montagehandleiding carport nagoya

8/19/2019 Montagehandleiding Carport Nagoya

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D411_200804C

1

D411

MY

NAGOYA - TAMPICO

Installation manual Single / Extended / J/ M / Y-Connection

Thank you for purchasing an AluPort carport.

Please follow the instructions of the manual before assembly for proper installation.

The following symbols are used in this manual

Safety Sign Meaning

CautionDanger in case of wrong installation

Notes for a trouble free installtionRules and advices to follow to help preventing damages and support a

set-up properly

General information sign

Point

Advice

Notes for a trouble free installtion

Additional information

Additional information for your convenience

Please note the following cautions to prevent damages and harms to persons or the product.

1. This product is a simple garage. Please do not remodel or change it.

2. The carport is constructed for areas with 20 cm snowfall. Please remove the snow before it exceeds 20

cm to prevent damages at your carport.

3. Install the carport in a location where snow from the building to

the roof does not fall directly. Falling snow may damage the

carport.

4. The product is designed to be installed on the ground floor.

Please do not install it on the second floor or higher.It might be blown over by the wind.

5. Please make sure that all measures of the installation places are correct.6. Do not install the carport in areas with direct contact to exhaust gas. The paint may start to flake.

7. Do not install the carport on a slope.

1. The size of concrete for the foundation and the foundation size itself changes depending on the soil

condition.

2. Place crushers on the ground to aviod frost damages.

3. Using sea sand and chloline and strong alkaline mixtured materials for concrete as mortar or cocrete may

cause corrosion to your carport due to the high salt content. Please wash it properly before using it as

mortar.

4. The extract liqiud of mortar or concrete containing strong alkaline may cause corrosion and bad

appearance to your carport

5. Please drill a drainage hole into the post.

6. Mortar or concrete on aluminium or on the product itself must be removed quickly.

Caution


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1. In case of moving the posts, please follow the instructions in this manual.

2. Please be carefull to not cover the caution stickers when installing the rainwater pipe.

3. Check for all screws and bolts beeing tightend up properly.

4. Note that the aluminium does not directly contact other metals except zinc and stainless steel.

5. Please do not drill other holes than instructed.

6. Please caulk all places properly as shown.

7. Using silicone caulkikng material may cause damages to the polycarbonate roof panels. Use alcohol-free

caulking materials.

1. Please check for all screws and bolts beeing tighted up properly.

2. Please return the manual to the product owner.

Caution


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1. Package list

2. Dimensional drawings and part discription 1.Part discription

2.General measures

3. Installing the basic unit

1.Foundation preperation

2.Installing the posts and the rising beams

3.Installing the front frame, roof purlins and the rear frame

4.Installing the side frames and the roof rafters

5.Installing the roof panels

6.Installing the rainwater pipe4. Installing the M-Connection


2.Installing the main unit

5. Installing the Y-Connection



6. Installing the J-Connection



3.J-connection on M/Y-connection

4

8 8

9

14

14

15

16

18

19

2122

22

23

24

24

25

26

26

28

30


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Name Image

QTY

Front frame

corner cap R

Front frame

corner cap L

Rear frame

corner cap R

Rear framecorner cap L

Rising beam cap L

Joint cover R

Joint cover L

Anchor stick

Caulking material

Hole cover

Rainwater pipe

attachment

Drainage

hole cover

Rainwater pipe

packing

Drain elbow

*Please check the content of the component boxes shown below.Package lists

Parts set

Rising beam packing

Mini Basic

29/50 Type 57 Type 14 Type 50 Type 50 Type 14 Type


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92° drain elbow

Pipe holder

Adhesive

Hex bolt (SW+PW)

Name Image

QTYMINI Basic

Parts set

Installation manual

Post set

Name Image

Image

Regular post H18

Long post H23

High Long post H28

Name Image

Joint

QTY

2 pieces

QTYMini Basic

57 Type29/50 Type 14 Type 50 Type 57 Type 14 Type

Panel cushion

Tapping screw

Screw

Washer head screw

Driling screw

1 pieceLong post

2 pieces

Long post

1 piece

H28

1 piece

Installation manual

Rainwater pipe

Content is for the width 30 type

NameQTY

2 pieces 1 piece 2 pieces 1 piece

Joint


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Side frame R

Side frame L

Side frame cover

Roof rafter

Roof rafter cover

NameName Image Image

Name Image Name Image

Frant/Rear frame set

Front frame

Rear frame

Roof purline

Rainwater pipe

NameName

M-connection

cover (Lower plate)

