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STAPLED AWNINGS
Fifteen years ago, awnings and signs
were two separate custom fabricated structures with specific
purposes. Since then, awnings and signs have become hybrids of one
another with interchanging roles: awnings for signage and signs
for protection against the elements. This trend is partly due to a
change in the type of framing materials used for both awnings and
signs. The new Staple-In Framing Systems have allowed some awning
companies to venture into the sign business and vice-versa.
Staple-In frames are constructed much like traditional steel
frames in that lengths of aluminum extrusion are cut, bent and
welded into the type of designs the projects require.
STEEL VS.
ALUMINUM
The similarities of Staple-In frames
and traditional steel frames ends here. When attaching a sewn cover to the traditional steel
frame a rope lace-on system or series of tek screws is used. A
Staple-In frame cover is attached by stapling fabric panels to the
aluminum extrusion frame. After the frame is completely covered
and the excess fabric is trimmed, a pvc trim is applied to cover
the staple channel.
PROFILE
SHAPES
Each extruded awning shape available
on the market comes in different wall thicknesses to accommodate for various wind and now
loads. Steel Stitch, consists of a series of extrusion profiles
also available in various wall thicknesses and designs. The most
common profile is 1" square with a 1/8" wall. Another
popular profile is a 4" I-Beam used for extended spans with fewer intermediary trusses.
FRAME FABRICATION
The ribs are cut to length and bent to
shape using an automated tubing bender or manually with a simple
jig. By using one rib as a pattern the rest can be bent to match
the first one. Finish the perimeter first and you have the
foundation on which to build the rest of the awning. Complete the
interior framework, then weld the ribs into place before laying
down the final welds.
COVER IT UP
Fabric panels should be cut about 6"
oversize to allow for gripping stretch over the frame. Start with
a few staples in the top-center area, a few more in the
bottom-center, then work your way out to the corners, being sure
to stretch the fabric as you go. This will minimize wrinkles and
puckers. There are normally about two staples in a seam. Special
clamps hold the fabric in place
while staples are secured. Excess fabric should then be trimmed
away. Continue the process for each section.
TIME TO TRIM
The final step is covering the staple
channel with a PVC trim so the fabric seam is protected from the
environment. The trim can be pressed into place manually or with a
hammer, but a neater and more efficient job can be done with the
use of an air hammer (which produces a rapid succession of blows,
enabling the operator to quickly insert the trim).
INSTALLATION
Installing the Staple-In awning is
relatively identical to that of a traditional steel frame awning.
"Z Brackets" are mounted so that the awning can be temporarily
hung. The rest of the brackets are marked for position and
installed. The awning is then re-hung for final alignment and
tightening. The Staple-In systems on today's market are opening
new doors to creative manufacturing within our industry.
John Workman, Unitex Corporation |
