permits and to follow the guidelines of the building code.
• Encourage deck owners to waterproof and otherwise maintain their decks, and to have them inspected every few years.

-- BUILDING PRODUCTS

A SAMPLING OF DECK FASTENERS AND CONNECTORS

USP Structural Connectors.Gold Coat is an organic polymer coating for the company's connection products, designed to resist corrosion with treated wood, the maker says. The Gold Coat line has 25 connection products, primarily for deck construction. Wood corrosion is 65 percent less than with other steel-coated products, the manufacturer claims. 800-328-5934. www.uspconnectors.com.

DeckLok. Available in an ACQ-compatible hot-dip galvanized coating and in 304 or 316 stainless steel, this bracket system adds a bolted attachment to critical structural locations, the manufacturer says. It meets IRC 2006 safety code requirements for lateral pullout and rail post stability. 866-617-3325. www.deck-lok.com.

Grabber. The Deckmaster fastening system employs hidden deck brackets that attach to the joists, allowing deck boards to be screwed down from underneath. Available with an ACQ-approved powder coating or in stainless steel, the maker asserts the system prevents rotting and loosening of the screws because there are no surface punctures. Powder-coated brackets have a 50-year warranty; stainless steel brackets have a lifetime warranty. 800-869-1375. www.grabberman.com/deckmaster.

Swan Secure.Dexxter screws, available in 305 and 316 stainless steel, are designed to prevent corrosion with treated wood and don't mushroom in composite decking, claims the manufacturer. The six-lobe drive prevents stripping, the firm says, and the small head diameter is less visible. The line is available with painted heads to blend into decking. The company offers a variety of stainless steels connectors. 800-966-2801. www.swansecure.com.

Simpson Strong-Tie. This connector secures the deck post to the floor beams, and is designed to help resist gravity, lateral, and uplift loads, the manufacturer says. This product is coated with a ZMAX finish for corrosion resistance, the company adds. 800-999-5099. www.strongtie.com.

Lumber Loc. The Exotic fastener allows for expansion and contraction on the length and width that naturally occurs on exotic hardwoods and composites, the maker says. This fastener eliminates drilling, keeps a spacing of 1/4-inch between boards, and is resistant to oils, salts, and insects, the company adds. 913-908-9445. www.lumberloc.com.