M-connection

cap

Rising beam

connecting bracket

ImageImage

Side frame set Side frame set

Package lists

QTY

50 type 57 type 29 type 50 type 29 type57 type

QTY

QTY3 pieces 4 pieces 2 pieces 1 piece

QTY

PC roof panel Rising beam

Roof panel set Rising beam set

Name Image

QTY

M-connection set M-connection set

50 type 57 type 14 type 29 type

2 pieces

QTY QTY

3 pieces 3 pieces 3 pieces 3 pieces 3 pieces 3 pieces 3 pieces 3 pieces 3 pieces

Hex bolt

Ø 4x13

Drilling screw

Plain washer

Spring washer

Cap nut

50 type50 type 57 type 14 type14 type57 type


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Y-Connection set J-parts for M-connection set

Name ImageQTY Name Image QTY

Y-connetion cover

(lower plate)

Y-connetion cap

Y-connetion

post bracket

(10-1) Ø 4x13

Drilling screw

J-connection cover for M/Y(upper)

(11-1) Ø 4x13 Drilling screw

M/Y-Connection beam set J-parts set

J-parts for Y-connection set

57 type 57 type 57 type

50 type 57 type 14 type

18-27 type 30 type

57 typeName Image

M/Y-connection

beam

Roof rafter

Roof rafter cover

Front frame

sleeve

Rear frame

sleeve

Roof purlin sleeve

Roof holder

Roof holder spacer

Name

Roof purlin enforcement set

(L=1500)

Name Image QTY

Name ImageQTY

Name Image

QTY

Name ImageQTY

J-roof rafter set

Roof material holder set Optional Optional


(15-1) Ø 4x13

Drilling screw

Roof purlin enforcement set

Image QTY7 pieces(50 type)

8 pieces(57 type)

2 pieces(14 type)




Instruction manual

Instruction manual (MAL-442A/D428)

For enformcement purposes such as windy places

J-connection cover for M

(lower)

J-connection cover for M/Y

(upper)

J-connection cover for Y

(lower)


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Dimensional drawings and parts discription

Side frame cover

Part discription

Ø 4x13 Drilling screw

Front frame corner cap

PC Roof panel

Roof rafter cover

Ø 4x10 Washer head screwRoof rafter

Ø 4x13 Drilling screw

Front frame

(1-4) Ø 4x10

washer head screw

Ø 4x10

washer head screw

M8X25 hexbolt

Joint

Joint cover

Post

Rising beam cap

Side frame cover

Side frame(Note the left and right side)

Panel holder

Foundation

Roof purline

Rear frame corner cap

Rising beam

Rear

frame

Ø 6 drainage hole Ø 4x13 Drilling screw

Ø 5x14 Screw

Tapping screw

M8x25

Hexbolt


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Dimensional drawing * basic version. ( ) size in this brackets is for long post, [ ] 28H

Width R type

Diagram 2-1

Diagram 2-1 18-21 Size Diagram 2-2 24-30 Size

Foundation concrete

Crushed stones

160-24 - 27 size

Width a: 50 Type a: 57 Type

Width F type

Diagram 2-3 18-21 Size Diagram 2-4 24-30 Size

Foundation concrete

Crushed stones

a : 50 Type a : 57 TypeWidth

Diagram 2-2


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Dimensional drawing *basic version. ( ) size in this brackets is for long post, [ ] 28H

50 type depth *moving range is 100 mm

57 type depth *moving range is 100 mm

Size

Size

28 type depth *No moving range

Joint cover

Rainwater pipe

Foundation concrete

Crushed stones

Foundation concrete

Crushed stones


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14 depth type*moving range is 100 mm. Type in this brackets < > is 57 depth type.

Foundation concrete

Crushed stones Size

J-connection *moving range is 100 mm. Type in this brackets < > is 57 depth type.

Foundation concrete

Crushed stones

Size


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Width M-connection R type

Diagram 2-3

14 depth type *moving range is 100 mm. Type in this brackets < > is 57 depth type.

