Fair Dinkum Sheds FLAT ROOF CARPORT User manual

FLAT ROOF CARPORT
RECOMMENDED
INSTRUCTION MANUAL
This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
TableofContents
Introduction ............................................................................................................................................ 2
Components ............................................................................................................................................
Step 1 – Marking out the Perimeter of the Carport ...............................................................................
Step 2a – Footing Set-Out for Concrete Block Pad Footing ....................................................................
Step 2b – Footing Set-Out for Concrete Slab .......................................................................................... 4
Step – 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 ................................................................................................. 10
Step 12 – Complete Fixing of the Frame ............................................................................................... 10
Step 1 – Gusset Plate Knee Brace ....................................................................................................... 11
Step 14 – Fit Roof Sheeting ................................................................................................................... 12
Step 15 – Fit Gutters and Flashings ....................................................................................................... 1
Step 16 – Cut and fit downpipes ........................................................................................................... 1
Step 17 – Finish ..................................................................................................................................... 1

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
Introduction
This Recommended Instruction Manual is a guide only.
IT IS IMPERATIVE TO REFER TO THE EN INEERIN 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
www.safeworkaustralia.gov.au for safety advice on specific items and OH&S safety requirements.
NOTE: Do not rely on t
his 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.

This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
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- ut 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 7.5mm. The centreline of the post
is 64mm + 7.5 set in from the string set-out.
The posts are set in on the endwall by 1 00mm 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.

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
Step 2b – Footing Set- ut 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 building perimeter plus 100mm slab extension each sidewall, thereby
adding a total of 200mm to the width of the Carport. Refer to Engineering Plans for the actual size
and specifications of your specific job.
As a guide, 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: The SHS post size is 75mm x 75mm so half of 75mm is 7.5mm. The C150 Rafter has a
flange width of 64mm. The slab extension is 100mm, therefore, the centreline of the post is 7.5 +
64mm +100mm from the edge of the slab / concrete slab set-out.

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
The posts are in on the endwall by 1 00mm 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
for BLOCK footing and edges of
concrete for SLAB to be left in place until the position of base plates are clearly marked.
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

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
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.
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
1 00mm 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.

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
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.
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.
N
OTE: T
riangular 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 1 for detailed
instructions of the Gusset Plate.

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
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.

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
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 D 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.

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
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.

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
TIP: If posts are embedded into concrete footings, it is recommended to wait for a few hours until
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 long
er 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.

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2

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This document remains the property of FBHS (Aust) Pty Ltd
Feb 201 – Version 2
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 10-16 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/FILIN S CAUSED BY AN LE RINDER.
CON RATULATIONS ON A JOB WELL DONE!