There is a great deal wrong with the pavilion we received aside from the timbers being badly cracked and the other small pieces being cracked, warped, and twisted. The unit appears like it was machined some months ago and stored. But for clarity let me just list the issues from beginning to end and let the reader decide.
The unit was ordered and purchased some months ago with the request to manufacture the pavilion when we were closer to completing our new house in Williams Valley, Prescott Arizona. We asked them to do this to minimize the checking or cracking that normally occurs to beams/wood over time.
From the start we had issues with the engineering. The county required the prints and engineering to be certified by an Arizona engineer. WTF found an inspector in Utah who was Arizona certified to submit the prints. Conversations between our contractor, WTF, and the county resulted in a set of prints we could work from. However, as of today with the pavilion assembled, the county inspector is asking for a set of prints that reflect the actual kit we were sold. We are assuming the changes are small but required to cover liability issues or comply with the current building codes.
The buyer needs to be aware that they are responsible for establishing a method and coordinating the offloading of the pallets. In our case we received the two pallets, one weighing 5400 pounds, and the other weighing 5600 pounds on 48 foot flatbed semi. After discussing the offloading with the WTF representative, who was under the impression we had a crane scheduled and standing by for this purpose, we realized we had to do it. The WTF uses third party shippers who need a load going in their direction so coordinating the availability of heavy equipment to offload these heavy pallets can be complicated. We did not have a contractor and heavy equipment standing by to meet a delivery deadline that was uncertain.
We live in an upscale neighborhood but our paved country roads are narrow and full of dead ends. We rented a 6000 pound capacity forklift from a neighboring town but could find no operator. I had some experience with Bobcat fork lifts in the past so I manipulated the heavy and long pallets off the flatbed with the help of the semi driver. By lifting the load and driving the semi out from under the pallet we eliminated excess turning in the cramped roadway. The 17 foot long pallets were problematic to work around the trees and on the inclined driveway of fresh gravel but after 1 1/2 hours the deed was done. The semi driver was fortunate enough to use a newly cleared lot, the only one left on our street, to turn around and leave the area.
We unwrapped the loads a week later to find the beams badly cracked snd checked. The WTF literature explains to the buyer that this is a natural condition of large beams and lumber. We were surprised that a supposedly newly fabricated kit would appear so worn. The tongue and groove material, while obviously not freshly cut, was in good condition. We rented a crane to assist with assembly positioning the crane on the gravel and partially on driveway pavers. On assembly the large beams fit together without any problem. The problems began when trying to fit the knee and web braces. The mating surfaces were no longer flat or at right angles, many had to be recut to have them fit correctly. One knee brace was missing and a beam extension and king post caps badly cracked. I suppose we could have requested replacements as long as we were ready to pay the costs of equipment and contractor delays.
The condition of the kit and assembly process did not inspire confidence in the product quality or value. When unpacking the tongue and groove we had to "break it apart" as the fresh stain had fused the planks together. All in all the experience was not rewarding. The 20 X 35 X 17 foot high kit cost $50,000.00 dollars. The extra slab costs and assembly $5000.00. The cost for roofing has not yet been determined. To cover all the scuff marks after assembly falls to us or a painter. How WTF qualifies for so many awards is surprising but then we are unaware of the Utah award criteria!
So where do we go from here? We are considering a 4 foot wall around the top of the structure in place of the poorly fitting braces to stabilize it and then paint it the same color as the house. Quality paint reduces maintenance and protects the wood much better. In our opinion RV garages can be unsightly and even more costly so the pavilion concept might have been a good alternative. Our recommendation to others is to do something different and/or use glulam beams and lumber best suited for dry regions. Metal can be a less expensive option if it fits your situation. Just remember...after you have paid for it you are stuck with it!!! read more