Calistoga Spa Surround

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REDWOOD
Cali
s
toga Spa Surround
REDWOOD
Naturally beautiful
Easy to use
Practical and economical
Durable and stable
Resistant to decay and insects
BUILD IT WITH
Calistoga Spa Surround
BUILD A SPA SURROUND
BUILD SIDE BENCH & STEPS
Enhance the alluring appeal of a backyard
spa with this handsome redwood spa
surround. Its elegant, custom-crafted
design features a comfortable wrap-
around lounging bench and two sets of
easy-to-build steps, which provide a safe,
convenient way in and out of the spa.
This brochure contains all the information you’ll need to construct
the redwood spa surround. Start by building the side bench, which
includes an attached set of steps. Then assemble the rear bench. Join
together the two benches to form the wraparound surround. Note
that the building plans and materials lists presented will help you to
build a spa surround 28 inches high that will fit a 6x6-foot spa. This
project can easily be adapted to fit any size spa.
The easy-to-follow plans include options for bench-board patterns and
corner treatments. Select the construction methods that best suit your
carpentry skills and personal preferences. There’s even an option for con-
verting the unused space under the rear bench into a valuable storage area.
This redwood spa surround is designed to be a freestanding unit. It
isn’t fastened to the ground in any manner, but simply sits on the
concrete slab that supports the spa or rests on a 6-inch deep stone bed.
Both styles of base will provide rock-solid support for the spa surround.
Before starting this project, carefully study the plans and materials
lists. Remember that it is best to measure and cut as you build for
the most accurate results. To prevent staining, use only high quality
non-corrosive fasteners.
The skeletal frame of the side bench is primarily constructed out
of vertical 2x4s and horizontal 2x6s; narrow 2x2s separate the 2x6
side boards. The entire frame rests on 2x4 sleepers, which form
a flat, stable base. The top surface of the bench is made of 2x6s
spaced
1
⁄
8
inch apart. Fasten the boards together with 3-inch
galvanized or stainless steel screws or 10d nails. If you use screws,
drive them in with a cordless drill/driver. When assembling the
frame, be certain to use a carpenter’s framing square to ensure that
the parts are perfectly square, meaning they form true 90º angles.
1. Assemble sleepers and frames
Start by cutting to length
the two 2x4 sleepers. (For a 6x6-foot spa, cut them to 63
7
⁄
8
inches.)
A power table saw provides a quick, accurate way to crosscut lumber,
but a portable circular saw or handsaw will work just as well.
Next, cut the five pairs of vertical 2x4 frames. Note that two pairs
(four pieces) are 25 inches tall, while the remaining pairs are
18, 11 and 4 inches tall. These tiered pairs form the three steps and
accommodate spas 28-29 inches tall. Ideally, the spa surround
should be slightly lower than the spa edge. Cut the 2x4s shorter or
longer to fit a spa of different height. Mark the positions of the
vertical 2x4s on the sleepers, and then attach them with screws or
nails driven up through the bottom of the sleepers.
2. Attach step risers
Cut four 2x6 risers to length and fasten
them flush with the top of the vertical 2x4s. Drive the fasteners in
from the back of the 2x4s so they won’t show.
3. Side boards and spacers
Cut only enough 2x6 side boards
and 2x2 spacers to fit across the spa-side length and the end of the
partially assembled bench. The outside side boards and spacers will
be trimmed to fit and installed later after the two benches have
been joined. Use the carpenter’s square to make certain that the
2x4 frames are true vertical before securing any side boards.
Starting at the bottom, fasten a 2x6 to the side of the frame that
will face the spa. Place a 2x2 spacer above the 2x6 and fasten it
to the frame. Repeat for the end of the frame. Continue alternating
2x6s and 2x2s until you reach the top of the frame. (See Design
Options for Corner Treatment details.) Slide the bench into position
alongside the spa, but don’t attach the side boards to the outside sur-
face just yet.
