How to fix rusted nails on deck?

[ezzie]

A couple of years ago, I sanded, treated the nails with a rust treatment, punched in any sitting proud and filled in each hole.  Then gave three coats of decking paint. Did the same for the balustrade, filled every crack and ding.

Now I'm back to square one!!!

But worse! Thr paintwork is fine, just needs a wash, but the nails are rusted out, have all popped up, balustrade holes are all back where I'd filled. Whats going on? What do I do? I really dont have the time or stamina to repeat the whole thing again. Any suggestions...other than burning it to the ground!

  

[Noyade]

@ezzie, would you consider (progressively) removing the nails - and replacing with screws?

[ezzie]

Good idea...but how do I remove rusted nails...is there an easy way, their heads have gone?

[Noyade]

It's hard to tell from your photos @ezzie  - but I think I can still see many heads intact?

And a small ring of wood rot around each one.

But the Bahco doesn't need the head intact to extract the nail. 

I don't know what length size your nails are, but this is a 60mm experiment...

With a bolt-cutter I cut the head off.

The inked ring sort of represents the 'rot'.

You can see the impression the jaws make - but considering the rot - tolerable?

Easily removed.

Generic brands are available on the net.

At the end of the day @ezzie - it's just a thought.

Cheers.