Patio Cover Installation

AS&D IMPORTANT NOTE

• Consult your local building department for any required permits. You may be required to obtain a building permit for this structure.
• Patio cover design and engineering do not allow for bearing any additional loads (for example: hanging plants, swings, people, trellises or other objects).
• American Structures and Design is not responsible for replacing parts lost or damaged due to incorrect assembly.
• All points of attachment to existing structures (such as house or patio) must be to solid, structurally sound, and secure material. Example: wood or metal studs, joists, headers, plates, or sills. Additional engineering may be required if surface you are attaching to is not included in the engineering report.

Note: Failure to properly attach and anchor unit per engineering requirements to existing structure may result in damage to the unit, damage to the structure it is attached to, and could cause serious bodily injury.

BEFORE YOU BEGIN

Check the Sales Order paperwork for any missing parts. Also, make sure that you have the correct quantities and sizes of components and hardware. If you find anything missing, please contact AS&D within two business days of receipt of materials.
Before beginning installation, make sure you read each step carefully.

• Clear work area of all obstacles prior to beginning installation.
• To prevent damage to material finishes, place patio components on protective surface (for example, on soft grass, etc).
• Have all the necessary tools and equipment. A list can be found on page 2.

PATIO COVER DO'S

DO follow the instructions in this guide.
DO check local building regulations before you begin.
DO use only fasteners per the engineering requirements.
DO store all materials indoors, under cover or keep them in a cool and protected environment until installation.

PATIO COVER DONT'S

DON'T proceed without reading this guide.
DON'T assume that any structure will meet local regulations without checking.
DON'T substitute with fasteners that do not meet engineering requirements.
DON'T store materials which have protective film (such as PolyPanel or Insulated Panel) in direct sunlight. Expansion prior to installation can cause installation difficulties.

Required Tools

Required Hardware

Attachment Types

1A,1B,1C - Patio covers are mounted to the structure in multiple ways. Always refer to AS&D Engineering documentation. Contact your local representative for detailed information.

Preparation

Lay out hanger rail, hanger, and gutter extrusions on the ground in the same direction as they will be installed on the house.

3A. Install hanger tape to the inside of the hanger between the top and bottom flange.

3B. Slide the hanger rail onto the hanger until they align on each end.

3C. Starting on the LEFT, mark the top flange of hanger as per your roof type: 12" o.c. for V-Pan and PolyPanel 6" o.c. for Flat Pan

4A. Starting at the left end of the gutter, mark the top flange according to panel type.

4B. Using a razor knife, modify the gutter dam to snuggly fit inside the gutter. Apply a generous bead of caulk around the gutter dam and the gutter. Spread evenly for a watertight fit.

Hanger and Rail Installation

5A. Starting on the LEFT side of desired attachment point, determine and mark the appropriate height.
5B. Using a leveling tool or chalk line, mark the width of the cover on the attachment wall.
Note: Cover must slope a minimum of 1/2" per foot.

Important Note: Customer is responsible for determining required lag screw length based on siding type.
Attach hanger rail using Hex Lag Screws 3/8” x 3”, 4”, or 5” (Part No.: FS-3/8X HEXLAG-18-8) @ 16" o.c. with a minimum of 3" penetration into wall studs.
Note:
• Ensure fasteners are fully secured into stud framing.
• [For additional attachment options, see engineering pages S4.4]

Rain Flashing Installation

Depending on your site conditions, there are three different ways to secure flashing.

Flashing Installation
8A. Starting at the left end, fasten flashing per Step 7, using appropriate fasteners.
8B. When two courses of flashing come together (over 10'), tuck the second course UNDER the first course a minimum of 2”.
8C. Repeat process the width of the patio cover.

Preparation for Gutter, Post, and Beam Assembly

9A. Prior to laying out post and brackets, find a protected work area (to avoid material damage) to mark bracket locations on gutter or I-Beam.
9B. If there are more than 2 posts, determine intermediate post spacing.
9C. Determine desired post layout and mark centerline of each post bracket location on gutter or I-beam.
Note: Post spacing is not to exceed engineering specifications.

Attach bracket to gutter or I-Beam using 4ea. Hex Tek #14 x 1" fasteners (Part No.: FZ-14X1-HEXTEK).

Site Layout for Post Locations

Understanding Patio Cover Slope
The front of the patio cover must be lower than the back. This will ensure water drains away from the house. The minimum slope must be ½” per foot.
Examples:
12’-0” Projection = 6” Drop
10’-0” Projection = 5” Drop
8’-0” Projection = 4” Drop
Important: Do NOT install patio cover completely flat.

Determine post height with I-Beam system
To determine the post height, follow this formula: A-B-C = Post height dimension
4” I-Beam Example: 120” (A) – 5”(B) – 4”(C) = Post Height (D) = 111” (9’ 3”)
7” I-Beam Example:120” (A) – 5”(B) – 7”(C) = Post Height (D) = 108” (9”)
Cut post to desired dimension (D) using a miter saw, Step 15.