4. Attach step treads
You can attach the treads now or wait
until installing all the bench boards. Trim six 2x6 boards to 24
1
⁄
2
inches. Set the boards into place, starting them even with the spa-
side framing and overhanging the outside edge by
1
⁄
2
inch. Allow
1
⁄
8
-inch spaces between treads and at the riser/tread joint.
For this project, you can use either
Construction Common or Deck Common
redwood; both grades are economical
and offer a rich mixture of heartwood
and sapwood. Where increased decay
resistance is needed, such as for the 2x4
sleepers, use the all-heartwood grades of
redwood: Construction Heart or Deck Heart.
1
⁄
8
" spacing
(typical)
1
⁄
2
" overhang front
and outer edges
11
1
⁄
4
" (typ.)
28"
7" (typ.)
31
5
⁄
8
" (36" max.)
10
3
⁄
4
"
10
3
⁄
4
"
10
3
⁄
4
"
1
1
⁄
2
"
63
7
⁄
8
" or to fit tub length
Optional braces if built as
stand alone unit
2x6 redwood side
boards and spacers
2x6 redwood treads,
spaced
1
⁄
8
"
2x6
redwood
risers
2x4
redwood
sleeper
2x4 redwood framing
 BUILD REAR BENCH
TOOLS AND MATERIALS
The rear bench is constructed much like the side bench using redwood
2x2s, 2x4s and 2x6s. The main difference between the two structures
is that the vertical 2x4 frames of the rear bench are all the same
height since they don’t have to form a set of steps.
Before starting on the rear bench decide on the type of bench-board
pattern you’d like; see the section on Spa Surround Design Options.
No special consideration is needed for laying the right-angle board
pattern, but you’ll have to install additional bracing for the 45º or
sunburst patterns; see Special Framing Details below.
Also, if you’d like to utilize the space beneath the rear bench for storage,
check out the Storage Access Option. It provides detailed instructions on
how to frame out a 48-inch-wide opening and build two swing-out doors.
1. Assemble framing
As with the
side bench, start by cutting to length the
two 2x4 sleepers. For maximum decay
resistance, use an all-heartwood grade of
redwood, such as Construction Heart or
Deck Heart. Cut all the vertical 2x4 frame
parts to 25 inches (for a 28-inch-tall spa).
Cut the horizontal 2x4 frame parts to 21
inches to ultimately create a bench that’s
24 inches wide. Use 10d nails or 3-inch
deck screws to fasten together the parts
to make five identical frames, each measuring 21 inches wide by
25 inches tall. Again, be sure to use non-corrosive fasteners.
3. Attach side boards
With the two benches joined together,
you can continue installing the side boards and spacers. Begin with
the boards on the end of the rear bench. Fasten the bottommost 2x6
side board, then work your way up to the top of the bench alternat-
ing a 2x6 with a 2x2. Move around to the back of the rear bench
and repeat the process. Again, start with a 2x6 and align each board
with its mating member on the end of the bench.
Once the end and back of the rear bench are covered, install the
2x6 side boards and 2x2 spacers to the side bench. Note that these
pieces extend all the way across both the side bench and the end of
the rear bench, thus hiding the joint between the two.
4. Install bench boards
Cover the tops of both benches and
the steps with redwood 2x6s. For the steps, cut the boards so that
they overhang the side boards by exactly
1
⁄
2
inch. Cut the bench
boards slightly long and trim them to fit afterwards. Use 16d nails
to help space the boards
1
⁄
8
inch apart. Fasten each one with four
10d nails or 3-inch deck screws flush to the bench surface; do not
countersink. When you get to the corner of the tub, you will want to
cut the boards to fit the tub radius allowing for a
1
⁄
4
- to
3
⁄
8
-inch
drain space. Make a cardboard template of the tub corner. Lay out
your bench boards on a flat surface including the
1
⁄
8
-inch spaces.
Transfer the trim line from the template and trim and install the
corner bench boards.
