Anatomy of a Balcony Facelift

Rita C. - Panoply
by Rita C. - Panoply
Correcting water leaks and damage in the original design, implementation of our 2004 porch renovation was the goal in our 2016 balcony facelift. Back in 2004, we renovated our property to add more character to the front house entry in the form of a porch/balcony. Twelve years later, the balcony got a major facelift, resolving issues overlooked in the original implementation of our ideas.
Water issues evident in the 2004 build.
Water seeped into the structure from just outside the balcony railings, and managed to wreak havoc from the inside out. The original contractors came back within two months with a temporary solution, but the problem persisted. Four years later, it was dismantled and rebuilt, but unsuccessful in correcting the root cause of the water.
Demolition Reveals Extent of Damage
Fast forward, 2016: a new, innovative contractor. You can see from the photo collage above the contractor ended up demolishing all the way back to the inner porch (where noted in green in the labeled photo earlier). The railings (a low-maintenance alternative to wood) were removed and reused.
Constructing templates, frame
Even with inclement weather, this contractor worked in his workshop at home, preparing the rebuild materials, and texting me photos with progress reports on those days. This job, though considered relatively small, turned out big, AND the arc shape of the balcony presented real challenges.
Rebuilding the arc shape of balcony
The wood had to be bent into the semi-circular shape of the arc. This was accomplished by the notch cuts in the boards (much like sewing cloth at necklines, armpits, waistbands, etc.). The thinner boards on the inner/outer layers were actually soaked (he went to the river across from our property!) to mold into shape.
"Drying in" the balcony surface
After the outer frame was rebuilt, the next step was bringing in the subcontracted roofer, who then "dried in" the balcony top with a rubber roofing. There is a drain on this roof, which is pitched to the outer edge of the arc, and a drainpipe is built in to take water away. It is from outside that lipped edge where the root problem occurred previously. Steps were taken to correct the root cause of the water issues with this outer ledge. Copper flashing was welded over the wood and rubber-coated ledge.
The "MacGyver" Project: heating PVC to an arc
For the finish millwork, there was just one obstacle with the alternative replacement materials (no wood, to ensure no rotting!): the PVC material is manufactured in flat sheets, and only bends with high heat (somewhere near 300°). Even with a successful bend, it molds within minutes, so the application must be quick. Breakage was a real concern. My contractor came up with a genius solution, MacGyver style!


After the radius measurements had been taken, my contractor went back to his workshop and constructed a model frame of the arc. He then devised a heating unit for the PVC material. Once heated sufficiently, his team molded the material onto the frame, and were able to clamp it into place, in order for it to set up.


The balcony is built in multi-dimensional layers for an aesthetically-pleasing appearance, so the contractor's team proceeded with the additional steps of heating the PVC material, bending it and layering it onto the prior layers.
The Completed Balcony Facelift
A crown molding finishes off the balcony facelift. The original columns and porch railings (all alternative PVC materials) were salvaged and reused. The balcony is sealed! This project was a game-changer for us and our water issues! For more detailed information on this project, please see the blog link below.
Rita C. - Panoply
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