How To Build a Double Shade Structure with Metal Roof

Difficulty: Very Complex  |  Estimated time: 6 hours  |  Help needed: 4 volunteers

Shade is a very important topic for many communities when it comes to their children. The structure not only provides a bit of relief from the sun but also adds to the aesthetic quality of the overall playspace. The more inviting a gathering area is, the more likely community members will begin to treat it like the “town square” it should be.

Download Instructions

Materials and tools

Quantity: Materials:
2 4x4x12' boards
6 4x4x10' boards
16 2x6x8' boards
9 80lb bags concrete
16 ½"x8" galvanized carriage bolts
16 ½" galvanized washers
16 ½" galvanized nuts
5lbs 2 ½" deck screws
16 H2.5A rafter ties
8 LS30-R skewable angle braces
2lbs 1 ½" N8 nails
5lbs Metal roofing screws
Tools needed:
Miter saw
Pencil
Tape measure
Carpenter's square
Safety glasses
Drill
½" long drill bit
Screwdriver bit
Ladder
Level
¾" socket with ratchet or ¾" open-ended wrench
String line
Marking paint

Preparation instructions

  1. Sort all materials into piles by like item to ensure you have materials needed to complete project.

  2. Take [2] of the 4x4x12' boards. Cut each into [4] 36" pieces, for a total of [8] 4x4x36" pieces.

  3. Do NOT cut the following:

    • [6] 4x4x10' boards
    • [16] 2x6x8' boards
  4. Angled Cuts:

    • Take the [8] 4x4x36" pieces cut in step 2. Set the miter saw to 45° and cut the angle off of both ends of each piece, for a total of [8] 4x4x36" trapezoids.

Build instructions

  1. Before building, inventory and sort all of your materials.

    Quantity: Inventory:
    6 4x4x10' boards
    8 4x4x36" trapezoids
    16 2x6x8' boards
    8 pieces Corrugated metal roofing panels
  2. Use the [6] 4x4x10s as the posts. Each post will be buried 2' in the ground with concrete. The footprint of the shade structure is 14' long by 6 ½' wide. Holes need to be 24" deep with an 8" diameter.

  3. Your posts need to be level, both side to side and front to back. They also need to be in a straight line with proper alignment. A string line can be helpful for this.

  4. Allow the concrete to set for several hours before moving on to the following steps.

  5. Take [8] 2x6x8' boards and lay them on the ground. The 2x6x8' boards will meet in the middle of the center post and run parallel with the long side of the structure stretching roughly 10" past the outside posts. The 2x6x8 boards will run on BOTH sides of the 4x4 posts.

  6. Raise the headers to the tops of the 4x4 posts and level them (keep in mind the tops of the posts might not be exactly the same height, it is not necessary). Attach the headers to the posts temporarily with 2 ½" screws.

  7. Using the long ½" drill bit, drill one hole through both 2x6x8 headers and the 4x4 post in order to fit the 8" carriage through this hole. On the center posts, each set of headers will get a bolt (2 bolts per center post).

  8. Now place a carriage bolt through each hole that has been drilled (there should be a total of 8 holes- 1 through each corner post and 2 though both center posts). Put the carriage both through the hole so that the head of the bolt is facing outward and the washer and nut are on the inside of the structure.

  9. Next attach the 4x4x36' trapezoid braces. Make sure the 45° angle sits flush with the 4x4 post but also passes through the 2x6x8 headers. Attach the lower end of the 4x4 trapezoid brace to the 4x4 post using the angled brackets and the 1 ½" nails.

  10. On the higher end of the trapezoid brace, again use the ½" long drill bit to drill a hole through both 2x6x8 headers and the 4x4x36" trapezoid brace. Place a 8" carriage bolt through this hole and attach using a washer and nut, again making sure the head is on the outside of the structure and the washer and nut are on the inside.

  11. Next lay out the remaining [8] 2x6x8 rafters above the headers. The rafters should overhang the outside headers by about 5 ¾" on each side. The rafters should be roughly 2'6" apart. The end rafters (red) should be approximately flush with the end of the headers. There are 2 rafters (green), side by side, in the center (to cover the seams where the 2x2s will meet).



  12. Use the rafter ties to attach the rafters to the headers. Make sure that 2 rafter ties are used per rafter (one on each end). You’ll use the 1 ½" nails to fasten the rafters to the headers.

  13. Next lay out 4 of the 8 corrugated metal roofing panels on top of the rafters you just attached. The panels will run perpendicular to the rafters. It is important the panels overlap, so before you screw any panels down, lay all 4 out first. Once you have all 4 spaced out, use the metal roofing screws to attach the panels to the rafters. Note: all panels will lie on top of both center 2x6x8 rafters (this is so the panels overlap end-to-end in addition to side-by-side).



  14. Finally, place the remaining four metal panels on the second half of the structure. Be sure these are also overlapping side to side as well as on the center two 2x6x8 headers.