5. Trim bench boards
To achieve a professional looking cut,
use a circular saw to trim the ends of all the overhanging boards at
the same time. Measure
1
⁄
2
inch out from the side board and use a
chalk reel to snap a line across the top surface of the boards. (You
could also use a long straight-edged board.) Guide the saw along
the line to trim off the overhanging bench boards. Smooth out any
rough edges and ease all sharp corners with 100-grit sandpaper.
Finishing
To protect the visual beauty of your project
and extend its life, finish the exposed surfaces with a clear water
repellent containing a mildewcide. See the finishes section on
the address panel of this brochure for more finish options.
Tools you will need
To build this redwood spa surround,
you’ll need a power miter saw, sabre saw, circular saw or fine-tooth
handsaw, hammer, cordless drill/driver, measuring tape, chalk reel,
carpenter’s square, combination square, and hand plane or belt
sander. A small clamp would also be helpful for holding together
the frame parts while you drive in the nails or screws.
Trim the 2x4 sleepers to fit the length of the spa plus the width of the
side bench framing—about eight feet. Fasten the assembled frames
to the sleepers, making certain that they’re evenly spaced. If your spa
requires a longer bench, you will need longer sleepers and additional
frames. Keep the frame spans equal and spaced no more than 24
inches on center (o.c.).
Before placing the bench frame into position alongside the spa, install
the 2x2 spacers and 2x6 side boards to the surface that goes up against
the spa. But, don’t cover the entire side. Fasten one continuous 2x6
along the entire bottom of the bench frame and another along the
top. Then cut three 2x2 spacers and two 2x6 side boards to span the
distance from the first frame to the second frame. These boards help
conceal from view the open space beneath the bench. (They’ll also
prevent cats and other critters from crawling under the bench.)
2. Join rear and side benches
Place the partially completed
bench into position against the rear of the spa. Check to make sure
that it’s properly aligned with the side bench and that the two structures
form an exact right angle. Fasten together the two benches with
several nails or screws.
Fasteners should be top quality hot-dipped galvanized or stainless-
steel nails or screws. The lists below itemize the sizes and amounts
of redwood needed to build the spa surround framing and steps.
Materials For 6-Foot Side Bench and Steps
Quantity Size
Length
Vertical frames
4
2x4
25 inches
(from two 8-foot 2x4s)
2
2x4
18 inches
21"
(typical)
2
2x4
11 inches
2
2x4
4 inches
Sleepers
2
2x4
8 feet/to fit
Side boards
8
2x6
8 feet/to fit
2x4s
25"
Side spacers
8
2x2
8 feet/to fit
Short side boards
4
2x6
21 inches
Short side spacers
4
2x2
21 inches
Step risers
4
2x6
24
1
⁄
2
inches
Step treads
6
2x6
24
1
⁄
2
inches
Bench boards
See bench-board patterns materials list
Fasteners
2 pounds 10d common nails or
3-inch deck screws
Optional boards to screen opening
Materials For 8-Foot Rear Bench
2x6 redwood
bench boards
2x6
redwood
treads
24" max.
(adjust for
tub width)
Quantity Size
Length
24"
Vertical frames
10
2x4
25 inches
Top and bottom frames
10
2x4
21 inches
Sleepers
2
2x4
10 feet/to fit
Spa-side back boards
2
2x6
10 feet /to fit
26
1
⁄
2
"
Side boards
4
2x6
10 feet/to fit
Side spacers
3
2x2
10 feet/to fit
Short side boards
4
2x6
21 inches
Short side spacers
3
2x2
21 inches
Optional side boards
4
2x6
27 inches
1
⁄
2
" overhang
(typical)
Optional spacers
3
2x2
27 inches
2x2 redwood spacers
2x6 redwood side boards
Bench boards
See bench-board patterns materials list
Fasteners
2 pounds 10d common nails or
3-inch deck screws
2x4 redwood
frame assembly
2x4 redwood sleepers
SPA SURROUND DESIGN OPTIONS
SPECIAL FRAMING DETAILS
STORAGE ACCESS OPTION
The building plan for this redwood spa is flexible enough to permit several
design options. Below are examples of four different corner treatments
and three bench-board patterns from which you can choose. And best
of all, none of these design options requires a significant increase in
the amount of time or materials needed to complete the surround.