Width M-connection F type

SizeSize

Size

Width a:50 type a:57 type B

SizeSize

Size

Diagram 2-4Width a:50 type a:57 type B


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Width Y-connection R type

Diagram 2-5

Size

Size

Size

Width Y-connection F type

Diagram 2-6

Size

SizeSize

Width a:50 type a:57 type

a:50 type a:57 type


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Installing the basic unit

Foundation preparation

Foundation praparation

Carport outer line Carport outer line

Diagram 1-1 29 Size

Diagram 1-2 50 Size

Carport outer line

Diagram 1-3 57 Size

Diagram 1-1

Advice

Size

Post moving range is up to 100 mm in total.

There is no moving range for the 29 size.

The width for the 29 size is only 18,21.

Prepare the foundation after determining the positions for the posts.

Without concrete slab Without concrete slabWith concrete slab With concrete slab


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Foundation preparation *For Y-connection with concrete slab on grade

Concrete slab

Post200 mm

1 0 0 mm

Concrete foundation

Reinforcing

steel (*2)

Crushed stones

Front frame

direction

Diagram 1-5 For Y-connection

Diagram 1-4 For concrete slab on grade

Size

Basic / M-connection Y-connection

The distance of the outside edge between the foundation and the concrete slab has to be 200 mm. (*1)

Please install reinforcing steel in the concrete slab. (*2)

Point

M8x25 hex bolt

Joint

Joint cover R

Joint cover L

Rising beam

Tapping screw

Caulking material

Caulking

Rising beam capDrainage hole (*1)

Anchor stick

M8x25

Hex bolt

Post

(*1)

Installing the posts and rising beams

Caution

Do not install the rainwater

pipe on the "precautions"

sticker side. Attach it to the

side without sticker.

A part Diagram 2-1

Sealing

1. Insert the anchor stick into the post.

2. Attach the joint (1-1) to the post.

3. Attach the rising beam to the joint.

4. Attach the joint cover R and L.

5. Apply caulking material into the rising

beam cap and attach it to the rising

beam. (Diagram 2-1 )

Drill a drainge hole into the post

close to the ground line (G.L.), (*1).

Rising beam

cap


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Installing the front frame, roof purlins, rear frame

Installing the front frame, roof purlins and the rear frame

Ø 5x14 Screw

PC Panel holder

Rear frame

Washer head screw

Panel cushion

Joint cover

Post

Roof purlin

Notch

Rising beam

After moving the posts, adjust the front

and brack frame and the roof purlin tothe rising beam and drill Ø 5,5 hole in to

the back and Ø 4,5 holes into the front

frame and into the roof purlin.

Please fix the rear frame to the

joint cover (1-3). (Diagram 3-1)

Please place the PC panel holder

so, that the space between the

two nothes are equal.

Point

Point

Point

Diagram 3-1

Panel cushion

Fin artRoof purlin

Risin beam

Rear frame

Front frame

Ø 4x10 Washer head screw

Front frame

Rising beam

Rising beam packing

Please attach the front frame to the

rising beam with washer head screws.

(Diagram 3-3)

Please cover all pre-drilled holes, with

cover seals.

Please cover all pre-drilled holes, with

cover seals.

Attach the cushioning material in

the center of the two nothes.

Please turn the fin part to the

front frame direction and fix the

roof purlin to the rising beam with

washer head screws.

Washer head screw


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Front frame corner cap R

Front frame corner cap L

Cauking material

Side frame R

Side frame L

Front frame

Roof purlin

Risin beam

Rear frame corner cap R

Rear frame corner cap L

Rear frame

Caulking material

Front frame corner cap R

Front frame corner cap L

Rear frame corner cap R

Rear frame corner cap L

Caulking

material

Roof rafterRoof rafter

Caulking

material

Rear frame

Side Frame R

Side frame L

Roof rafter

Notch

Side frame RSide frame L

Point

Point

Advice

Drilling screw

Installing the roof rafters and the side frames

Caulk all the front frame corner

caps and the back frame corner

caps and attach them to the

side frame R and L.

(Diagram 4-1, 4-2)

Drilling screw

Notch

(Diagram 4-1)

Please note the left and right side of

the side frame. Turn the side with

the notch to the rear frame direction.

Adjust the front frame, rear frame and the

roof purlin to the side frame R and L holes

and fix them with washer head screws

Rear frameRear frame

Please note the back and front direction of

the roof rafter. Adjust the front and rear

frame, and the roof purlin to the roof rafter

holes and fix them with washer head screws.

