ALUMA-VENT AWNING REGULAR END STYLE INSTALLATION INSTRUCTIONS Contact us at: 1-888-442-2928 or www.americana.com Options in your kit: A. Splice Pg 16 B. Column Pg 17 C. C-Channel Brace Pg 19 D. Runner Brace Pg 21 E. Kicker Brace Pg 23 F. Extended Ends Pg 24 G. Flat Ends Pg 25 Before You Begin: Consult your local building department for any required permits You may be required to obtain a building permit for this structure. Contact your local building department for details. Read instructions thoroughly Please read all instructions and notes carefully prior to assembly. Americana is not responsible for replacing parts lost or damaged due to incorrect assembly. A solid attachment is required for all existing structures All points of attachment to existing structures (such as house, deck, or patio) must be into solid, structurally sound, and secure material. Example: wood or metal studs, joists, headers, plates, or sills. Attachment may be made to block, concrete, brick, or stone veneer with suitable anchors, purchased separately. Note: Failure to properly fasten unit to wall, deck, porch, or patio may result in damage to the unit, damage to the structure it is attached to, and could cause serious bodily injury. Check for all parts Use the Parts and Hardware List to check for any missing parts. To prevent scratching of painted materials, place on a tarp or other protective material. Assistance may be required during certain steps of assembly. CAUTION Proper site preparation is required. Standard shade structure design does not include additional loads such as hanging heavy plants, swings, or other objects. DO NOT stand or sit on the shade structure roof. Repair or replace broken parts immediately. This kit contains parts with metal edges. Please be careful when handling. Americana Building Products. 1 10/29/2013
Tools Needed for Installation Safety Glasses Socket / Hex Head Driver Sizes: 1/4, 11/32, 3/8 Drill Bit Sizes: 1/8, 5/16 Tape Measure Electric Drill Screw Driver Flat & Phillips Carpenters Level Ladder Other Required Tools: Gloves, Chalk Line, Silicone Caulking Recommended Tools: Rubber Mallet, Carpenters Square, Pliers, Tin Snips Required Parts Not Included In Kit: Appropriate anchors or lag screws to attach awning to your home s exterior finish, 3/16 diameter. Installation Notes and Tips Complete site preparation before beginning assembly. DO NOT attempt to assemble on a day with strong winds. Have assistance nearby to lift and secure parts in place. It is recommended to lower the speed of electric drills during this installation. Installing Tek screws at a high RPM may cause the Tek screws to become damaged or break during installation. Avoid over-driving, under-driving, or driving at an angle to properly install fasteners. Over-driven fasteners can depress the material and allow water to collect around the fastener, which will corrode the surface finish. Under-driven fasteners can cause leaks and may back out over time. CORRECT TOO LOOSE TOO TIGHT We strongly recommend using a high grade sealant, such as our 100% silicone caulk and sealant. Caulking should be applied uniformly and without skips. A poor caulking job can cause leaks. Note: These are basic installation guidelines for our standard load units and may not be suitable to your specific installation. It is important to follow all local and national building codes when installing any exterior improvement product. If you have questions regarding the proper installation of any Americana product, please call us toll free at 1-888-442-2928 and ask for assistance. Americana Building Products. 2 10/29/2013
NOTE: Length and quantity of parts will vary based on the size of the awning. Parts List A Rafter Part Code: 60506 B Sawtooth Part Code: 60507 C Runner Part Code: 10459 D Apron Bar Part Code: 60502 E Flashing Part Code: 10459 F Clip Part Code: 60505 G Wall Bracket Part Code: 60504 H Louvers Part Code: 10417 I Bottom Pan Part Code: 10417 J Top Pan Part Code: 10417 K End Pan (RH Shown) Part Code: 10417 Americana Building Products. 3 Aluma-Vent Installation Guide
