awning carport (attached) recommended instruction manual...

AWNING CARPORT

(ATTACHED)

RECOMMENDED

INSTRUCTION MANUAL

This document remains the property of FBHS (Aust) Pty Ltd

April 2019

1


April 2019

TableofContents

Introduction 2

Components 4

Step 1 – Marking out the Perimeter of the Carport 4

Step 2a – Footing Set-Out for Concrete Block Pad Footing 4

Step 2b – Marking out the Perimeter of the Carport with Slab 5

Step 3 – Preparation of Carport Posts 7

Step 4a – Post Sleeve on Base Plate Set-out on Footing only 8

Step 4b – Post Sleeve on Base Plate Set-out on Slab 9

Step 5 – Preparation of Rafters 10

Step 6 – Post, Rafter, Purlin and Existing Structure Assembly 11

Step 7 – Fixing of Eave Purlin 12

Step 8 – Fixing of Roof Purlins 13

Step 9 – Plumb the Posts 13

Step 10 – Fix Base Plate Permanently 13

Step 11 – Carport Frame to be Square 14

Step 12 – Complete Fixing of the Frame 14

Step 13 – Gusset Plate Knee Brace 15

Step 14 – Fit Roof Sheeting 17

Step 15 – Fit Gutters and Flashings 18

Step 16 – Cut and fit downpipes 18

Step 17 – Finish 18

2


April 2019

Introduction

This Recommended Instruction Manual is a guide only.

IT IS IMPERATIVE TO REFER TO THE ENGINEERING PLANS SUPPLIED WITH THIS MANUAL FOR

SPECIFICATIONS AND DETAILS TO ALL THE CHAPTERS IN THIS MANUAL.

Due to the large range of sizes and styles available, it is not possible to prepare an instruction

manual for all styles, sizes and models.

The following instruction manual is an EXAMPLE of a 6m wide x 6m long Awning Carport.

Things to do before you commence construction

a. It is recommended to obtain professional advice to ensure your needs are adequately met.

b. Check with your local government of any approval or restriction requirements. It is your

responsibility to ensure that all approvals required are obtained.

Safety Advice – Important

DISCLAIMER: This is a general safety advice. Refer to relevant state workplace authority website

www.safeworkaustralia.gov.au for safety advice on specific items and OH&S safety requirements.

NOTE: Do not rely on this guide as exhaustive of all hazards that may exist on a construction site.

Construction hazards must be assessed for risk and controls put in place to reduce the risk identified

before commencing work.

CHECK AND ENSURE THAT YOUR COMPONENTS ON SITE ARE CORRECT AND COMPLETE AS

PER THE BILL OF MATERIALS. IF IN DOUBT, PLEASE CONTACT YOUR SUPPLIER.

3


April 2019

4


April 2019

Components

Step 1 – Marking out the Perimeter of the Carport Mark and set-out the perimeter of the Carport with pegs and strings. In this example, the size of the

carport is 6.0m wide x 6.0m long. The FRAME length dimension reference is from outer face to

outer face of the Rafters. The FRAME width (span) dimension reference is from outer face of Eave

Purlin to outer face of Attachment Beam. Refer to Engineering Plans for the actual size and

specifications of your specific job.

Step 2a – Footing Set-Out for Concrete Block Pad Footing Mark and set-out the location of concrete pad footings to be excavated. The centre line of the posts

is equivalent to the centre line of the block or bored footings. Using the string set-out perimeter as a

guide, the outer edge of the post is set in on the low (gutter) end by the flange width of the Eave

Purlin. To determine the centreline of the post, add 1/2 of the post size to the flange width of the

Eave Purlin.

Example specific to this job:

C150 Eave Purlin has a 64mm flange width so the outer edge of the post is set in by 64mm from the

string set-out. The post size is 75mm x 75mm so half of 75mm is 37.5mm. The centreline of the post

set-in from the string set-out is 64mm + 37.5mm.

The length of the carport is from outer faces of the C Purlin rafters (outside of frame to outside of

frame). The webs of the rafters are attached directly to the outer face of the post.

5


April 2019

The centre line of the posts is equivalent to the centre line of the block footings set-out as shown in

Diagram Ab.

Refer to the Engineering Plans for size and specifications of the concrete block footing. Dig out and

pour concrete block footings.

Step 2b – Marking out the Perimeter of the Carport with Slab

Mark and set-out the edges of the concrete slab to be excavated. On the sidewall, the edge of the

slab is equivalent to the string set-out of the building perimeter plus 100mm slab extension on each

side, thereby adding a total of 200mm to the length of the Carport.

On the endwall, the edge of the slab is equivalent to the string set-out of the building perimeter plus

100mm slab extension to the low end only, thereby adding a total of 100mm to the width (span) of

the Carport.