Bracing for 45
º
pattern
In this popular pattern, the
2x6 bench boards from the side
and rear benches meet at the
bench corner. As a result,
there’s a seam running diago-
nally across the bench. To
support the board ends along
this seam, install a pair
of notched 4x4 posts and a
double-2x4 cross brace. Cut
a 3
1
⁄
2
-inch-deep notch into
the top of each post. Before nail-
ing together the double-2x4
brace, slip three short strips of
1
⁄
2
-inch plywood between the
2x4s, to allow water to drain
through to the ground.
Bracing for sunburst pattern
The bench boards for this attractive
pattern require additional bracing because they are cut to a taper and
span too great a distance. To install a diagonal brace across the bench
corner, cut the ends of a 2x4 to 45º and nail it in place.
Trimming boards for a sunburst pattern
To make this job
easier, create a template of the corner construction on a large piece of
plywood or cardboard, as shown below. Establish the diagonal starting
line across the bench corner. Lay the first 2x6 board on the starting line.
As you add boards remember to space the boards
1
⁄
8
inch apart.
Mark the tapered cutting line from the inside corner of the board to
where its outside edge would meet the bench frame. Cut the taper with a
circular saw and repeat for the other boards, making sure you leave the
ends running long.
2x6 redwood
bench boards,
cut ends at 45
°
Take advantage of the empty space beneath the rear bench by building
a convenient storage compartment. Its opening measures about 21
inches high by 48 inches wide and is concealed behind two easy-to-
assemble doors.
1. Framing details
Build the structural frames of the rear
bench out of 2x4s and space them 24 inches apart, as shown
below. Note that each frame is made up of four 2x4s, except the
center frame. It only has one vertical 2x4 and one horizontal 2x4.
The front and bottom pieces are purposely left out to create the
wide-open, easy-access storage area.
When installing the 2x6 side boards and 2x2 spacers, cut them flush
with the vertical 2x4 frames on each side of the opening. Fasten a
long, continuous 2x6 at the top of the opening and allow the 2x4
sleeper to run across the very bottom of the compartment.
Tr i m
1
⁄
8
"-
1
⁄
4
" from top and sides as needed for clearance
1
⁄
8
" spacing
21"
2x2
redwood
spacers
24"
1
3
⁄
4
"
2x6
redwood
side
boards
48"
4. Hinges
Hang each door with a pair of galvanized metal strap
hinges. You can attach the hinges with the short wood screws
provided but, for maximum strength, replace them with
3
⁄
8
-inch
by 2-inch galvanized lag screws. Drill
3
⁄
16
-inch screw pilot holes
into the doors and screw on the hinges. Set the doors in the opening
and use shims to hold them in place. Drill pilot holes into the 2x6
side boards and attach the second hinge leaf with lag screws.
Butt joints
Miter joints
1x2
redwood
spacers
2x6
redwood
side
boards
Double 2x4 with
1
⁄
2
" spacers
4x4 redwood posts
with notched tops
1x4
redwood
vertical
battens
3
1
⁄
2
"
24"
These lists detail the materials needed for each bench-board pattern
and any special framing, if required, along with the additional framing
and hardware needed for the storage access.
C
Box joints
Recessed accent
24"
Corner treatments
The outside corner joints, where the side
boards and spacers meet at right angles, can be fitted together in many
ways. The easiest approach is to alternately stack the side boards and
spacers using either butt joints or box joints. For a visually cleaner
look, use miter joints; recommended for well-seasoned (dry) lumber
only. To create a series of interesting shadow lines around the spa
surround, choose the recessed-accent option and separate the 2x6 side
boards with smaller 1x2 spacers.