Screws shown actual size. Hardware List AA #8 x 3/4 Screw Part Code: 20121 BB #8 x 1/2 Bolt Part Code: 20754 CC #8 Hex Nut Part Code: 20502 DD #14 x 3/4 Screw Part Code: 20792 NOTE: Length and quantity of parts will vary based on the size of the awning. Optional Coordinating Parts and Hardware L Flashing Splice Part Code: 10457 M Runner Splice Part Code: 60515 N C-Channel Brace Part Code: 30151 O C-Channel Wall Bracket Part Code: 60515 P Upper Column Bracket Q Column Mounting Bracket Part Code: 50131 EE 1/4 x 2-1/2 Bolt Part Code: 20406 S Kicker Brace Part Code: 6081X (varies by length) R Column Part Code: 60722 FF 1/4 x 3/4 Bolt Part Code: 20751 GG 1/4 Square Nut Part Code: 20503 HH 1/4 Flat Washer Part Code: 20902 II 1/4 x 1-3/4 Tapcon Anchor Part Code: 20794 Americana Building Products. 4 Aluma-Vent Installation Guide
STEP 1 In some cases, rafter (A) and sawtooth (B) are not pre-assembled. If this happens, position rafter (A) so the curl rests on top of sawtooth (B) and the front ends are flush. Attach using a #8 x 3/4 screw (AA) through the pre-drilled hole in sawtooth (B). 1A FRONT VIEW Open the right-hand rafter (A) and sawtooth (B) assembly to approximately the desired slope of the awning. 1B Americana Building Products. 5 Aluma-Vent Installation Guide
STEP 2 Attach wall bracket (G) to sawtooth (B) using (2) #8 x 3/4 screws (AA) through the pre-drilled holes. DO NOT completely tighten screws at this time. 2 NOTE: If you ordered the optional flat style louver ends, see Optional Sheet G. STEP 3 Select the right-hand set of louvers (H). Lay each one on a flat surface and make a horizontal bend even with the notch at the top end. Bend at approximately a 90 degree angle. 3 Americana Building Products. 6 Aluma-Vent Installation Guide
STEP 4 Insert the curl of the shortest louver (H) into the curled channel of rafter (A) over the first tab from the front on sawtooth (B). Align the holes in louver (H) with the holes in sawtooth (B) by raising or lowering rafter (A). If necessary, also change the bend on louver (H). Attach using (2) #8 x 3/4 screws (AA). 4 TIP: Install screw (AA) in the back hole of louver (H) first, then use the leverage of sawtooth (B) and rafter (A) to align the front hole. FRONT VIEW STEP 5 Repeat step 4 to complete the right end louver assembly, beginning with the longest louver (H) and working down. On awnings with extended ends, begin with the louver closest to the back end of rafter (A). Sawtooth (B) will have extra tabs for the extension louvers. Be sure not to attach the last louver to an extension tab. 5 NOTE: If you ordered extended louver ends, see Optional Sheet F. Americana Building Products. 7 Aluma-Vent Installation Guide
STEP 6 Select the right-hand end pan (K) by checking the sticker at the top of the pan. Attach to the right-hand louver (H) assembly using #8 x 3/4 screws (AA). Line up the pre-drilled holes in end pan (K) with the pre-drilled holes in rafter (A). 6 Look for sticker at top of pan. STEP 7 Bend the valance of end pan (K) and attach to louver (H) using #8 x 3/4 screws (AA) through the pre-drilled holes. This completes the right-hand end assembly. Repeat steps 1-7 to complete the left-hand end assembly. 7 Americana Building Products. 8 Aluma-Vent Installation Guide
STEP 8 Attach runners (C) to the left- and right-hand end assemblies using #14 x 3/4 screws (DD) through the pre-drilled holes in rafter (A). 8 STEP 9 Select flashing (E) and attach to end pans (K) using #8 x 1/2 bolt (BB) and #8 hex nut (CC) through the pre-drilled holes. 9 Americana Building Products. 9 Aluma-Vent Installation Guide
STEP 10 At this point, the awning may be lifted up and attached to the mounting surface. Anchors are not supplied with this kit. 3/16 diameter anchors suitable for your mounting surface are required. 10 NOTE: Awning must be attached to a solid structural support. DO NOT attach awning to sheathing, siding, flashing, or any other non-structural surface. While using a level to keep flashing (E) plumb, attach to the mounting surface through the pre-drilled holes. Pre-drill a pilot hole into the mounting surface using a 1/8 drill bit before attaching anchors. STEP 11 With only the top of the awning attached to the mounting surface, use a level to plumb sawtooth (B) and louvers (H). Looking at the side of the awning, the louvers should be parallel to the mounting surface. Looking at the front of the awning, the louvers should appear straight up and down. 11 With the awning properly aligned, attach mounting bracket (G) to the mounting surface using 3/16 diameter anchor, purchased separately. Then be sure to tighten the #8 x 3/4 screws (AA) attached to mounting bracket (G). Pre-drill a pilot hole into the mounting surface using a 1/8 drill bit before attaching anchors. TIP: Align and attach one end of the awning before moving to the other side to avoid either side falling out of alignment. Once the awning is attached, if you need to move runner (C) to avoid an out-swinging door or window, remove #14 x 3/4 screws (DD), re-position the runner, then re-attach screws. Americana Building Products. 10 Aluma-Vent Installation Guide
