What to use between columns for Castellated Panel install?

Question

Hi, I have a section of a 1.8m high rendered brick wall with columns spaced 2.7m that I want to mount the Ekodeck Castellated Panel onto. Total length is about 9m. I've already done a previous section as seen in the photo (at an increased height) but that was between two columns that was only circa 1m wide. I will need to put some timber supports between the paneling and the brick wall to support the horizontal timber - but the columns vary in depth between 100mm and 110mm. What is the best way to mount supports the depth of the columns, and what timber should I use to get a nice straight finish?

RenoMike · Answer

Hi Pumpkins!

Thanks Mitchell. Cool rendered pic. Pumpkins I posted a detailed description under "Ekodeck castellated panel fence" and in there I described with photos how I created an underlying timber frame for the panels to attach to. I think this should cover your questions together with Mitchell's diagram.

VERY lucky it is 1.8m high, as you can just cut each panel in half. Please see my post with some tips about calculating how many panels you need and how to cut them, it's trickier than you think!

Let us know if you have any questions as you go, and of course please post the final result!

MitchellMc · Answer

Hi @pumpkins001

With spans of around 2.7m between the columns, I'd be inclined to build an internal frame system rather than trying to pack out individual battens to match the varying column depths.

A frame constructed from

https://www.bunnings.com.au/90-x-45mm-outdoor-framing-h3-treated-pine-2-4m_p8032172

would provide a solid and straight mounting surface for the Ekodeck Castellated Panels. The advantage of this approach is that you can build the frame perfectly plumb and level regardless of whether the columns vary between 100mm and 110mm in depth.

The frame could be fixed to the sides of the columns, anchored to the ground where appropriate, and tied back to the rendered wall with suitable brackets. This would create a rigid structure that is less likely to move or twist over time and will help ensure the finished castellated panels remain straight and aligned across the full 9m length.

While it may be possible to pack out timber battens in the low spots to achieve the required depth, I think a framed approach will give you a much better result, particularly over those longer spans.

I've created the rendering below to help illustrate the concept. The frame sits between the columns and provides the mounting points for the horizontal members that support the castellated panels.

Let me tag @bsdll, @RenoMike, @Naidoo021 and @Neil1984 to see if they have any thoughts.

Please let me know if you have any questions.

Mitchell