Every homeowner dreams of a seamless remodel, but hidden issues in older homes can quickly turn a simple project into a stressful challenge. Unexpected structural problems, like rot in critical beams, can force difficult decisions mid-build.
At Custom Built, we’ve guided homeowners through remodels for over 20 years, tackling surprises with clear communication, thoughtful solutions, and a commitment to quality craftsmanship. We know how daunting it can feel when plans change unexpectedly.
In this article, we’ll walk you through how our team identified, communicated, and resolved an unforeseen change order during a deck project, showing you how proactive planning, trust, and expert guidance can turn a potential setback into a successful remodel:
- Discovering the Issue
- Acting Quickly and Communicating Clearly
- Implementing the Solution
- Lessons Learned
- The Result
1. Discovering the Issue
During demolition of the existing deck, we immediately noticed severe wood rot in the home’s structural beams. Unlike a traditionally framed house, this home had timber-framed beams running through the center of the structure, carrying weight from the second story.
The original assumption was that these beams were cantilevered, meaning they extended outward from the house without additional support underneath, and could be trimmed flush to set a ledger board for the new deck.
However, previous repairs and improper flashing had allowed water to penetrate the beams, causing extensive rot that extended over a foot and a half into the home.
Only an inch of the beam remained resting on the foundation, a dangerous scenario that could compromise the entire structure. The perimeter beams were also rotted, meaning the elevated deck, nine feet off the ground, could collapse if we proceeded without addressing the issue.
2. Acting Quickly and Communicating Clearly
From day one, it was clear that a change order was unavoidable. Our priority was to communicate the situation immediately to the homeowners, who were away from their Up North cabin.
Using photos and videos, we explained the severity of the issue and walked them through potential solutions.
Options included:
- Freestanding Deck: Avoiding attachment to the house. But this was risky due to lateral racking at nine feet high.
- Structural Repair: Jacking up the house and replacing the rotted beams, ensuring safety and stability.
We provided a clear recommendation based on our experience: “If this were our house, this is how we’d fix it.”
The homeowners trusted our guidance, later commenting, “You took the approach that you’re remodeling your own house, please keep doing this.”
3. Implementing the Solution
Once the decision was made, our team acted immediately:
- The house was carefully jacked to support the structure.
- Critical beams were replaced.
- Rotted siding and exterior elements were updated, creating a cohesive finish.
- Additional updates, like sliding glass doors and exterior lighting, were completed as part of the project.
This approach added two weeks to the timeline but ensured safety, stability, and a high-quality finished product.
4. Lessons Learned
This experience reinforced several key lessons for our team:
- Always plan for the unexpected: If flashing isn’t visible during initial inspections, assume potential rot behind ledger boards.
- Prioritize communication: Quick, transparent updates give homeowners confidence to make informed decisions.
- Trust is essential: A strong client-contractor relationship makes difficult conversations manageable and keeps the project moving forward.
- Growth mindset: Each unique home structure teaches us new techniques and solutions for future projects.
5. The Result
The final deck and exterior updates look amazing, blending seamlessly with the home’s design. More importantly, the structural repairs ensured the home’s integrity for years to come, reinforcing the framing, eliminating hidden rot, and providing a solid foundation for the new deck. The result was a safer, longer-lasting structure that looks as good as it performs.
The homeowners were thrilled, returning to request additional projects and referring friends. To us, that’s the ultimate measure of success: satisfied clients who trust us to serve their needs and protect their homes for the long run.
Our Advice for You, The Homeowner
Unexpected change orders happen, even with the best planning. Our advice:
1. Plan for Surprises
Even with careful planning, remodeling often uncovers hidden challenges, like rot, wiring issues, or outdated framing, that no inspection can fully predict. Building a 10-20% contingency fund into your investment goals helps ensure these discoveries don’t derail your progress.
It’s not about expecting the worst; it’s about being prepared so you can respond confidently instead of reactively.
2. Ask Questions Early
Your remodel is a collaboration, and communication is key from the start. Before construction begins, ask your contractor about potential risks, what-if scenarios, and how unexpected findings are handled.
The earlier you clarify expectations, the smoother your project will run when surprises do appear. Proactive communication helps prevent misalignment and builds trust between you and your remodeling team.
3. Prioritize Safety First
When structural or safety issues arise, they must take priority, no matter how they impact your schedule or budget. Problems like wood rot, foundation shifts, or compromised framing can threaten the integrity of your home.
Addressing these immediately protects both your family and your investment, ensuring that any cosmetic upgrades rest on a strong, lasting foundation.
4. Trust Your Contractor
A skilled contractor doesn’t just build; they guide. When unforeseen issues appear, a trustworthy contractor will walk you through the problem, explain your options clearly, and recommend solutions as if it were their own home.
Trusting that expertise allows you to make confident decisions and keeps your project moving forward with transparency and shared purpose.
5. Document Everything
Clear documentation creates confidence. Encourage your contractor to share photos, videos, and detailed notes that show what’s been found and how it’s being resolved.
This record not only builds transparency but also helps you understand the reasoning behind each change order or repair. When you can see the “why,” every decision feels more informed and intentional.
6. Focus on the End Result
Unexpected challenges can feel discouraging in the moment, but they often lead to a stronger, more beautiful finished product. Keep your eyes on the goal: a safe, functional, and thoughtfully designed space that will serve your family for years to come.
Every adjustment made with care brings your home one step closer to that vision.
Next Steps to Remodeling Your Home
Unexpected challenges can arise in any remodel, especially when dealing with older homes or complex structures.
By communicating quickly, offering expert guidance, and prioritizing safety and quality, our team turned a critical change order into a smooth, successful outcome.
At Custom Built, we approach every project with the same focus on trust, craftsmanship, and proactive problem-solving to protect your home and investment.
Planning a deck build or replacement? Schedule a consultation with our team to see how we manage surprises before they become setbacks.
Now that you know more about how we resolve unforeseen change orders, let’s explore the top flora to plant for your oasis, how much composite decks cost, and the projects that can increase the resale value of your home:
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- How Much Does a Composite Deck Cost in Boyne City, Michigan? - Explore how much composite decks cost in Boyne City and the factors that affect it.
- 5 Remodeling Projects That Can Increase Resale Value - A high-level review of the various remodeling projects that will increase your home’s resale value, curb appeal, and return on investment.
