It definitely took more time, effort, and material (I think I’ve said that many times before) but the roof and deck roof are complete – and just in enough time. The day I got the deck roofing half finished, there was a storm and a downpour. But let’s back up.
I knew I wanted a steel structure for this roof and figured out that I could manage 20’ long, steel roof joists by myself. I previously posted about getting them to the top, building the main roof structure, and then pitching it to get the correct angle. I thought the deck roof would be easier. Instead of building it, then hoisting it; I decided I should build this part piece by piece. The first step was getting the posts welded. Easier said than done. Managing a 12’ long 4×4 steel post, while keeping it level and welding it in place, is quite a challenge for one person. But I did it, four times over.
After the main posts were up, I could start on the outer structure. Standing on a ladder, at the edge of the deck, two stories up, while bolting a 20’ long segment of steel joists – well, I’ve done easier things. Making sure they match the pitch that the main roof has adds another layer of challenge.
In between the assembly time of the deck roof structure, I continued working on the main roof. I laid down purlins on the joists to add stability and allow me to use thinner roof decking. I used the ForceField product again.
As I continued on the deck roof structure, the hardest part was getting the last 20’ long piece up to the highest point, while on a ladder, and getting it secured. But I got it done after a couple of adrenaline producing moments.
After the whole of the structure was up and secured, I could then begin to fill in non- structural elements that would just be holding the roof panels. The deck roof was lighter and thinner panels, so the support didn’t need to be as beefy.
Once both roof structures were complete, adding the roof panels was actually the easiest part. I did originally plan on using recycled vinyl billboards as the roof and deck coverings. I still think they’d work for my purposes. But after all the time I had been spending on the roof, the last thing I wanted was to have to redo it in a year or so. I instead opted to use actual roof panels. Although it took tons of screws, it wasn’t hard.
I had to complete the roof panels and the flashing on the main roof before I could put up the panels on the deck roof. That’s because the only way up to the roof is from the deck. Once it’s covered in roof panels, there’s no easy way to get back up there. So I checked and rechecked the roof before moving on. I also painted all of the structure before the panels went on. Eventually I was able to get started on the deck roof panels.
I ran out of screws halfway through but I did get half of the panels installed on the roof over the deck. And as I originally stated, the timing could not have been more perfect. A major thunderstorm hit right as I was wrapping up what I could do. Several inches of rain fell over the next couple of hours. All I could do was watch, but it was comforting to know that I didn’t see any leaks from any of my panels. So I drank a beer, sat on the deck, and watched the rain fall.
McGowen Container House (and more) 
Amazing work Will!
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