Carport and Awning Fabrication: Materials, Methods, and Sourcing Considerations
Want to fabricate carports and awnings that last for decades?
Fabrication has become quite competitive these days. The North American market alone is valued at USD 3.48 billion in 2023 and is expected to grow rapidly.
But here’s the kicker:
It doesn’t always hold lawn chairs and summer toys. Fabrication shops these days are erecting commercial canopies sheltering high-end industrial equipment. Examples include LNG fuelling stations, hospital oxygen tanks, industrial gas yards and aerospace test stations. These structures often require custom hardware such as cryogenic valves integrated into the building to properly manage the super-cold liquids stored below.
Sourcing the correct cryogenic valves from a trusted partner like Evergreen Midwest can mean success or failure of these specialty projects. They take care of the cryogenic end of your project while allowing the fabricator to focus on the steel and building the structure.
In this article, discover what materials and methods the premier fabrication shops are using along with where to source them to build durable carports and awnings that stand the test of time.
Let’s get into it!
What you’ll discover:
- The Top Materials Used In Fabrication
- Proven Fabrication Methods
- Sourcing Considerations You Can’t Ignore
- Mistakes That Kill Carport Projects
The Top Materials Used In Fabrication
Your material choice is the single most important decision in every project. Build it wrong and the carport will fall apart after the first heavy rain.
Here are the 3x main materials pro fabricators rely on today.
Steel
Steel is the king of carport fabrication. Why?
- It’s super strong
- Affordable for most budgets
- Easy to weld
- Widely available everywhere
Galvanized and powder coated steel are probably the most popular finishes since they don’t rust…Plus they last decades if done right.
The problem with steel though: It’s heavy. You have to have proper equipment, welders, and expertise to handle it properly.
Aluminum
Fabricators second favorite building material is aluminum. It is lighter than steel and doesn’t rust naturally.
The downsides? It’s pricier and harder to weld correctly.
Aluminum is the go-to choice for:
- Awning frames
- Lightweight residential carports
- Coastal projects where salt air destroys steel
- Retractable awning systems
Fabric And Polycarbonate
The roof material matters just as much as the frame.
Most awnings are made with heavy-duty fabric such as acrylic, vinyl, or polyester. Fabric awnings are very popular today because they are versatile and allow easy customisation.
Typical carports are made with polycarbonate panels or corrugated metal sheets… Due to needing to resist snow load, hail, and abuse from Mother Nature.
Proven Fabrication Methods
There are thousands of fabrication processes. However only some of them concern themselves with constructing durable carports and awnings.
Welding
Think welding. Welding holds together every metal carport being built today. The two types of welds you will need to know are:
- MIG welding: fast, easy to learn, perfect for steel frames
- TIG welding: slower but cleaner, best for aluminum work
The strength of your welds will affect the lifespan of the build. Poor welds lead to premature failure. Guaranteed.
Bending And Forming
Curved awning frames and ornamental carports require bending. Hydraulic press brakes or tube benders are typically used for this.
Done correctly, bending adds:
- Strength
- Visual appeal
- Custom shapes customers love
Done incorrectly? Cracks, kinks and weak spots that sabotage the entire project before it even hits the streets.
Finishing
Finishing is where a lot of fabricators cut corners. Don’t be one of them.
Good finishing always includes:
- Sandblasting
- Primer coating
- Powder coating or industrial paint
- UV-resistant sealants
Steps that prevent rust, sun fading and weather damage to the metal. Do not skip steps or you will quickly loose return customers.
Sourcing Considerations You Can’t Ignore
Now here is where the smart fabricators separate themselves from the pack…
Sourcing is not about who can provide the lowest cost steel. Sourcing is about developing relationships with suppliers that have proven track records of on-time delivery.
Specialty Industrial Projects
Some carport jobs are way more complex than a residential build.
Take LNG bunkering stations, for instance. They require special canopies built around cryogenic storage tanks. The US Energy Information Administration stated that America exported over 10 billion cubic feet daily of LNG in 2023. All of that equipment needs adequate shelter and protection.
These specialty jobs need integration with components like:
- Cryogenic valves and fittings
- Insulated piping
- Pressure relief systems
- Drainage routing for cold spills
You need to use specialized suppliers if you want to get a job like this done correctly.
Local Vs Imported Materials
Another big sourcing decision is local vs imported steel and aluminum.
Local materials:
- Faster delivery times
- Easier to inspect before purchase
- Better quality control
Imported materials:
- Often cheaper up front
- Longer lead times
- Quality can vary a lot by supplier
In general, local sourcing is superior to non-local sourcing. However, for large projects on a budget, a combination of both may allow you to meet your financial goals while still maintaining quality.
Pro Tip: Build relationships with 2-3 trusted vendors for each type of material. This provides you with options if another supplier is out of stock. Sudden shortages can close your business down if you only have 1 supplier.
Mistakes That Kill Carport Projects
Plenty of fabrication projects fail miserably. Here are the top things you should not do.
Skipping The Engineering
Lots of fabricators just “eyeball” the design. Huge mistake.
Every carport and awning needs proper engineering for:
- Wind loads
- Snow loads
- Soil conditions
- Local building codes
Skip this step and you risk collapse… Or worse, expensive lawsuits.
Using The Wrong Fasteners
Bolts, screws, and rivets seem boring. But they hold the entire structure together.
Use only stainless steel or galvanized fasteners for the metal you’re working with. Attaching different metals together will cause corrosion and fail joints.
Ignoring Maintenance Access
Smart fabricators design carports so they can be cleaned and serviced easily.
This includes:
- Inspection access points
- Removable roof panels
- Drainage paths that actually work
- Easy access to fasteners
It seems like such a minor thing, but it’s a big deal for your clients later on.
Tying It All Together
Carport and awning fabrication is a growing industry full of opportunity.
As the worldwide cryogenic valves market is expected to reach USD 5.40 billion by 2030, demand for industrial specialty canopies is rising along with the residential market. Shops that are equipped to do both will have more jobs.
The shops that win are the ones that:
- Pick the right materials for every job
- Use proven fabrication methods
- Source from quality suppliers
- Avoid the common pitfalls
You are building a residential awning or a large industrial canopy with cryogenic machines inside. The same principals still hold true. Build it right and take your time, they will last 100 years.
Fabrication Pricing Market Heating Up. Time to prepare your shop for the future.
