FLAT ROOF CARPORT RECOMMENDED INSTRUCTION MANUAL

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1 FLAT ROOF CARPORT RECOMMENDED INSTRUCTION MANUAL

2 Table of Contents Introduction... 2 Components... 3 Step 1 Marking out the Perimeter of the Carport... 3 Step 2a Footing Set-Out for Concrete Block Pad Footing... 3 Step 2b Footing Set-Out for Concrete Slab... 4 Step 3 Preparation of Carport Posts... 5 Step 4 Post Sleeve on Base Plate Set-out... 6 Step 5 Preparation of Rafters... 7 Step 6 Assemble and Stand the Carport Post and the Rafter... 8 Step 7 Fixing of the Beam... 9 Step 8 Fixing of Roof Purlins... 9 Step 9 Plumb the Posts... 9 Step 10 Fix Base Plate Permanently... 9 Step 11 Carport Frame to be Square Step 12 Complete Fixing of the Frame Step 13 Gusset Plate Knee Brace Step 14 Fit Roof Sheeting Step 15 Fit Gutters and Flashings Step 16 Cut and fit downpipes Step 17 Finish

3 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 Flat Roof 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 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. 2

4 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. 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 pad footings. Using the string set-out of the perimeter as a guide, edge of the post is set in on the sidewall by the flange width of the Rafter. To determine the centreline of the post, add 1/2 of the post size to the flange width of the Rafter. Example: C150 Rafter has a 64mm flange width so the 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 is 64mm set in from the string set-out. The posts are set in on the endwall by 1300mm to centre line of posts as shown in Diagram Ab. Ensure that the diagonal measurements of the pad footings are equal, level and square. Refer to the Engineering Plans for size and specifications of the concrete pad footing. Dig out and pour concrete pad footings. 3

5 Step 2b Footing Set-Out for Concrete Slab Mark and set-out the edges of the concrete slab to be excavated. The edge of the slab is equivalent to the string set-out of the perimeter and using it as a guide, edge of the post is set in on the sidewall by the flange width of the Rafter. To determine the centreline of the post, add 1/2 of the post size to the flange width of the Rafter. Example: C150 Rafter has a 64mm flange width so the 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 is 64mm in from the concrete slab set-out. The posts are in on the endwall by 1300mm to centre line of posts as shown in Diagram As. Ensure that the diagonal measurements of the concrete slab are equal, level and square. Refer to the Engineering Plans for size and specifications of the concrete slab. TIP: Pegs and strings marking the perimeter of the building to be left in place until the position of base plates are clearly marked. 4

6 Step 3 Preparation of Carport Posts Check levels of footings 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 holes specifications. Size of holes and punching details vary according to the size of the C-Purlin Rafter. A table below is provided for the C-Purlin punching details 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. 5

7 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 or go to Step 5 to bolt the eave purlin to the posts before standing the posts. Step 4 Post Sleeve on Base Plate Set-out Using the set-out string marking the perimeter of the building as a guide, mark the position of the post sleeve on base plate. The post sleeve which is inserted to the bottom of the post is in on the sidewall by the flange width of the edge beam plus 1/2 of the post size and is in on the endwall by 1300mm from edge to centre line as shown in Diagram D. Fix the post sleeve on base plate to the concrete footing with fastening type as per the Engineering Plans. TIP: The centre line of post is equivalent to the centre line of post sleeve on base plate. NOTE: The post sleeve on base plate comes in 2-hole or 4-hole depending on the size and the requirements of the carport. Refer to the Engineering Plans for the specifications of the post sleeve. 6

8 Step 5 Preparation of Rafters On the outer web side of the Rafters, set-out and attach the shorter leg of the angle cleat bracket with 2 frame bolts. This bracket will be fitted inside the web of the beam. Refer to Diagram E. NOTE: Triangular carport knee braces run in two directions, along the sidewall between the rafter and the post and along the endwall between the beam and the post. Refer to Step 13 for detailed instructions of the Gusset Plate. 7

9 Step 6 Assemble and Stand the Carport Post and the Rafter Bolt the Rafter to the carport posts temporarily with the framing bolts supplied, one per column. Stand post in footing holes if embedded or insert the post over the post sleeve with base plate if not embedded. Refer to the Engineering Plans for specific footing requirements. Plumb the post and hold in place with 2 frame screws through the rafter into the post. Adjust and plumb the post as required. The bolts for this sidewall frame can now be completed and permanently tightened. Refer Diagram F. Repeat this process to erect the other Rafter. 8

10 Step 7 Fixing of the Beam Place the beam in position on the side of the front posts and bolt temporarily into the angle cleat attached to the rafter. Refer Diagram H. Repeat this step at the rear pair of posts. Step 8 Fixing of Roof Purlins Fit and bolt the general purpose bracket to the inner web face of the Roof purlins and the outer web of the Rafter. The beams at the low and high ends have the open side of the C-Purlin face out. Refer to Step 12 3D View. Step 9 Plumb the Posts Plumb the front posts on one side and temporarily brace it into position. Drill the remaining top hole and fit the second bolt. Plumb the rear post on the same side and fit the remaining bolt through the rafter. Step 10 Fix Base Plate Permanently Drill and fit masonry fixings to the base plates with post sleeve for posts that have been plumbed if base plate is required OR set concrete into the footing hole if embedment is required. 9

11 Step 11 Carport Frame to be Square Ensure the diagonals shown dotted are equal and 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 (length 2 + width 2 ). 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 10

12 the concrete is set before starting on the roofing sheets. Step 13 Gusset Plate Knee Brace Gusset Plate knee brace are to be fitted in 2 different directions, along the sidewall between the outer flange of the end posts and the web of the rafter on 1 side only, Refer Diagram M. The endwall will have the gusset plate between the inner flange of the end posts and the web of the beams. Refer Diagram N. NOTE: Mid posts on longer carports have the gusset plate fitted between the web of the rafter and the outer 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. 11

13 12

14 Step 14 Fit Roof Sheeting Lay the first sheet in position and ensure that the roof sheet is flush with the outside face of the rafter on the high end. This edge of the rafter should be pan fixed using wall screws to aid in the fitting of barge capping. 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. Ensure that roofing sheets are turned up at the high end to prevent water running off this end. 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 c) Fit gutter brackets to the cover flashing with pop rivets. Ensure the brackets are fitted with a string line to the required fall location. d) Fit the gutter brackets into the gutter 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. 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! 13

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