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After just seven years, my patio stairs have completely rotted out. These weren’t some cheaply thrown together stairs, either. The structure was built with pressure-treated wood, and the decking boards were cedar. Given the materials, I expected at least a decade or more of life, but here I am, staring at a pile of rotted timber after taking them down myself. So, what went wrong? Well, I’ve learned a few things after looking into it.
First off, no joist tape was used. That seems to be the big one. For those of you who don’t know, joist tape helps protect the tops of joists and beams from water accumulation. Without it, water just sits between the boards and slowly eats away at the wood. Combine that with cedar, which is rot-resistant but not immune, and it sped up the decline.
Why Did the Stairs Fail?
The stairs were about 7 feet tall, which is a decent height for outdoor stairs. Cedar was supposed to be a good choice, but between the lack of joist tape and the exposure to the elements, moisture worked its way into everything. The pressure-treated wood beneath didn’t fare much better in places, likely because the cuts and notches were exposed, and we know untreated cuts on pressure-treated wood can still rot. Not to mention, the heavy rains we get around here just pushed things along faster.
The real kicker is that I’ve already done the demolition, so now I’m left with the decision of what comes next. Do I rebuild with wood but use better building practices, or explore other materials? I’m leaning toward the latter, but there are pros and cons to each option.
Rebuilding with Wood – Lessons Learned
If I go the wood route again, I’ll definitely be using joist tape this time. It seems like a small, inexpensive step that can make a huge difference in the longevity of outdoor structures. I’d also reconsider the material itself. While cedar is great for a lot of projects, maybe something like Ipe or composite decking boards would be a better call for long-term durability. I’ll also ensure all the cuts in pressure-treated wood are properly sealed to avoid rot starting from the inside out.
But even with these improvements, wood still requires ongoing maintenance—staining, sealing, replacing worn boards, etc. Part of me just wants to move away from the hassle of wood altogether.
Metal Stairs – My Novice Welding Skills Might Come in Handy
Since I’ve recently gotten into welding (but my welds aren’t pretty), I’m seriously considering metal as an alternative. Steel or aluminum would eliminate the rot issue entirely and drastically cut down on maintenance. But, here’s the catch: metal stairs aren’t cheap. I haven’t found any pre-fabricated options that are even close to economical. Plus, fabricating them from scratch is probably above my current skill level without a lot more practice and the right tools.
That said, the idea of having something that will last decades with minimal care is appealing. I could design a framework with a metal structure and use something like composite boards or even steel grating for the steps themselves. I feel like that would give me a nice balance between durability and aesthetics.
Other Options?
There are definitely other materials out there, but each comes with its own trade-offs.
- Composite Decking with a Wood or Metal Frame
Composite materials are extremely low-maintenance compared to wood. They don’t rot, they’re resistant to insects, and they look pretty close to wood. However, the cost can add up quickly, especially if I go for a top-tier brand. I’d still need to decide whether to use a wood frame (with joist tape!) or metal. The composite itself should last much longer than traditional wood, but the upfront costs and possible warping under extreme heat are things I’ll have to weigh out. - Concrete Stairs
If I had unlimited funds, I’d consider masonry stairs. But for a 7-foot structure, it’s just not economically feasible. The cost of concrete, rebar, and labor for a custom job would blow my budget out of the water. And let’s be honest—mixing concrete and getting all the forms perfect isn’t exactly a quick DIY project. - Metal-Wood Hybrid
One option I’m really intrigued by is a hybrid—using a metal frame for structure and topping it with wood or composite boards. This way, I’d get the durability of metal, but the aesthetics of wood or a composite. It might be a good compromise between all-metal stairs and something that still feels warm and inviting. I just need to figure out if I can find a metal frame at a reasonable price, or if I’ll end up trying to build one myself (and hoping my welds hold up!).
What Have You Tried?
I’m open to suggestions and advice, especially if anyone has experience with metal or hybrid stairs. Have any of you replaced outdoor stairs recently? What materials did you use, and how are they holding up? If you’ve gone the metal route, was it worth the cost, or did you regret not sticking with wood or composite?
At the moment, I’m torn between practicality and aesthetics, but I definitely don’t want to be in the same boat seven years from now. So, let me know what worked for you, or if you’ve come across any prefab solutions that won’t break the bank.
Feel free to share your thoughts—whether it’s lessons learned from your own builds or opinions on the best materials for outdoor stairs.