STEP 12 Select the bottom pans (I). Lay each one on a flat surface and make a horizontal bend even with the notch at the bottom end. Bend to approximately a 90 degree angle. 12 STEP 13 Attach bottom pans (I) to flashing (E) using #8 x 1/2 bolt (BB) and #8 hex nut (CC). 13 Americana Building Products. 11 Aluma-Vent Installation Guide
STEP 14 Select apron bar (D). Using a flat head screw driver, pry up each hook so there is approximately 1/8 gap. This will make it easier to attach top pan (J) in later steps. 14 STEP 15 Position apron bar (D) behind end pans (K) and bottom pans (I). Fit the hooks of apron bar (D) through the rectangular holes of the pans. Bend the valance of bottom pans (I) forward as necessary. Attach apron bar (D) to end pans (K) using #8 x 3/4 screw (AA) next to the rectangular holes. 15 NOTE: Apron bar hook MUST fit through each hole for proper alignment of pans. Americana Building Products. 12 Aluma-Vent Installation Guide
STEP 16 Attach clip (F) to runner (C) between two pans. Hook clip (F) over one side of runner (C), being sure the retainers are over the lip of both pans. Compress the top of runner (C) until you can snap clip (F) over the other side. 16 Start from both ends and alternate, working towards the center of the awning. Install all clips (F) on the lower runner (C) before installing on the upper runner. If necessary, lightly tap bottom pan (I) to keep the hooks of apron bar (D) inside the rectangular holes. This MUST be done to maintain proper spacing of the pans. 2 1 STEP 17 SIDE VIEW Hook one side of top pan (J) over the large cover locks of clips (F). Press down on the other side to snap the locks together. 17 FRONT VIEW Americana Building Products. 13 Aluma-Vent Installation Guide
STEP 18 Bend the valance of top pan (J) and snap to the hooks on apron bar (D). Repeat steps 17-18 for all remaining top pans (J). 18 BOTTOM VIEW Once all top pans (J) are installed, apply a continuous bead of caulk along the top of flashing (E). Caulking should be applied uniformly and without skips. A poor caulking job can cause leaks. Assembly Completed Other Products Available From Americana: Fabric & Aluminum Awnings - Carports - Patio Covers - Pergolas - Room Enclosures - Park Shelters Americana Building Products. 14 Aluma-Vent Installation Guide
Care and Maintenance Every 12 months your shade structure should be inspected and maintained by: Tightening loose nuts and bolts at all connections. Repairing damage to the finish to prevent corrosion. Replacing lost or damaged fasteners, brackets, and other parts. Replacing brittle or cracked sealer to prevent leaks. Removing obstructions and miscellaneous build-up from gutters, eaves, and downspouts. Warranty What the Warranty Covers: Americana Building Products (Americana) warrants its products that have been installed in accordance with the installation guidelines, under normal usage conditions, and with proper maintenance as follows: Ten (10) year warranty against peeling, cracking, blistering, or crazing of the surface finish of aluminum components. One (1) year warranty against defects in materials and workmanship. Period of Coverage: The warranty period begins on the date of original shipment. What Americana Will Do To Correct Problems: If defects or damage of the kind mentioned above should occur within the warranty period, Americana will replace the defective parts only; FOB its plant at Salem, Illinois, upon receiving the written and documented claim of purchaser. What the Warranty Excludes: Because of normal aging and weathering of materials, it may not be possible to perfectly match the colors of original parts and replacement parts. Americana will not provide or pay for the installation of such replacement parts. Americana shall not be responsible for weather related failures, damages due to faulty installation, misuse or abuse of the product, or for consequential damages, including personal injuries or property damages. There are no warranties, express or implied, which extend beyond the description on the face hereof. How Do You Get Service: If you believe that you have a claim under this warranty, submit a copy of your original receipt or other reasonable evidence of the date of purchase, the identity of the product, and photos and a description of the allegedly defective product to the address below. Please also include your name, address, and phone number so that a customer service representative can respond to your submission. Ultimate determination of the existence and extent of any claimed defect under this warranty shall be made by Americana in its sole discretion. Submit Claims To: Americana Building Products, Inc Warranty Claim, P.O. Box 1290, Salem, IL, 62881 Americana Building Products. 15 9/28/2012