Refer to Engineering Plans for the actual size and specifications of your specific job.

6


April 2019

As a guide, outer edge of the post is set in on the sidewall by the flange width of the Rafter plus the

100mm slab extension.

To determine the centreline of the post, add 1/2 of the post size and flange width of the Rafter and

100mm slab extension.

Example specific to this job:

SHS post size is 75mm x 75mm so half of 75mm is 37.5mm. The C150 Rafter has a flange width of

64mm. The slab extension is 100mm, therefore, the centreline of the post is 37.5 + 64mm +100mm

from the edge of the concrete slab set-out.

7


April 2019

Step 3 – Preparation of Carport Posts Check levels of footings and concrete slab and if required, cut posts accordingly to suit the building

height requirements as the posts are supplied in stock lengths.

Set-out and bore two holes at the top of the carport posts to match the punching (holes) detail of

the C-Purlin Rafters. Refer to the Engineering Plans for the hole specifications. Punching distance

specifications vary according to the size of the C-Purlin Rafter. A table below is provided for

reference. The Rafter is to be bolted to the top of the post on an angle based on the roof pitch. Refer

to the Engineering Plans for bolt size and specifications.

Set-out and bore two holes at the bottom of the carport post, punching details to be the same as the

top of the post. Holes at bottom of post are only required if posts are to be bolted to the post sleeve

on base plate fixed to concrete footing or slab. Refer to Diagram B.

TIP: If Post is to be embedded, angle bracket at the base of the post with 2 tek screws is to be fixed

in lieu of the bolt holes. Refer to Diagram C. You may stand the plumb post into the excavated

holes and pour concrete at this stage, where possible, keep the concrete above ground height and

taper the concrete away from the base of the post to prevent water pooling around the embedded

SHS OR bolt the eave purlin to the posts before standing the posts.

8


April 2019

Step 4a – Post Sleeve on Base Plate Set-out on Footing only Using the string set-out marking the perimeter of the building as a guide, mark the position of the

Post Sleeve on base plate. The Post Sleeve is inserted to the bottom of the post. Refer to Step 2a for

the Post set-out.

The length of the carport is from outer face of Rafter to outer face of the other Rafter.

The centre line of the posts is equivalent to the centre line of the Post Sleeve and block footings as

shown in Diagram Da.

Fix the Post Sleeve on Base Plate to the concrete footing with fastening type as per the Engineering

Plans.

9


April 2019

Step 4b – Post Sleeve on Base Plate Set-out on Slab Using the string set-out marking the perimeter of the building on the slab as a guide, mark the

position of the Post Sleeve on base plate. The Post Sleeve is inserted to the bottom of the post. Refer

to Step 2b for the Post set-out.

TIP: Check diagonal measurements on the slab for square set-out against existing structure.

The length of the carport is from outer face of Rafter to outer face of the other Rafter.

Slab on the lower end (gutter/endwall) with 3 posts is extended by 100mm from the outer face of

the Eave Purlin to allow for a 4-hole base plate connection to the slab.

Slab on the length (sidewall) is extended by 100mm from each of the outer face of the Rafter to

allow for a 4-hole base plate connection to the slab. Refer Diagram Db for reference.

10


April 2019

Step 5 – Preparation of End & Intermediate Rafters On the End Rafter, set-out and attach the angle bracket with frame bolts OR tek screw as required.

This bracket will be fitted to the web of Rafter and web of Purlin. Refer to Diagram Ea for reference

of the type of bracket to be used for Tek Screw Frame and Bolted Frame options. Refer to the

Engineering Plans for specific fastening requirements.

On the Intermediate Rafter, set-out and attach the angle bracket with frame bolts OR tek screw as

required. This bracket will be fitted to the web of Rafter and web of Purlin. Refer to Diagram Eb for

reference of the type of bracket to be used for Tek Screw Frame and Bolted Frame options. Refer to

the Engineering Plans for specific fastening requirements.

11


April 2019

Step 6 – Post, Rafter, Purlin and Existing Structure Assembly

Install the Awning Attachment Bracket to the existing structure. Install the Attachment Beam to the

bracket.

Stand post in footing holes if embedded or insert the post over the Post Sleeve with base plate if on

slab. Adjust and plumb the post as required.

Bolt the Rafter directly to the Post temporarily with the framing bolts supplied, one per column.

Attach the Rafter to the Attachment Beam with the specified type of angle bracket. Refer to the

Engineering Plans for fastening and bracket specifications.

The fastenings for this endwall frame can now be completed and permanently tightened.

Refer Diagram F. Repeat this process to erect the other Rafters.

12


April 2019

Step 7 – Fixing of Eave Purlin Attach the Eave Purlin to the front posts. Refer to Engineering Plans for Splice plate if required.

For Rafter, Post, Eave Purlin and Attachment Beam Plan View set-out, Refer Diagram H.