Determine Post Height with Gutter System
To determine the post height, follow this formula: A-B-C = Post height dimension
Example:120”(A) – 5” (B) – 2” (C) = Post Height (D)=113" (9' 5")
Cut post to desired dimension (D) using a miter saw, Step 15.

Bracket Attachment to Post and Concrete Slab
16A. Transfer dimensions from previously installed post brackets to slab. (Step 11)
16B. Install post brackets using wedge anchors.
Note: Minimum 6” setback from concrete edge is required.
See Engineering report for wedge anchor or footing sizes

Install Support Framework
Install gutter or I-Beam to posts, secure using 4ea. Hex Tek #14 x 1" fasteners
(Part No.: FZ-14X1-HEXTEK), 2ea. per side, 2 ea per side.
Note: Post brackets are already installed to I-Beam or gutter in Step 10.

Roof Panel Installation

Roof Panel Installation
19A. Starting at the LEFT side of the hanger, insert roof panel into hanger, ensure male lock is on the outside and female lock is on the inside.
19B. If patio cover is over 16’ temporarily install a middle roof panel to avoid sideways ratcheting and bowing.
19C. Fasten roof panel to hanger using Hex Tek #10 x 5/8” fasteners (Part No.: FZ-10X.625-HEXTEK).
Number of fasteners is based on your roof type and per engineering detail S3.3 no.: 1 and 2.

20A. Ensure a minimum overhang of 1/8” into the inside lip of the gutter.
20B. Fasten roof panel to gutter end using Hex Tek #10 x 5/8” fasteners (Part No.: FZ-10X.625-HEXTEK).

20A. Fasten roof panel to I-Beam through the top of the I-Beam on the outward-facing side as shown using Hex Tek #10 x 5/8” fasteners (Part No.: FZ-10X.625-HEXTEK).
PRO TIP: Fasten roof panel to I-Beam in the hidden fastener channel using Hex Tek #10 x 5/8” fasteners (Part No.: FZ-10X.625-HEXTEK).

Important Note: This step requires two people for installation.
Gutter attachment with I-Beam system
21A. Starting at left side of cover, hoist gutter up so that the inside lip of gutter meets the underside of the panel, ensure gutter is flush with outside edge of panel.
21B. Using Hex Tek #10 x 5/8” fasteners (Part No.: FZ-10X.625-HEXTEK), secure gutter through panel to inside lip of gutter. Ensure a minimum overhang of 1/8” into the inside lip of the gutter.
21C. Repeat process to secure right end of gutter to roof panel.
Note: If patio cover is over 16’, secure gutter to middle panel (Step 19A) using 2ea. Hex Tek #10 x 5/8" fasteners (Part No.: FZ-10X.625-HEXTEK). Attach gutter clip to the male lock (left side) using 1ea. Hex Tek #10 x 5/8" fasteners (Part No.: FZ-10X.625-HEXTEK).

Continuing Roof Panel Installation

22A. Starting at left side of patio cover, continue installing roof panels.
22B. Tilt the male end of the next panel and interlock it with female end of the previously installed panel.

22C. Roll panel downward until it lies flat completing the joining of the two locks.
22D. Slide interlocked roof panel back until it is seated against the hanger tape.

Continuing roof panel installation
23A. Continue installing three (3) additional roof panels. A total of four (4) roof panels are now installed.
23B. Anchor previously installed flashing (Step 8) with 1ea. Hex Tek #10 x 5/8” (Part No.: FZ-10X.625-HEXTEK) to the lock of the THIRD installed roof panel. Important Note: Secure flashing through locked roof panels ONLY.
23C. If using the I-Beam system anchor panels to I-Beam (Step 20, Option 2 or 3), then secure panels to gutter Step 21. If using gutter system anchor panels to gutter (Step 20, Option 1).
23D. Attach gutter clips to interlocked panels. Slide flanged end of clip into gutter lip and secure clip to interlocked panels using 1ea. Hex Tek #10 x 5/8" fasteners (Part No.: FZ-10X.625-HEXTEK).
Note: Do NOT install clip onto unlocked end panel, it will interfere with sliding on the next panel.

Fascia Installation

26A. At the hanger end of the side fascia cut back the top and middle flanges 1”.
26B. Repeat process for right side fascia.

27C. Secure side fascia to underside of gutter using 2ea. Hex Tek #10 x 5/8” fastener (Part No.: FZ 10X.625 HEXTEK)

27D. Secure side fascia at hanger using 1ea. Hex Tek #10 x 5/8” fastener (Part No.: FZ 10X.625 HEXTEK).
Note: Flashing is installed but not shown in image for installation clarity.

27E. Using Hex Tek #10 x 5/8” fastener (Part No.: FZ 10X.625 HEXTEK) fasten side fascia to the length of the panel every 12"-16".
27F. Repeat process for right hand side fascia.

Corner Installation

Downspout Installation

Note: Downspout can be installed to front of post or to side of post, depending on installer preference.
29A. Mark location for dropout hole.
29B. Cut using a 2-inch hole saw.

