Flat Pan Patio Cover: Installation Guide

Flat pan patio covers are a great way to protect your outdoor space from the elements and are a relatively simple DIY project. These covers are made from durable, low-maintenance aluminum and can be customized to fit your space, with different sizes, colours, and styles available. You can also choose between a range of projections and widths, depending on your local load requirements. In this discussion, we will explore the steps involved in installing a flat pan patio cover, including the tools and materials needed, as well as offer tips for a successful installation.

Flat pan patio cover kits: what's included

Flat pan patio cover kits are a great option for those looking for a strong, durable, and low-maintenance solution for their outdoor space. The kits are typically made of aluminium and are designed to be easy to assemble for the average DIY homeowner. Here's what's typically included in a flat pan patio cover kit:

Flat Pan Patio Cover Kit Components:

• Flat pans: These are the main components that form the roof of the patio cover. They are typically made of aluminium and come in various sizes, such as 3" x 12" or 3" x 8". The thickness of the flat pans may vary, with options like .024, .030, and 24-gauge thicknesses available to meet local live load requirements.
• Fascia gutters: Gutters are included for all four sides of the patio cover. They are typically made of roll-formed aluminium and come in different colours like white, bronze, clay, ivory, grey, brown, and black.
• Fascia corners: These are used to connect the fascia gutters at the corners of the structure.
• Beams: Beams provide structural support to the patio cover. Different types of beams, such as box beams or C-beams, may be included depending on the load requirements and span of the cover.
• Posts: Aluminium posts provide additional support and come in various colours like white, ivory, or dark bronze.
• Screws, sealant, and hardware: Kits include the necessary screws, sealant, and hardware for assembly.
• Downspouts: Some kits include downspouts as part of the gutter system to direct rainwater away from the structure.
• Instructions: Detailed instructions are provided to guide homeowners through the installation process.

It's important to note that some kits may vary in terms of what they include. For example, some may offer a "top-only" system, where the customer is expected to supply the support structure. Additionally, optional accessories like leaf guards may be available for purchase separately.

Preparing your tools

Before you begin installing your flat pan patio cover, it is important to ensure you have all the necessary tools for the job. The flat pan patio cover system you purchase should come with instructions, fascia gutters for all four sides, flat pans (typically 12" wide or 8"), corners, screws, sealant, scuppers, beams, posts, top brackets, and fastener bars.

In addition to the provided materials, you will need tools to cut extruded aluminum and steel. It is also recommended to have step ladders, screwdrivers, pliers, a tape measure, a level, a carpenter's square, a caulking gun, a pencil, a box cutter, and a chalk line. Don't forget that you'll also need a helping hand, so be sure to have at least one other person assisting you.

The thickness of your flat pan system will depend on the live load rating set out by your local building department. This is an important consideration, as it will impact the strength and durability of your patio cover. Be sure to check with your local building department to determine the required load rating for your area.

Additionally, you will need to confirm the local municipal building department's live load requirements in lb./sq.ft. and wind speed requirements in mph. This information will be crucial for determining the panel thickness, beam placements, beam size, and distance between posts for your patio cover.

Once you have gathered all the necessary tools and information, you can begin the installation process, which should be outlined in the instructions provided with your flat pan patio cover system.

Cutting the flat pan systems

Firstly, it's important to understand that flat pan patio covers are typically supplied as DIY kits, which require final cuts to be made on-site by the installer. This means that you will need to have the necessary tools and equipment for cutting the flat pan systems. The specific tools you will need may vary depending on the material of the flat pan system you have chosen. For example, if you are installing an aluminum flat pan patio cover, you will need different tools than if you were working with a vinyl or wooden material. Make sure you refer to the instructions provided with your chosen product for specific tool requirements.

When it comes to cutting the flat pan systems, precision is key. Before making any cuts, carefully measure and mark the desired length of the flat pans, beams, and posts. It is crucial that your measurements are accurate to ensure a proper fit during installation. Take into account any adjustments that may be needed, such as the recommended 1" - 2" drop per foot of projection for the front height. This will ensure that your patio cover is level and secure once installed.

The specific cutting techniques and methods will depend on the material of your flat pan system. For aluminum flat pan systems, you may need to use power tools such as a circular saw or a metal cutting blade. Remember to take the necessary safety precautions when working with power tools, including wearing protective gear such as gloves and eye protection. If you are unsure about the cutting process, it is always best to refer to the instructions provided with your chosen flat pan patio cover system.

Additionally, when cutting the flat pan systems, it is important to consider the load requirements and local building codes. The spacing of the posts and the size of the beams will depend on these factors, so ensure that you are familiar with the specific requirements for your area. This information should be available from your local building department or in the product specifications provided by the manufacturer.

Finally, once you have made all the necessary cuts, it is important to handle the cut edges with care. Depending on the material, you may need to smooth or finish the edges to prevent sharp surfaces or to prepare them for any additional treatments, such as painting or sealing. Always refer to the manufacturer's instructions for specific recommendations on how to handle and treat the cut edges of your flat pan systems.

Anchoring and cementing your unit

Anchoring and cementing your flat pan patio cover unit is a crucial step in the installation process. Here are the detailed instructions you need to follow:

Firstly, determine the spacing of your support posts. According to IBC standards, the spacing of the posts will depend on the required load rating. Ensure you refer to the IBC standard to accurately calculate the spacing.

Once the spacing is determined, it's time to install the posts. If you are installing your flat pan patio cover on a deck or cement slab, you can request bottom brackets to attach the posts. The posts should be cemented into the ground, ensuring they are at least 2 feet deep. If installing on a deck or patio, the poles can be shortened to 8 feet.

For a wall-attached system, ensure that the posts are securely attached to the existing structure. If you are installing a free-standing system, the posts must be properly cemented and allowed to cure before proceeding.

The next step is to add the beam, which will be placed on top of the posts. The beam size is determined by the load requirements. When a beam is included, it will come with angle brackets, hardware, and screws for assembly. Ensure you follow the manufacturer's instructions for properly securing the beam.

After the beam is in place, you can start assembling the flat pan system. The pans are available in different sizes, typically 3" x 12" or 3" x 8", and should be placed on top of the beam. Secure the pans with the provided screws, following the instructions for the correct fastening pattern.

Finally, install the fascia gutters, which will cover the edges of the pans and provide a finished look. The fascia gutters typically come in several colour options, so you can choose the one that best matches your patio cover.

Remember, it is essential to refer to the manufacturer's instructions that come with your flat pan patio cover kit and follow local building codes and requirements to ensure a safe and compliant installation.

Installing on a deck or patio

If you're installing a flat pan patio cover on a deck or patio, you'll need to make sure the support posts are properly anchored. The flat pan patio cover system will come with instructions, fascia gutters for all four sides, flat pans, corners, screws, sealant, scuppers, beams, posts, top brackets, and fastener bars.

If you're attaching the cover to an existing deck or cement slab, you can request bottom brackets at no extra cost. The height of the cover will determine whether you need brackets. The flat pan patio cover company can shorten the poles to 8 feet and provide bottom brackets if needed.

You'll need to cement the support posts into the ground at least 2 feet deep. Make sure to follow any local code requirements for post depth. The distance between posts will depend on the load requirements and beam size. When a beam is used, it will include angle brackets, hardware, and screws.

Before installing your flat pan patio cover, be sure to confirm the local municipal building department's live load requirements in lb./sq.ft. and wind speed requirements in mph. You may or may not need a building permit, but it is recommended that you acquire one before purchasing or ordering your flat pan patio cover.

Frequently asked questions