OPTIONAL SPLICE ASSEMBLY Longer awnings may require certain parts to be sent in more than one piece. If this happens, follow the steps below to splice the parts before beginning assembly. STEP A1 To splice flashing (E), first apply an ample amount of caulk to the back of the provided splice (L). Position the splice equally inside two pieces of flashing and attach using (4) #8 x 3/4 screws (AA). A1 SIDE VIEW STEP A2 To splice runner (C), position the provided splice (M) equally inside two pieces of runner. Attach using (12) #8 x 3/4 screws (AA) as shown. A2 SIDE VIEW Americana Building Products. Optional Sheet A - Page 16 Aluma-Vent Installation Guide
OPTIONAL COLUMN INSTALLATION Complete these steps after Step 11 of the standard instructions. STEP B1 Measure the distance from the bottom of the front runner (C) to the top of the mounting surface. Trim column (R) to the required length. NOTE: When measuring for column height, take into account the added height of brackets (P) and (Q). The brackets will add approximately 3/8 to the overall column height when installed. B1 STEP B2 Insert upper column bracket (P) and (2) column mounting brackets (Q) in the legs of column (R), tapping with a rubber mallet if necessary. Attach the brackets using #8 x 3/4 screws (AA). B2 Americana Building Products. Optional Sheet B - Page 17 Aluma-Vent Installation Guide
STEP B3 Position column (R) under the front runner (C). While using a level to keep the column plumb, attach upper column bracket (P) to the runner using (2) #14 x 3/4 screws (DD). B3 STEP B4 While using a level to keep column (R) plumb, attach each column mounting bracket (Q) to the mounting surface using (2) 1/4 x 1-3/4 Tapcon concrete anchors (II) per bracket. Pre-drill a pilot hole into the mounting surface using a 1/8 drill bit. NOTE: If attaching to wood or composite deck, appropriate lag screws are required, purchased separately. DO NOT use Tapcon anchors to attach to wood or composite surface. B4 Americana Building Products. Optional Sheet B - Page 18 Aluma-Vent Installation Guide
OPTIONAL C-CHANNEL BRACE INSTALLATION C-channel braces are required on awnings with a projection greater than 78. A column or post is required to install a C-channel brace. Complete these steps after column installation. STEP C1 Position C-channel brace (N) against the bottom of runners (C) and the side of column (R). The back end of the brace should reach the mounting surface. Attach C-channel brace (N) to each runner (C) using #14 x 3/4 screws (DD). C1 FRONT VIEW STEP C2 Using a 5/16 drill bit, drill (2) holes through C-channel brace (N) and one leg of column (R) approximately 2 apart centered in the C-channel brace. Attach the brace to the column using (2) 1/4 x 2-1/2 bolts (EE), 1/4 flat washers (HH), and 1/4 square nuts (GG). C2 SIDE VIEW Americana Building Products. Optional Sheet C - Page 19 Aluma-Vent Installation Guide
STEP C3 Mark (2) holes approximately 1-1/2 apart centered one side of C-channel bracket (O). Drill the holes using a 5/16 drill bit. Position the C-channel bracket (O) against the mounting surface and C-channel brace (N). Mark and drill the same hole pattern through the side of C-channel brace (N). Attach the bracket to the brace using (2) 1/4 x 3/4 bolts (FF) and 1/4 square nuts (GG). C3 Depending on the drop of your awning, the brace may be cut at the wall to the proper angle. OPTIONAL FIELD CUT STEP C4 Attach C-channel bracket (O) to the mounting surface using (2) 1/4 diameter anchors suitable for your mounting surface. Pre-drill a pilot hole into the mounting surface using a 1/8 drill bit. NOTE: Awning must be attached to a solid structural support. DO NOT attach awning to sheathing, siding, flashing, or any other non-structural surface. C4 Americana Building Products. Optional Sheet C - Page 20 Aluma-Vent Installation Guide