13


April 2019

Step 8 – Fixing of Roof Purlins Bolt the Roof Purlin on the web to the pre-fitted General Purpose Bracket (GPB) for Bolted Frame or

Tek Screw the Roof Purlin on the web to the pre-fitted Purlin Connection Bracket (PCB) for Tek Screw

Frame whichever is applicable to the job. Refer to the Engineering Plans for the Fastening

specifications required. The Eave Purlin on the low end and the Attachment Beam on the high end

have the open sides of the C-Purlin face out. Refer to Step 12 “Connection Layout” 3D View.

Step 9 – Plumb the Posts

Plumb the front posts on one side and temporarily brace it into position. Fit the second bolt to the

pre-drilled hole.

Step 10 – Fix Base Plate Permanently Drill and fit masonry fixings to the Post Sleeve on base plates that have been plumbed OR set

concrete into the footing hole for embedment whichever is applicable. Refer to the Engineering

Plans for the Footing specifications required.

14


April 2019

Step 11 – Carport Frame to be Square Check diagonal measurements for square set-out of the frame against the existing structure. Prop

the side that is not fixed into position. Refer Diagram K.

TIP: Another option to use to check that the diagonals are equal is to calculate using this formula.

Diagonal = square root (length2 + width2).

Step 12 – Complete Fixing of the Frame On the side that is on props, fix the remaining two posts to the Rafter. Plumb the posts then either

bolt to the post sleeve with base plate or concrete them into position whichever is required. Ensure

the rafters are on the correct roof pitch angle. Fit and permanently fix the long bolts supplied

through to the post sleeve inside the base of the posts.

TIP: If posts are embedded into concrete footings, it is recommended to wait for a few hours until

the concrete is set.

15


April 2019

Step 13 – Gusset Plate Knee Brace Gusset Plate knee brace are to be fitted in 2 different directions after the frame is checked for

square and adjusted if required. The gusset plates are to be fitted along the endwall between the

flange of the Posts and the web of the Rafter, Refer Diagram M. On the opposite direction along

the sidewall, the gusset plates are to be fitted between the flange of the Posts and the web of the

Eave Purlin. Refer Diagram N. Gusset Plate may need to be notched as required. Refer Diagram P.

NOTE: Triangular carport knee braces (Gusset Plate) run in two directions, along the sidewall

between the Post and the Eave Purlin and along the endwall between the Post and Rafter. Refer to

Step 13 for detailed instructions of the Gusset Plate.

NOTE: Mid posts on longer carports have the gusset plate fitted between the web of the eave

purlin and the flange of the mid post on 2 sides of the post. If fitted at this stage, the corner of the

gusset plate will need to be notched 20mm both sides to allow for easy fitting. Refer Diagram P.

16


April 2019

17


April 2019

Step 14 – Fit Roof Sheeting Lay the first sheet in position to flush with the outside face of the rafter on the high end. Ensure that

the female rib of the roof sheeting faces away from the prevailing winds. Refer Overlap Detail. Fix

the roof sheeting and allow approximately half the gutter width or 50mm (whichever is lesser) to

overhang into the gutter. This edge of the rafter should be pan fixed using 10-16 wall screws to aid in

the fitting of barge capping. Refer Diagram R. If the frame is square, the first sheet should now be

flushed along the length of the rafter. All other sheets may now be fixed at crest with the number of

screws per sheet at supports specified on the Engineering Plans. Refer Roof Sheeting Profile

(example only). Ensure that roofing sheets are turned up at the high end to prevent water running

off this end.

18


April 2019

Step 15 – Fit Gutters and Flashings Remove plastic cover protecting gutters and flashings before they are fitted.

a) Fit the cover flashing to the gutter end of the roof

b) Fit the stop ends and nozzle to the guttering and seal with silicone sealant on the inside.

c) Fit gutter brackets to the cover flashing with self-drilling gutter bracket screws or pop rivets.

Ensure the brackets are fitted with a string line to the required fall location and ensure that

there is adequate fall.

d) Fit the gutter to the installed brackets.

e) Fit side and head barge flashing and ensure that the bottom edge of the flashing is fixed to

the bottom lip of the C-Purlin with pop rivets.

f) Ensure all swarf are swept from the roof, flashings and guttering.

Step 16 – Cut and fit downpipes

Cut and fit the downpipes to the drainage system.

Step 17 – Finish Remove any temporary bracing and check that all the required bolts and tek screws are fitted and

tightened.

BRUSH COMPLETE CARPORT DOWN WITH A SOFT BROOM TO REMOVE ANY METAL

DUST/FILINGS CAUSED BY ANGLE GRINDER.

CONGRATULATIONS ON A JOB WELL DONE!

awning carport (attached) recommended instruction manual...

Documents