The client was seeking a deck replacement. The existing deck measured 16×12, and the client wanted to upgrade to a 16×16 three-season porch along with a floating deck.
Millhawlk managed every detail of this project—from design and permitting to framing, finishes, electrical work, and more.
The Design Process
When Millhawlk was awarded this project, the client selected our complete package, which included design services as well as construction. We began the development process by gathering references and inspiration from the client to better understand their vision. From there, we presented a proposed design that connected the three-season porch directly to the floating deck, creating the impression of a large landing leading to the porch stairs.
For the floating deck, we designed the framing to allow for two steps. This decision was intentional, as Massachusetts building code requires railings for decks with more than two steps. By staying within this limit, we were able to maintain an open, unobstructed look while also reducing construction costs.
In terms of finishes, we followed the client’s preference for warm, natural details. Mahogany was selected for the trims, while all other accents were finished in matte black to create a sophisticated contrast. Initially, the client considered installing a natural wood-burning stove inside the porch. However, after evaluating code compliance requirements and the significant cost increases associated with them, the client decided not to move forward with this option.
This process reflected the collaborative approach we take at Millhawlk—balancing client preferences, code compliance, and budget considerations to deliver a design that is both beautiful and practical.
Construction Phase:
1. Footing and Framing Process
For the porch, two critical considerations guided our approach:
- Setbacks: The existing structure was already built to the limit, which meant that every inch along the lateral side of the deck had to be respected. To ensure compliance and avoid potential issues, we installed stakes with tensioned lines to clearly mark the boundaries of the porch.
- Over-framing at the roof: This process involves overlaying the new framing on top of the existing structure to connect both roofs, essentially creating a “bridge.” The challenge with over-framing is that it sometimes requires additional reinforcement inside the house. This reinforcement is achieved by adding a structural element to the exterior wall to support the new roof load. Such reinforcement was necessary in the case of our project at 493 Dutton St.
Figure 1 – Over framing section
Figure 2- Over Framing structure
Figure 3 – Over Framing Final look
When exterior wall reinforcement is required, it often means additional work inside the home. In this project, a sliding door was located at the center of the roof line, so the reinforcement had to be placed on the door’s header. To achieve this, we opened the drywall and installed a 9-1/2” LVL header supported by two PSL posts.
Figure 4 – LVL Header
After installing the header, we completed the drywall and plaster patching, then repainted the entire wall to ensure a consistent color tone with no visible differences.
The remainder of the rough framing went smoothly. For the porch, we used 12-inch diameter footings with Bigfoot bases to support the framing structure. The floating deck was supported by 11×7-inch concrete blocks under the middle double beam, while 24×10-inch concrete pads were installed around the perimeter to support the step structure.
Before placing the concrete blocks, we prepared the ground to prevent weed growth by laying down a protective membrane topped with crushed stone, ensuring a clean and stable foundation.
2. Framing
For the porch, we used 2×10 P.T. joists at 16” O.C., and 2×8 P.T. joists also at 16” O.C. The porch features a central beam composed of a triple 2×12 P.T. configuration at the middle of the joist system. For the roof, 2×8 K.D. rafters were installed at 16” O.C., supported by a box system beam, with a triple front beam and double side beams carrying the rafters.
3. Finishes
For the finishes, the flooring was Trex Enhance in Saddle, while all trims and fascias were made of natural wood Mahogany, sourced from Carbys. The railings were Trex Select Black with square balusters. The roof soffit was finished with Beab Plywood. For the screen panels, the client requested aluminum screens, so we installed Saint-Gobain aluminum panels, using 1×2” aluminum extrusions for the frame and 2×2” aluminum extrusions as division panels.
4. Electrical
For the electrical services, the client requested strip lighting for the steps and around the porch, as well as outdoor outlets for both the porch and the floating deck. We also installed a central ceiling fan with an integrated light. For convenient and efficient control, all switches were upgraded to smart wireless models. The porch and floating deck outlets were equipped with outdoor GFCI boxes featuring brown covers to match the design aesthetic.
Final consideration
This project was truly a dream to work on. The location is incredibly peaceful, almost like being in the woods, and the client’s vision was to maximize this feeling. We believe Millhawlk captured that vision perfectly, bringing a sense of tranquility and harmony into the final product. Even the natural aroma of the Mahogany added to the ambiance, integrating seamlessly with the space. By the end of the project, the client shared that they were planning a second office in the porch to enjoy this environment as much as possible. The floating deck was designed as a space for fun and relaxation, perfect for BBQs and sunny days. Ultimately, everyone involved felt proud of the final result.