Materials For Bench-board Patterns
Quantity Size
Length
1x6
redwood
diagonal
batten
45º pattern
Board boards
13
2x6
24
1
⁄
2
inches
Corner bench boards
6
2x6
trim to 45˚ to fit
Braces
2
2x4
29 inches/to fit
Barrel
bolts
Strap hinges
Spacers
3
scrap
1
⁄
2
-inch plywood
Sunburst pattern
Corner bench boards
2. Assemble storage doors
Build the two doors out of alter-
nating 2x2s and 2x6s to match the surround. Cut the boards to
length, then lay them face down. Make sure they are square and use
a clamp to hold the doors while you fasten the boards together. Attach
two vertical 1x4 battens and a diagonal 1x6 batten strip across the
joints. Note that the 1x4 battens are positioned 1
3
⁄
4
inches up from the
door bottom in order to clear the 2x4 sleeper.
3. Trim to fit
Test fit the doors in the opening. If they fit too
tightly, trim
1
⁄
8
-
1
⁄
4
inch from the top and side of each door with a
belt sander or hand plane.
8
2x6
4 feet/to fit
Bench boards
13
2x6
24 inches
Make a cardboard template of
the spa’s rounded corner and use
it to mark the curved cut line
onto the board ends. Trim
boards with a hand or sabre saw.
Fasten the trimmed boards in
place on the bench frames with
deck screws or nails. Predrill
nail holes at the board ends to
prevent splitting. Trim all the
bench boards to length, leaving
a
1
⁄
2
-inch overhang.
45
°
top brace
Start at
center
diagonal
Brace
1
2x6
29 inches/to fit
Cutting line
Right angle pattern
Bench boards
8
2x6
24
1
⁄
2
inches
Right angle
45
°
Sunburst
Additional Materials For Storage Access
Bench-board patterns
The right-angle bench-board pattern
shown above is by far the easiest to build, but the 45º and sunburst
patterns are much more interesting. Remember that these two patterns
require the installation of additional framing to support the 2x6
bench boards; see Special Framing Details at right.
Quantity Size
Length
Vertical battens
4
1x4
25
3
⁄
8
inches
Diagonal battens
2
1x6
31 inches
Strap hinges
4
Barrel bolts
2 sets with wood screws
1
⁄
8
" spacing
Lag bolts, nuts
as needed
3
⁄
8
x 2 inches
and washers
1
⁄
2
" overhang (typical)
STAND ALONE STEPS
Redwood
For beauty and performance, redwood is naturally superior to
other woods. That’s why it’s the first choice for decks, fences and
most outdoor projects. Redwood retains its beauty outdoors, shrinks
and swells less than other woods and is less likely to warp, split,
check or cup. With relatively little or no pitch, redwood is easy to
drill, saw and shape. Redwood heartwood has natural durability and
resistance to insects and will last longer outdoors than most woods.
Grades
The knotty garden grades of redwood are ideal for outdoor projects.
These grades are beautiful, durable and economical.
Construction Heart/Deck Heart
is all heartwood and con-
tains knots; used for load-bearing applications near the ground.
Deck Heart is graded for strength and is available in 2x4 and 2x6.
Construction Common/Deck Common
contains sapwood
and knots; used for decking and above-ground uses. Deck Common
is graded for strength and is available in 2x4 and 2x6.
Merchantable Heart
is all heartwood and contains larger knots
than Construction grades; used near the soil.
Merchantable
contains sapwood and larger knots; used for
fence boards, rails and above-ground uses.
Finishes
Redwood accepts finishes better than most woods. Some heighten
redwood’s natural beauty, bringing out the color and the grain.
Others help the wood harmonize or contrast with surrounding
structures. Read the labels on all finish products before using.
No-finish option
Redwood performs better than most woods if
left unfinished. This no-maintenance option will result in redwood
weather-bleaching to a soft driftwood gray.
Clear water repellent finish
with mildewcide is recommended
to stabilize the color at tan.
Bleaching and weathering stains
produce a permanent drift-
wood gray effect, a good, low-maintenance option.
Semitransparent stains
in “redwood” shades tint the wood
without hiding the grain.