31A. Attach A-Elbow to dropout using 2ea. Hex Tek #10 x 5/8” (Part No.: FZ-10X.625-HEXTEK), one on each side.
31B. Place second A-Elbow in desired location.
31C. Measure the dimension between the two elbows and add 4”, cut downspout to this dimension.
31D. Install downspout by crimping the bottom of first A-Elbow (31A) to fit inside the downspout (31C).
31E. Complete downspout installation by crimping base of downspout to fit into the lower A-Elbow (31B).

32A. Measure from bottom of the second installed elbow to ground level and add 2”, cut downspout to this dimension.
32B. Crimp bottom of upper elbow and attach the downspout to the upper elbow using 2ea. Hex Tek #10 x 5/8” (Part No.: FZ-10X.625-HEXTEK), one on each side.
32C. Secure lower end (optional upper end) of downspout to post using a piece of aluminum downspout strap.

Gutter Only Configuration: Downspout Installation

33A. Measure from bottom of gutter to ground level, cut downspout to this dimension.
33B. Attach the downspout to the drop out using 2ea. Hex Tek #10 x 5/8” (Part No.: FZ-10X.625-HEXTEK) one on each side.
33C. Secure lower end of downspout to post using a piece of aluminum downspout strap.
Note: Elbow is attached to the downspout.

PolyPanel Single Bend Roof Panels Installation Instructions

P1A. Starting on the LEFT side of the hanger, fasten T-Bar to the hanger through the top of hanger using 2ea. Hex Tek #10 x 5/8” (Part No.: FZ-10X.625-HEXTEK).
P1B. Repeat T-Bar installation for RIGHT side.
P1C. If patio cover is over 16’ temporarily install a T-Bar to avoid sideways ratcheting and bowing of beam.

Option 1 - Gutter

P2A. Ensure a minimum overhang of 1/8” into the inside lip of the gutter.
P2B. Fasten T-bar to gutter end using 2ea. Hex Tek #10 x 5/8” fastener (Part No.: FZ-10X.625-HEXTEK).

Option 2 - I-Beam

P2A. Ensure a minimum overhang of 1/8” into the inside lip of the gutter.
P2B. Fasten T-bar to gutter end using 2ea. Hex Tek #10 x 5/8” fastener (Part No.: FZ-10X.625-HEXTEK).

Important Note: This step requires two people for installation.
Gutter attachment with I-Beam system
P3A. Starting at left side of cover, hoist gutter up so that the inside lip of gutter meets the underside of the T-Bar, ensure gutter is flush with outside edge of T-Bar.
P3B. Using 2ea. Hex Tek #10 x 5/8” fasteners (Part No.: FZ-10X.625-HEXTEK), secure gutter by screwing fastener up through inside lip of gutter into T-Bar. Ensure a minimum overhang of 1/8” into the inside lip of the gutter.
P3C. Repeat process to secure right end of gutter to T-Bar.
Note: If patio cover is over 16’, secure gutter to middle T-Bar (Step P1C) using 2ea. Hex Tek #10 x 5/8" fasteners (Part No.:FZ-10X.625-HEXTEK).

Installing PolyPanel Roof Panels
P4A. Rest PolyPanel on inside lip of T-Bar.
P4B. Install the next T-Bar 12” o.c. as per steps P2 (Gutter Option 1, I-Beam Option 2).
P4C. Ensure PolyPanel is seated into hanger tape.

T-Bar Snap Bead Installation
P5A. Prior to installing T-Bar Snap Bead, center PolyPanel between the two T-Bars.
P5B. Lay T-Bar Snap Bead (Part No.: PC-TBSB-241-WHT or 289-WHT) to the INSIDE of the farthest T-Bar.
P5C. Using a rubber mallet gently tap the T-Bar Snap Bead so it is firmly seated to the T-Bar.
P5D. Install T-Bar Snap Bead on the opposite T-Bar.

Hanger Snap Bead Installation
P6A. Lay Hanger Snap Bead (Part No.: PC-HSB-10.4375-WHT) on PolyPanel, gently push Hanger Snap Bead into hanger until it snaps into place.

Continue PolyPanel Roof Panel Installation
P7A. Continue installing one additional T-Bar, PolyPanel roof panel, T-Bar Snap Bead and Hanger Snap Bead.
P7B. Anchor previously installed flashing (Step 8) through the screw chase center on the T-Bar with 1ea. Hex Tek #10 x 5/8” (Part No.: FZ-10X.625-HEXTEK).
P7C. Attach gutter clips to every second T-bar. Slide flanged end of clip into gutter lip and secure clip to T-bar using 1ea. Hex Tek #10 x 5/8" fasteners (Part No.: FZ-10X.625-HEXTEK).

P8A. Continue installing T-Bars and PolyPanel roof panels
P8B. Install side fascia, refer to page 19 for continued instruction.

Inspection Checklist for Patio Cover Installation