Caulk the space between the roof

rafter and the rear frame before

installing it.

Levelling

Please check:

1. Posts positioning/required interval

2. Rigth angles where appropriate

There are no pre-drilled holes on the

front, rear frame and the roof purlins.

Caulking

material(Diagram 4-2)

(Diagram 4-3)


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Installing the roof panels

Cover part

Roof panels

Front frame

Roof panel holder

Rear frame

Cover art

Roof anelRoof panel

Roof rafter cover

Front frame

Side frame

Roof anel

Side frame cover

Rear frame

Roof rafter cover

Caulking material

Front frame

Caulking material

Side frame cover

Point

Point

Diagram 5-1

Diagram 5-2

Diagram 5-3

Installing the side frame and roof purlin

Installing the roof panels

Insert the roof panel into the

rear frame completely.(*1)

Place the roof panels on the

roof rafters properly.

Insert the roof panel into the

front frame and then into the

rear frame.

(*1)

Please attach the roof panels

the right way up, peel off theprotection and install it.

Washer head screw

Please make sure the roof rafter

and the roof rafter cover interlock.

Press the roof rafter cover and the

side frame cover into the front

frame and fix them with screws.

Caulk the space between the

front frame and the roof rafter

cover, the front frame and side

frame before installing them.

Diagram 5-5 Caulking


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Drainage hole

Installing the rainwater pipe

Rainwater pipe packing

Rainwater pipe attachment

Drain elbow

Adhesive positon

Drainage hole

Rainwater pipe packing

Drainage hole cover

Pi e holder

Adhesive position

Washer head screw

Rear frame

Caulking material

Rear frame

Adhesive position

Rising beam

Washer head screw

Rainwater pipe

drilling screw

Diagram 6-1 Pipe size adjustment

92° drain elbow

Size

1.Please adjust the pipe size. (Diagram 6-1)

2.Apply adhesive/caulking material to the rear frame drainage holes, rainwater pipe hole packings, rainwater

pipe attachment, drain elbow, 92° drain elbow and the pipe holder and fix them with screws (1-4 and 1-5).3.Close the unused drainage hole with the rainwater pipe packing and drainage hole cover using the washer

head screws (1-4).

4.Caulk the screw area properly.


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Installing the M-connection

Foundation preperation

Carport outer line

Diagram 1-1 29 Size

Size

Name

Diagram 1-2 50 Size

Diagram 1-3 57 Size

Without mat foundation

With mat foundation

Without mat foundation

With mat foundation

Carport outer line

Diagram 1-1

Prepare the foundation after determining the post positions.

Additional

information

Point

Post moving range is up to 100 mm in total.

There is no moving range for the 29 size.


The size of the foundation changes depending on the sizes of the width and depth.

Carport outer line


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Installing the main unit

M8x75 Hex bolt

M8 Plain washer

Caulking material

M-connection cap

M/Y-connection beam

M8 cap nut

M8 spring washer

M8 Plain washer

Rising beam

M-connection cover

Front frame

Rising beam

Reference position

P ost l en gt h

Front

frame

M/Y-connection beam

Front frame

Rising beam

Rising beam

connecting bracket

Approx. 900

Approx. 1700

Approx. 1500

1. After setting up the rising beam and the posts, remove the roof purlin push button and connect the roof purlins with the

roof purlin connecting bracket. (2-1)

2. Please insert the M/Y-connection beam between the two front frames and fix them with M-connection covers.

3. Apply caulk to the M-connection cap and the M/Y-connection beam and fix the M-connection cap with drilling screws.

(Diagram 2-4)

Approx. 900

Approx. 1700

Approx. 1500

Diagram 2-3

M/Y-connection beam

Side frame

Drilling screw

Diagram 2-5

Drilling screw

P ost l en gt h

M-connection cover M-connection cover installation position

Please make sure that the posts length keep the same height from the reference position (Diagram 2-5)

Point

Advice

To install the main unit please refer to point "3 Installation basic unit".

Please make sure that the space between the both front frames are 14 mm.

In case of depth 57 type, M-connection cover need to be placed at the center of the M/Y-connection beam.(*2)


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Installing the Y-connection


Carport

outer line

Carport

outer line

Carport

outer line

Diagram 1-1 29 Size

Diagram 1-2 50 Size

Diagram 1-3 57 Size

Size

Name

Make sure to fix the anchor stick to the post.