Solid-color stains or paints
should be applied over compatible
oil-based primers.
This optional set of steps is constructed very much like the spa sur-
round. It has a 2x4 frame and 2x6 side boards separated by 2x2
spacers. The treads and risers are cut from 2x6s. For maximum
safety and convenience, build the steps long enough to span the
entire width of the spa. The steps illustrated here are 48 inches long,
but you can easily adjust the dimensions to fit any spa. When
you add framing, keep the spans at 24 inches o.c. or less.
1. Assemble the framing
Begin by cutting the three 2x4
sleepers to 18
3
⁄
8
inches long. Next, make the nine vertical 2x4
frame parts; cut six of them to 11 inches long and three to 4 inches
long. Nail or screw the vertical 2x4s to the sleepers, as shown.
Cut two 2x6 back boards and one 2x2 spacer to 45 inches. Attach
these boards to the three sleeper/framing assemblies, positioning
one assembly at each end and one in the middle.
2. Install inner boards and side boards
Cut to length
the 2x6 side boards and spacers. Attach two side boards and one
spacer to each end of the step assembly. Next, trim to fit two
2x6 inner boards and fasten them to the middle 2x4 frame.
3. Attach risers and treads
Each step tread consists of two
2x6s and each riser is made up of a single 2x6. Saw the four tread
boards to 49 inches; cut each riser to 45 inches. Fasten the two
risers to the vertical 2x4 framing members. Set the 2x6 treads into
place. Check to make
sure that their ends over-
hang by
1
⁄
2
inch and that
there’s a
1
⁄
8
-inch space
between the boards.
Secure each tread with
six 10d non-corrosive
nails or 3-inch deck screws.
2x6 redwood treads, spaced
1
⁄
8
"
2x6 redwood inner boards
1
⁄
2
" overhang,
front and sides
3" deck screw
(typical)
2x6
redwood
risers
2x6 redwood
back boards
2x2
redwood
spacers
24" max.
C
24" max.
2x6
redwood
side boards
2x4 redwood sleeper
Materials For 48-inch Stand Alone Steps
Quantity Size
Length
Sleepers
3
2x4
18
3
⁄
8
inches
Vertical frames
3
2x4
4 inches
6
2x4
11 inches
Inner boards
1
2x6
7
5
⁄
8
inches
1
2x6
12
1
⁄
4
inches
Side boards
2
2x6
10
5
⁄
8
inches
2
2x6
21
3
⁄
8
inches
2x6 treads
Side spacers
2
2x2
10
5
⁄
8
inches
Risers, back boards
4
2x4
45 inches
2x6
risers
Back spacer (optional)
1
2x2
45 inches
Treads
4
2x6
49 inches
Fasteners
1 pound 8d common nails or
2
1
⁄
2
-inch deck screws
1 pound 10d common nails or
3-inch deck screws
48"
2x2
spacer
2x6 side boards
Contact the California Redwood Association for more great publica-
tions containing redwood technical and building information. Call
us toll free at 1-888-Cal-Redwood for a complete literature list or to
ask for any of the titles listed here:
7
5
⁄
8
"
18
3
⁄
8
"
12
1
⁄
2
"
Fasteners
Use only non-corrosive hardware such as aluminum, stainless
steel or top quality hot-dipped galvanized screws or nails.
Ordinary nails and screws will cause stains.
5
1
⁄
2
"
Other Construction Tipsheets
Also Available
Freestanding Deck
Deck Construction
11
1
⁄
8
"
2x4 framing
Deck Over Concrete
Deck Grades, Nails and Finishes
1
⁄
8
"
1
⁄
2
"
Windsor Shade Shelter
Fences for All Reasons
11
1
⁄
4
"
Monterey Potting Center
Landscape Architecture
405 Enfrente Drive, Suite 200
Novato, CA 94949-7206
Telephone 415 382-0662
Toll Free 888 Cal-Redwood
Fax 415 382-8531
www.calredwood.org
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⁄
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3
⁄
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