Michael: The back of our project house faces south which gives a constant exposure to the punishing summer sun. We’re going to address that problem by creating a little oasis. We’re installing an ultra lattice structural aluminum arbor from Metals USA.
People have been building arbors for thousands of years because they add both shade and beauty to a home. Now it’s traditional to use stone and wood and other types of materials like that. We’re using something totally different. We’re working with Metals USA building products. We’re building this arbor out of aluminum.
Now it looks just like wood because it’s embossed with a wood grain. It’s got special commercial grade paint so we don’t ever have to repaint. It won’t crack, it won’t chip, it won’t ever chalk, it’s not going to fade. It comes in a variety of colors so you can really do anything that will look good with your house and it’s a simple system to install.
This arbor will extend from and be attached to the cabana room. The first step for installer Derek Serpa and the crew from Dallas Custom Patio is to determine where to place the columns that will support the arbor. This square marks the location of one of the footers for the 6 columns. The crew digs deep hole for the footers the old fashion way with shovels and a manual logger. Treated 4x4’s will be the internal brace for the columns. Steel or aluminum braces can also be used.
Derek: We have to make sure at the base of the structure is going to be strong because that’s all you’ve got as the base, like the foundation of the house.
Mike: Once the hole is dug and the support hole is in place, the crew sets the wooden form that will frame the top of the concrete footer. Before pouring the concrete for the footer, the crew checks to be sure that everything is properly aligned and level. This one needs to come up a few inches. So the crew adds a little dirt to the base.
When everything is set, the crew mixes and pours the concrete, making sure that the supporting brace is perfectly plumb. A few final touches to smooth the surface and that footer is ready to go. When this one’s done, the crew moves on to the next one. At the end of day one, the arbor’s foundation is set.
The next day the installers begin to set the columns, beams and rafters. The installers make sure that the column is centered on the footer then the base is put in place. The column fits snugly into the base. The columns are secured to the base post by screws set through a counter sun called that would be filled in later. These columns are cast from a polyresin material that’s designed to carry a heavy load. They’re 10 feet tall and are custom cut on site. Once the columns are in place, the crew uses mounting brackets to attach one end of the header beams to the exterior wall of the cabana.
The other beams are mounted on top of the columns and get quickly be attached using a simple screw. Because of the heavy gauge of this structural aluminum, these beams can spend a long distances without the need for extra support. Then rafters are mounted on top of the beams. To add an elegant touch, beams can be suspended from the rafters because we’re using structural aluminum, there’s a lot of flexibility when it comes to design.
Derek: It’s a combination of beams, rafters and lattice. You can use variations of those and get different looks. You can go for a little more elegant look. You can keep it real simple. You can eliminate components. If you put this material in the hands of some guys and know what they’re doing with it, you can do some pretty amazing things with it.
Mike: Erin Maddox of Metals USA says there are other benefits to building arbors out of aluminum.
Erin: Instead of having to refinish year after year and have this up keep instead of enjoying it, you just have to wash it off once a year and get a little bit of the dirt off. It doesn’t harbor insects; you don’t have to worry about termites or anything like that. There are tons of styles to choose from and you can create pretty much any look you want to fit the style of your home and your individual tastes.
Mike: The ends of the beams and rafters on the project house arbor are an elegant scallop cut. When the rafters and beams are set, it’s time to install the most important element of this or any arbor, the lattice. The lattice is what actually provides the shade. The lattice is made of square links of extruded aluminum. Custom fit plastic caps are fitted on to the ends.
The installers uses facing tool to evenly separate the lattice. Aluminum is light weight and easy to work with, so the installation of the lattice goes quickly. Because we want our arbor to block out most of the hot Texas sun, we’re using a close spacing for the lattice in the project house. After the lattice is installed, all that’s left to do is add a few spots of cork and our project house has an elegant and useful addition that’s going to be a source of beauty and comfort many years to come. Metals USA guaranties that this arbor will last a lifetime.
For more information on how the ultra lattice arbor can add beauty and value to your new house, visit Metals USA on the internet at buildingproductsusa.com.
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