Sutton Screened in Awning / Porch Sections: Project Overview Roof Work Cedar Framing Canopy Frame Screen Frames Misc. Sheet 1 - - - Index Sheet 2 - - - Project Summary Sheet 3 - - - Roof Work overview Sheet 4 - - - Roof Work dimensions Sheet 5 - - - Roof Work edge detail Sheet 6 - - - The Cedar Frame Sheet 7 - - - Cedar frame dimensions Sheet 8 - - - Cedar elements, trim, shelves... Sheet 9 - - - Aluminum Canopy Frame Sheet 10 - - Aluminum Elements Sheet 11 - - Aluminum Elements Sheet 12 - - Detail Parts I and H Sheet 13 - - Detail Parts J and G Sheet 14 - - Screen channel brackets Sheet 15 - - Rear Canopy assembly Sheet 16 - - Front Canopy assembly Sheet 17 - - Screen Frames Sheet 18 - - Detail Screen frames Sheet 19 - - Stainless Steel Anchor Brackets Index Sheet # 1
This is to be a well built awning structure which will function as a screened three season porch. A new curved dormer will be added to the existing roof, and the new awning will tuck up under the new gable edge. The awning material will cover an arched aluminum canopy frame.manufactured off site and deleivered in two sections. The aluminum arches will rest on a cedar base of 4x4 posts, 4x6 lintels, doorways, with a base shelf rail around the bottom edge. The cedar will be bolted to the deck with stainless steel angle brackets. The area between the railing and the canopy will be filled with specially made aluminum framed screens, which will be assembled on site. Existing House Canopy frame of rolled aluminum arches, built in two sections and bolted together on site. It will then be covered with the canopy fabric, lifted into place and secured to the cedar base, and the new dormer. Upper screen frames are made of special 1"x1" aluminum channel extrusions. The end frames will be prefabricated and covered prior to installation. The top of the front screen is welded into the front arch section, and the bottom and vertical sections will bolt into place. These screens will be installled on site. New curved dormer to be added to existing sloped roof. The cedar base is built of 4x4s, 4x6s, with a 2x10/2x6 shelf around the perimenter. The doorways are 2x12s with a 4x4 lintel. Some 1x12 stock is used against the building and under the eave to frame the transition between the house and the canopy. The area below the shelf is filled with screen which is held in place by.75 x.75 strips which fill matching notches in the corners of the 4x4s or areas adjacent to trim pieces. Project Summary Project Summary No Scale Sheet # 2
The Dormer is built centered on the cement porch slab. The canopy will slip in under the edge of the dormer and seal with a gasket. The facia will need to be cut to fit around the ends of the main canopy support beams and the upper extension of the door frame. The facia is the curved trim piece below the edge of the roof. The canopy edge sits on it. Roof Work The gutters should be installed in the roof edge and a leg built oo catch the water at the ends of the awning and carry the water out beyond the deck area. A strap can be bolted to the aluminum arch members as needed. I leave the roofing details to the roofer. Save for the fact we need a short drip edge around the dormer face. (see sheet 5) Dormer surface to match roof edge. Facia supports the canopy edge. Roof work overview No Scale Sheet # 3
278.225 69.298 calculated dimension from iffy drawing field varify. Plan view See detail on sheet # 5 277.509 width of truss without sheathing R242.134 roof truss radius 43.702 3.000 R239.134 3.500 outside radius facia. (approximate match al. arch) width of supporting facia 0.625 5/8" roof sheathing Face of dormer should match the existing vertical face of the roof edge, 157.702 height of dormer end truss above the deck. Front elevation Dormer 1/4" = 1 ft. Sheet # 4
Dormer section at Peak drip edge Closed cell gasket material Canopy fabric Roofing material to be determined Aluminum Canopy frame lashing rail goes all the way around the perimeter of the canopy The Canopy goes under the edge of the dormer and seals against a gasket. The cover is lashed onto it around the perimeter lash rail. The supporting facia should be fit to the actual frame when it arrives so the roofer needs to mark the top edge of the dormer face to show where his structure is. Supporting facia dormer face (even with edge of roof trim) Structure by roofer Dormer section at Peak Half Scale Sheet # 5
These upper 4 x 6 beams and this lower shelf/rail must be level and in close tolerance for the screens to fit. The Cedar Frame The cedar support frame presents the the biggest construction challenge. It is here that the sloped and slightly irregular patio base must be adapted to, as well as any inconsistancies the roofer leaves. We will specify that the canopy and screens be made square. To make this work, the legs supporting the outer end need to be about an inch longer than the ones by the doors. The beams on top of the posts must be level and the 2 x shelf below must be level and a given distance below the beam. length for these vertical members should be as indicated length for all other vertical members should be field verified. The Cedar Frame No Scale Sheet # 6