OPTIONAL RUNNER BRACE INSTALLATION If you received any additional braces, follow the steps below after Step 11 of the standard instructions. Awnings with a projection between 57-71 require the runner brace. STEP D1 A runner brace consists of two extra pieces of runner (C). Typically, one piece is longer than the other. Position the longer piece of the runner brace against the bottom of runners (C). The back end of the brace should reach the mounting surface. Attach the brace to each runner (C) using #8 x 3/4 screws (AA). D1 STEP D2 Position wall bracket (G) against the brace and the mounting surface. Attach the bracket to the brace using (2) #8 x 3/4 screws (AA). Attach mounting bracket (G) to the mounting surface using 3/16 diameter anchor, purchased separately. Pre-drill a pilot hole into the mounting surface using a 1/8 drill bit. NOTE: Awning must be attached to a solid structural support. DO NOT attach awning to sheathing, siding, flashing, or any other non-structural surface. D2 Americana Building Products. Optional Sheet D - Page 21 Aluma-Vent Installation Guide
STEP D3 Position the remaining piece of runner brace (C) over the other, going back horizontally to the mounting surface. Attach the two pieces of runner brace (C) using (2) #8 x 3/4 screws (AA). D3 STEP D4 Position wall bracket (G) against the brace and the mounting surface. Attach the bracket to the brace using (2) #8 x 3/4 screws (AA). Attach mounting bracket (G) to the mounting surface using 3/16 diameter anchor, purchased separately. Pre-drill a pilot hole into the mounting surface using a 1/8 drill bit. NOTE: Awning must be attached to a solid structural support. DO NOT attach awning to sheathing, siding, flashing, or any other nonstructural surface. D4 Americana Building Products. Optional Sheet D - Page 22 Aluma-Vent Installation Guide
OPTIONAL KICKER BRACE INSTALLATION If you received any additional braces, follow the steps below after Step 11 of the standard instructions. Awnings with a projection between 36-50 require the kicker brace. STEP E1 Position kicker brace (S) so the flat, formed end is against the bottom of runner (C) and the pre-attached bracket reaches the mounting surface. Attach kicker brace (S) to runner (C) using #8 x 3/4 screw (AA). E1 SIDE VIEW STEP E2 Attach kicker brace (S) bracket to the mounting surface using 3/16 diameter anchor, purchased separately. Pre-drill a pilot hole into the mounting surface using a 1/8 drill bit. NOTE: Awning must be attached to a solid structural support. DO NOT attach awning to sheathing, siding, flashing, or any other non-structural surface. E2 Americana Building Products. Optional Sheet E - Page 23 Aluma-Vent Installation Guide
OPTIONAL EXTENDED ENDS ASSEMBLY When mounting an awning to an overhang, sawtooth (B) will be furnished with extra tabs and extra louvers (H) will be provided. Attach sawtooth (B) to the mounting surface as shown in Step 11 of the standard instructions, then complete the steps below. STEP F1 Measure the distance from the center of the holes in the tabs of sawtooth (B) to the bottom of the overhang. Add 1 to this measurement and cut the extension louvers (H) to the required height, measuring from the center of the holes. F1 STEP F2 Lay the extension louvers (H) on a flat surface and bend a 1 tab at the top. Attach extension louvers (H) to sawtooth (B) using (2) #8 x 3/4 screws (AA), as done in Steps 4-5 of the standard instructions. Attach the 1 tab to the overhang using appropriate lag screw or anchor. F2 Repeat steps for all extension louvers. Americana Building Products. Optional Sheet F - Page 24 Aluma-Vent Installation Guide
OPTIONAL FLAT ENDS ASSEMBLY If you ordered the optional flat style louver ends, complete the steps below after Step 2 of the standard instructions. Sawtooth (B) will not have the tabs as shown in the Parts List. STEP G1 Insert the curl of the shortest louver (H) into the curled channel of rafter (A) over the first set of holes from the front of sawtooth (B). Align the holes in louver (H) with the holes in sawtooth (B) by raising or lowering rafter (A). Attach using (2) #8 x 3/4 screws (AA). G1 TIP: Install screw (AA) in the back hole of louver (H) first, then use the leverage of sawtooth (B) and rafter (A) to align the front hole. SAWTOOTH FRONT VIEW STEP G2 Repeat step G1 to complete the right end louver assembly, beginning with the longest louver (H) and working down. G2 Repeat steps G1 and G2 to complete the left end louver assembly. Continue with Step 6 of the standard instructions. Americana Building Products. Optional Sheet G - Page 25 Aluma-Vent Installation Guide