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Patio rebuild with rectangular tubing

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(@koykoy)
Posts: 63
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Hello again guys, thinking of getting materials this early for another project and need your inputs. I will be doing this together with my stairs project when my trusted helpers are available already.

Project is roofing for my patio. 5 years ago, I installed a polycarbonate roofing over 2x6 mahogany rafters with 2x8 yakal beam supported by 2 concrete columns. The PC roofing was supposed to last for 10+ years but damn those claims, mine lasted for less than 3. They cracked and my mahogany rafters were starting to deteriorate.

Initial plan was to salvage the wood but since I am into steel projects these days, might as well change so this will last longer. I thought of doing the angle bar truss system (rereading the angle bar truss thread here) but it would not blend architecturally since the house is sort of a mexican style so a trellis look is preferred. I plan to use 2x4x1/8 (3mm) hollow rectangular tube for the rafters supported by the two concrete columns and two sides to be anchored to the wall using 1/2" lag bolts. Then, 2x3 (1.2mm) c-purlins will be welded on top at 60cm intervals. Slope of the roof will be about 20 degrees. Top view plan:

Colorbond Rusko 0.40 mm (26 ga) GI/Steel (resembling clay roof design) will be installed on top which is very light.

Prices:
2x4x1/8 (3mm) - 6m rectangular tubing - 2,700++
2x3x1.2mm - 6m c-purlins - 500++
Roofing - 1m x 12.2m - 3,800

Any inputs on the sizing or design? Can I get away with say 2mm rectangular tubing?

 
Posted : 15/01/2014 3:54 pm
rosy
 rosy
(@rosy)
Posts: 4307
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Re: Patio rebuild with rectangular tubing

Hey Koykoy,

Based on the pic you posted and the line drawing rendition below, it seems you are extending your patio roofing design towards the left up to the existing wall. Aren't you gonna add a supporting post at the end of the extended roofing plan to support your 2" x 4" rectangular rafter ? just curious here. Plus will you also raise a part of your wall at the end of the roofing extension so you can also install some flashing.

Why not make your rafters 2" X 6" and make your purlins 2" X 4", this will be welded on the rafters.

Oh the Rusko Tile roofing looks great for its roofing.

GOOD LUCK on the plan construction !! 😉

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Posted : 15/01/2014 8:40 pm
(@koykoy)
Posts: 63
Trusted Member
Topic starter
 

Re: Patio rebuild with rectangular tubing

Hi Rosy, sorry for the confusion. That sloping wall in the picture will still rise so I plan to attach the leftmost rafter to the wall using 4 or 5 x 1/2" anchor bolts.

2x6 is good but they might be too heavy and too expensive (I need 4 for this project). 🙁 Your suggestion however is spot-on on the rules of thumb of structural steel design:

http://www.mbjeng.com/wp-content/uploads/2011/03/Craigs-article.pdf

I emailed my CE cousin who is in Saudi about this design and explained it in detail. I just got a two word response" "That's ok". hehehe, not the most reassuring response I was expecting.

 
Posted : 16/01/2014 9:46 am
rosy
 rosy
(@rosy)
Posts: 4307
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Re: Patio rebuild with rectangular tubing

Well bro, I suppose with the simple design and detailed explanation you gave your cousin, to him he finds it simply OK, no more, no less so not give you additional things to think about. But then if you can't seem to accept his say then I guess you can still ask for more inputs/opinions from other people or friends simply to satisfy your curiosity on the design of your extension project. 😉

CIGWELD Weldskill 250 amp Mig Welder
AHP Alpha-TIG 200X welder
HITRONIC 300 Amp DC Inverter IGBT Welder
YAMATO 300 amp AC Stick Welder
YAMATO 200 amp DC Inverter IGBT Welder
DeWALT Chopsaw
HOBART and ESAB Welding Helmets
cloned STIHLs
MS 044 chainsaw
MS 070 chainsaw

 
Posted : 20/01/2014 12:17 pm
(@koykoy)
Posts: 63
Trusted Member
Topic starter
 

Re: Patio rebuild with rectangular tubing

Just want to share and document this project. 🙂

1. Used 6 2x4's instead of the planned 4 so the spacing will be even at 120cm. 2 of them were 3mm while 4 were 1.5mm. I used angle bars to fix them to the wall with fischer anchor bolts. 🙂

2. Purlins were 2x2's-1.5mm and were painted brown. Ends are covered with 3mm flat bar.

3. Action pic with the helper/latero. He was grinding the painted tubulars so the rod can stick. I used 3/32 6013 rods and at times, I get a hole.

4. After a lot of sunburn, finally fixed the support. Will be painting the rest with choco brown after the roofing is installed so we will have some shade. Its so hot these days.

 
Posted : 07/03/2014 4:25 pm
(@koykoy)
Posts: 63
Trusted Member
Topic starter
 

Re: Patio rebuild with rectangular tubing

5. The most unscientific way to test the steel choice & weld strength is to hang my 90kg body. hahaha. If it flexes by a lot, then its no good. :-)))

6. After the latero installed the rusko tile-look-alike 0.40mm steel roof, which for me, looks very very good.

7. The void was also filled by the mason which also serves as support for the small additional beam. He also smoothened the roof edge for safety. The stairs project was also finished and primed and the dogs are loving the roofdeck playground. 🙂

Thanks for the support and advices. Hoping this will last longer. For now, small projects nalang muna kay have to attend to the office kc marami ng backlogs. hehehe

 
Posted : 07/03/2014 4:32 pm
rosy
 rosy
(@rosy)
Posts: 4307
Member
 

Re: Patio rebuild with rectangular tubing

CONGRATS bro koykoy,

Good job on the PATIO REBUILD project, finally you finished it already. In addition to that, even your dogs seems to be enjoying the new constructed metal stairs on the side of the house ! 😎 :banana2:

CIGWELD Weldskill 250 amp Mig Welder
AHP Alpha-TIG 200X welder
HITRONIC 300 Amp DC Inverter IGBT Welder
YAMATO 300 amp AC Stick Welder
YAMATO 200 amp DC Inverter IGBT Welder
DeWALT Chopsaw
HOBART and ESAB Welding Helmets
cloned STIHLs
MS 044 chainsaw
MS 070 chainsaw

 
Posted : 07/03/2014 7:11 pm
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