148.310 143.211 224.934 20.528 39.000 89.379 3.500 89.379 124.440 120.575 39.000 224.934 139.626 The section under the edge of the roof will have to be measured and cut to fit on site. 3.500 5.500 The vertical measurements at left and right are good only at the roofline. Field verify the rest so the beams and the shelf are level. 110.226 1.500 1.500 5.500 36.000 35.196 0.750 0.750 0.750 53.230 53.230 53.231 244.129 53.230 Gussets are 4x4s cut on a 45 46.072 46.072 Cedar Frame 1/4" = 1 ft. Sheet # 7
244.129 224.956 223.429 5.228 0.650 1.500 9.500 Front shelf and backboard 1.500 3.500 1.500 3.500 0.750 0.750 Typical shelf members, 2x10 shelf board and notched two by six backboard. Backboard length and position relative to the overhead beams is critical. 5.500 1.500 0.650 0.850 1.500 3/4 square battens and 3/4 x 2.75 trim added. Shelf backboard profile 6.100 119.075 120.575 2.750 3.504 Rather than trying to cut into the structural posts supporting the canopy, I have added these trim pieces to the side of them to secure the screen in the section below the shelf. Another pair are fastened to the bottom of the shelf to secure the screen there. 0.751 3.504 0.750 0.750 Typical posts and floor frame members that go under the shelf unit above. Standard profile, but lengths will vary per print and site measurements. A 3/4" square batten fits in the slot to hold the screen. End shelf need two reverse and repeat. 110.226 109.376 104.130 97.148 95.621 9.600 3.504 0.750 Typical post Door frame need 4, two this length and two longer, cut to fit. Framing member for floor. 0.750 3.504 Cedar elements 1/2" = 1 ft. Sheet # 8
Aluminum Canopy Frame The canopy frame is fabricated of aluminum tube, round and flat bar, T bar and a proprietary design channel extrusion called Staplestitch which we are using to frame the screens. The canopy is fabricated in two arches for transport which will be bolted together on site. Part L Part A Part B Part C Part D Part E There are seventeen basic parts that are required to make it. 3 of which are mirror images of others. The parts: A and B the main arches 2x2. and 1x2 in. tubing resp. C standoff/stiffener made of 1x2 tube D curved lashing bar made of 1/2" round E standoff made of 1/2"r F lashing bar of 1/2" r G and H, r & l screen mounting rail made of 2x2 T bar J and I, r & l, Bearing plates which sit on the Cedar beams made of 2x3" tube K mosquito seal seat 1/8 x 3" Part K Front Arch Assembly L Top screen mounting channel for front 4 screen panels. M and Nr & l Screen channel brackets hidden under part K in drawing. O Lateral edge of front arch section P Lateral edge of rear arch section Part I-r Part H-r O Part J Part G Part F Rear Arch Assembly P Aluminum Frame No Scale Sheet # 9
267.809 133.904 B A 30.000 30.000 30.000 30.000 Part A has no holes Part B has 3/8" holes on the centerline 15.000 40.277 265.558 Ø0.375 R24 R239.000 A B Part A 1x2 x 1/8" wall 6061 Al tubing Need 3 Part B 2x2 x 1/4" wall 6061 Al tubing Need 4 29.000 Part C 1x2 x 1/8" wall 6061 Al Need 7 R239.656 Part D 1/2" dia 6061 Al rolled to OD shown & cut to fit Need 48 feet 1.750 29.000 Part E and Part F 1/2" dia 6061 Al Need 63 Need 10 265.704 245.103 K K L L 3.000 K unrolled length is 281.7".125 x 3" 6061 Al flat Need 1 0.125 L unrolled length is 257.35 1"x1" staplestitch channel rolled edgeways (slot on side) Need 1 R239.005 OD of part K ID of part L K L Aluminum Components 1/4" = 1 ft Sheet # 10
Part J shown as solid is actually tube. 2 x 3 x 1/4 wall 6063 Al tube Need two 6 See detail on Sheet# 13 Sheet # 11 G J Perspective drawings not to scale 29.000 29.000 9 87.248 Part I shown as solid is actually tube 2 x 3 x 1/4" wall 6063 Al tube Need 1 left hand and 1 right hand version 1/2" holes for stay cable assemblies See detail on Sheet # 12 29.000 6 3.000 Ø0.500 5.752 Ø0.500 23.248 29.000 29.000 0.500 Part H 2 x 2 x 1/4" 6061 Al T Need 1 left hand and 1 right hand version Sheet # 11 1/2" = 1 ft. Sheet # 11
3.000 Part H Top cope is where the rolled piece of staplestitch channel is seated. the tang portion must be cut out to match the top of the side screen frame, illustrated above in ghosted silhouette. 2.970 Part I this cope allows for the 1/8" x 3" mosquito seal holder The end meets the outer arch tube 1/8" above the lower edge of the arch. Part H Lower cope in this piece allows for the front end of the side screen which is mounted at a 45 and offset. 5.752 1.611 1.611 0.272 0.159 0.875 Part I Copes in the top of the tube for the 1" and 2" wide arch tubes are the same as those indicated for Part J on sheet Part H These two parts, H and I need come in left and right hand versions, we need one of each. Detail parts H & I Half Scale Sheet # 12