The moving range of the posts is up to 100 mm in total.

The size 29 has no moving range.


The foundation size changes depending on the sizes of the width and depth.

Without concrete slab With concete slab

With concrete slab

Prepare the foundation after determining the post position.

Advice

Point

Without concrete slab


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Joint

Post

Hex boltPost Y-connection bracket

Side frame

M/Y-connection beam

Y-connection cap

Drilling screw

Diagram 2-1

Diagram 2-2

M/Y-connection beam

Rear frame

Y-connection cover

Drillin screwY-connection cap

Post

Y-connection cover installtion position

Advice

Point

Insert the joints into the posts and fix only the front side of the posts.

Fix the screws loosely (1-1) and insert Y-connection post bracket inside and tighten it firmly.

(Diagram 2-1)

The space between the posts is 30 mm.

Please make sure that the posts have the same height.

Y-connection post bracket need to be placed at the lower part of (1-1) hex bolts for fixing the joints.

1.Please put the M/ Y-connection beam into the rear frames and fix it wth the Y-connection cover.

2.Caulk the Y-connection cap and the Y/M-connection beam and fix the Y-connection cap.

To install the main unit please refer to point "3 Installation basic unit".

In case of depth 57 type, Y-connection cover need to be placed at the center of the M/Y-connection beam. (*1)

Rear frame

29: Apporx.900

50: Apporx.170057: A orx.1500

(*1)

29: Apporx.900

50: Apporx.170057: Apporx.1500


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Installing the J-connection


Depth size 50 + 50Carport

outer line

Diagram 1-1

Size

NameWithout concrete slab

Without concrete slabWith concrete slab With concrete slab


Advice

Depth size 57 + 57

Carport

outer line

Refer to "2 Dimensional drawings and part dispriction" for preparing the foundation.





With concrete slab With concrete slabWithout concrete slab Without concrete slab

Advice


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Depth size 50 + 14

Carport

outer line

Diagram 1-3

SizeName




Carport

outer line

Depth size 57 + 14

Size

Name




Without concrete slab Without concrete slabWith concrete slab With concrete slab

Advice

Without concrete slab With concrete slab Without concrete slab With concrete slab

Advice


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Dimensional drawings J-connection part

Rear frame

Front frame

Roof purlin

Diagram 2-1 Installing the rear frame

Diagram 2-2 Installing the front frame

Diagram 2-3 Installing the roof purline

Refer to the drawings and drill holes into the front and rear frame and into the roof purline.

Point

The holes of the roof purlines need to be drilled to the fin part.


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J-connection

Caulking works

Please caulk the rear frame sleeve before attaching it. (*1)Fix the respective sleeves with drilling screws to the front and rear frame and to the roof purlin.

Caulk all the respective places around the drilling screws.

Front frame

Drilling screw

Drilling screw

Rear frame

Roof purlin

Front frame sleeve

Roof rafter

Roof purlin

sleeve

Rear frame

sleeve

Rear frame sleeve

Caulk

Roof purlin sleeve

Caulk

Front frame

sleeve

Caulk

Refer to "3 Installing the basic unit" for setting up the main unit.

(*1)

Caulk all the necessary parts of J-connection.


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J-connection on M/Y-connection

Drilling screw

Drilling screw

Fix the J-connection on M/Y connection covers (upper and lower) with drilling (11-1, 12-1) screws to

the connection part of the M/Y-connection beams.

M-connection cover

Y-connection cover (57 only)

Y-connection cover

Front frameRoof rafter

M/Y-connection

beam Roof rafter

In case of the 14-extended length, please refer to diagrams 3-2 and 3-4 for the M/Y-connection positions.

Refer to " 4 Installing the M-connection" and "5 Installing the Y-connection" for the complete installation.

Front frame

Diagram 3-1 J-connection on M-connection

Diagram 3-3 Y-connection

Diagram 3-2 M-connection cover

installation position

Dia ram 3-4 Y-connection cover ositon

M-connection cover (57 only)

Post

Rear frame

Advice

Point

Front frame

M/Y-connection

Beam

Rising beam


(lower)


u er


(upper)

J-connection cover for M (lower)


(lower)

J-connection cover for M/Y(upper) J-connection cover for M/Y(upper)


(lower)


(lower)

J-connection cover for Y (lower)


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montagehandleiding carport nagoya

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