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How to fix rusted nails on deck?

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!

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Comments

Noyade

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

ezzie

https://www.workshop.bunnings.com.au/discussion/comment/60449#Comment_60449

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

Noyade

https://www.workshop.bunnings.com.au/discussion/comment/92693#Comment_92693

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.

MitchellMc

Hi @ezzie,

That's an interesting one. If you sanded before punching the nails, I would think that if you sanded before punching the nails you've taken off the protective galvanised coating that was on the nails. Now, anytime moisture gets to them, they're just going to start rusting as they are bare steel.

It sounds like you’ve been thorough with your previous attempts, but unfortunately, what you’re experiencing is very common with older decks and the type of nails used. Even with sanding, rust treatment, and filler, any moisture that reaches the nails will eventually cause rust, which expands and pushes the nails out. The fact that your paint is still in good condition shows that the coating isn’t the issue, it’s the nails themselves reacting to moisture.

At this stage, there’s no quick fix that will reliably stop it. Punching the nails back down and filling around them will only give temporary results because the rust will continue underneath. Given the widespread popping and surrounding timber damage, the most practical and long-term solution is to remove the affected boards and start fresh. Using corrosion-resistant screws or nails specifically rated for outdoor decking will prevent this from happening again.

Essentially, the deck’s timber and fasteners have reached the point where continuing patch-ups won’t hold up, so replacing the decking is the way to go if you want a lasting result.

Please let me know if you have any questions.

Mitchell

ezzie

https://www.workshop.bunnings.com.au/discussion/comment/60449#Comment_60449

Whats that tool in the picture you've posted?

ezzie

https://www.workshop.bunnings.com.au/discussion/comment/112485#Comment_112485

Barcoo is a brand, whats the tool called?

ezzie

https://www.workshop.bunnings.com.au/discussion/comment/60464#Comment_60464

Nope, punched nails, repaired, coated and filled before sanding.

There's no way im ripping up good boards and balustrades for some rusty nails. There has to be a way to better fill with a long lasting sealant, or to remove them and replace with screws....and protective coat.

Also, what about the damage to balustrade in the original post, posted a photo.

Noyade

Afternoon @ezzie

Just try googling "Nail-Puller" - sometimes with "Heavy Duty" of "Industrial."

It's the pincer variety with a cast iron handle that slides - this impacts and forces the jaws into position.

https://www.google.com/search?client=firefox-b-d&q=heavy+duty+nail+puller

ezzie

https://www.workshop.bunnings.com.au/discussion/comment/60486#Comment_60486

Cheers for that, I'll give it a go! Any suggestions for a product that would seal the hole from bleeding leftover rust after I've pulled the nail?

EricL

https://www.workshop.bunnings.com.au/discussion/comment/92712#Comment_92712

Hello @ezzie

Should you manage to remove the nails, I suggest washing each hole with CLR 1L Calcium Lime Rust Remover to remove the rust stains and deposits on the old nail holes. I propose using a pressure washer to rinse the holes to remove as much of the rust as possible. Please note that despite the use of the chemicals and pressure washer some of the rust elements may remain buried inside the decking panel.

If you are relocating the position of the nails, I recommend using Earl's 1L Wood Hardener and covering the old holes with Turbo 500ml Builder's Bog. Please note that this is to cover the old holes. The bog will not provide any structural support should you drill into its surface and use it as an anchor for the decking panel.

Please remember to wear personal protection such as gloves, goggles and a mask when working on your project.

Eric

ezzie

https://www.workshop.bunnings.com.au/discussion/comment/112501#Comment_112501

Thanks Eric, Ill give it a go

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