These are actually 2 x 3 x 1/4" wall tube not solid 6061 or 6063 Al as avail. need 2 parts G and 2 parts J Part J 3.000 " (or 2" for those tubes) Part G 0.265 1.878 Part J cope dimensions for all intersections with arch tubes A and B on parts I and J 0.159 0.250 Part G Detail parts J & G Half Scale Sheet # 13
1.250 1.250 0.125 0.125 3.000 0.875 0.125 0.875 0.125 0.500 Ø0.187 0.500 3.000 1.670 0.500 0.500 2.670 0.500 Part N cut from 1.25 sq tube 1.25 x 1.25 x 1/8 wall Al tube cut and coped Need 4 (one for the front canopy arch and 3 for the bottom of the front screen) Part M (left and right) cut from 1.25 sq tube 1.25 x 1.25 x 1/8 wall Al tube cut and coped Need 2 (one left and one right) Al. Comp. Parts M and N Half Scale Sheet # 14
271.120 9.667 9.667 9.667 See Sheet 17 for additional details weld all joints solid, grind outer surfaces smooth Grind/sand sooth 1/8 radius on outer edges of Lateral edge (part F) 14.743 135.560 135.560 224.934 6 8.350 4.069 6.458 11.402 224.934 center line 241.634 112.467 C 4.069 A C B 43.402 B D - cut to fit E standoffs mounted on 1ft centers on arches J G J - Bearing Plate P F P - Lateral Edge G - Screen mount rail Rear Canopy Assembly 1/4" = 1 ft Sheet # 15
All part C spacer/support bars are parallel to and 1/8" above the bottom edge of the arches that they seperate. All dimensions and comments about positioning analogous parts shown on Sheet # 15 the rear assembly also apply here. W will focus on the uniique parts of this assembly. 59.188 59.188 60.705 c-c 60.705 c-c N - left M N - right 43.402 Tensioning cable assembly center line 94.000 B C I-right H-right I-left H-left A C C O A C N-r C M A N-l D Double nut the threaded ends of the tensioning cable E L K The lower face of Part K is in the same plane as the lower face of all the structural arches The screen mounting channel (L) is at the rear edge. The open channel faces out towards the front of the canopy. O Radius outside corners to relieve stress on the fabric. Front Canopy Assembly 1/4" = 1 ft Sheet # 16
T bar - Part H-right shown (there is a mirror of it on the other side) Part L Rolled screen channel on the front arch section. Screen Frames Screen Frames the front two are welded together in the shop the last frame by the house will be cut on site and simply screwed to the porch frame through the tube section at the back of the channel. Plan View Left end screens Part K Side screen frame The front post is rotated 45 deg. so it can also be used as the edge of one of the front screens *note that it is coped to match the horizontal member, so that the screen material can fit down into it and be secured with a snap fit part. Part M - Welded to lower channel and bolted/screwed to verticals. trim off for angle 0.264" 109.630" on the long side trim end to fit channel on the front arch This is a diagram of the most complex corner of the entire structure. The edge rolled channel is wedged between the mosquito seal flat above and the end of the T bar which acts as the upper seat for the end screen frames. The channel way from the top arch must be coped open to match the top of the channel on the corner of the end screen so that the screen fabric can be pushed down into it. I have shown it with the T bar coped, it may be simpler to extend the rolled channel down further and miter and cope that. Either would be acceptable but all edges must mate and be smooth so as not to tear the screen. Front view Front screen, lower members 117.371 Mirror the other side. Right View Front screen,lower members 85.311" Front channel ends square mounted at 45 deg. End screens, (left end.shown) Both ends are the same. The double screen front panels flip top to bottom to work on the other end. 83.311" center post Right View Left End Screens 109.540" Top and bottom channels coped one end, mitered down and up 85.311" Rear channel, mitered channel facing out 21.833 35.991 Side screen Transom miter corners and chamfer interior edge Need 2 Measure About 68" M M 60.655 121.360 Detail (b) Sheet 18 242.720 Detail (a) Sheet 18 Plan View, Front Screen Lower members Detail (c) Sheet 18 Side screen Double frame Need 2 1/4" = 1 ft Sheet # 17 Side Screen under soffet measure and cut on site Screen Frames
Sheet # 18 Sheet # 18 Screen Frame details The horizontal channel must be coped and chamfered to mate with butt joined verticals here and also at the top arch and on the end screens The octagonal corner face of the staplestitch channel should be flush with the face of the side channel when the cope is finished 45.00 0.293 0.237 Detail (b) Detail (c) Weld brackets to the lower channel 0.293 0.177 Detail (a) 0.530 Al. Comp. Parts M and N Half Scale Sheet # 18
3.000 1.375 3.000 Ø0.500" holes 3.000 1.375 1.500 3.000 Stainless Steel anchor bracket material 3"x3"x1/4" 304 Stainless angle NEED: 9 Anchor Bracket Half Scale Sheet # 19