Need advice on closing in a carport

[MadeByMiller]

I run my welding and fabrication business from my single car detached garage. I'm out of space and am needing to do something quickly to increase my square footage. This would ideally be solved by building a nice big shop, but that unfortunately is not in the budget and this project must be cash flowed - so no loans. Attached to the garage is a carport, which I thought could be closed in with a slab poured to nearly double my space. I've had a few contractors come out and give differing opinions on what the best way to go about this would be. The consistent issue for most of them is the connection point between the carport and garage. A 2x6 was fastened to the 2x4 rafter tails on the eaves of the garage and joist hangers were then nailed to that 2x6. The roof of the carport is made up of 2x6x12' spaced the same as the garage rafters - 24" on center. The majority of contractors have told me that is a structural weak point, living in South Dakota snow load is an important factor. Another issue is the flatness of the roof, when a 4' level is placed on the roof, theres only about 1" of slope. This has me worried about water getting in by running backwards and under the garage shingles. Some have suggested a metal roof or a rubber roof over the carport to combat this. Finally, the issue of whether or not to add a footing to the new concrete slab has been getting conflicting opinions. The existing garage does have a footing all the way around.

To try to clear up the thread I'll try to summarize my questions:

1. Is the existing carport roof worth salvaging or is the best method scrapping it and building a new roof?

2. If the existing carport roof is worth saving, will I be safe from leaks with a metal roof or rubber roof?

3. Do I need a footing on the new concrete slab?

4. I'm hoping to stay within $6-8,000 for this project, is that realistic?

Note: The existing garage is 24'x14', the carport is 24'x12' added on to the 12" roof overhang, with the posts at a 10' distance from the garage walls. I'm wanting the addition to be 24'x12'.

 

[Bretny]

That does not look strong. You should run those car port rafters over the wall of the garage. Im not your you can accomplish that with saving whats there.

 

[Slednut]

I have a patio cover that's screwed to the end of the rafters the same way. During the winter I always keep the snow off it, worried it will come down. I would not leave it that way.

 

[jshillin]

Rip the carport roof off, then get 24 or 26' lumber, 2x8 or 2x10's. Then you start the new roof at the peak of your old roof and take it down to your header. Then you build a knee wall off of the outside garage wall to come up in the middle of the 2x's to help spread the load.

 

[mike93lx]

That's tough. You'll spend a lot on concrete alone. Is that required?

For that much, you can get a decent size shed built and delivered. Maybe consider that?

 

[rsanter]

I would look at other options verses closing in that carport.
They are right that is a weak point

The only way I would close that in and use it like it is would be to put a garage door on the side and have the area under that carport be a open work area where I have no equipment and I would only work there when there is not a bunch of show on that roof

 

[MadeByMiller]

I really appreciate you all chiming in. It's reassuring that there is a consensus here. It's hard to judge who's right and wrong when local contractors are giving me conflicting opinions. Not having expertise in the carpentry field it's nice to have a resource as broad as the forum to bring subjects like this to. The obvious answer to me now is to be safe and smart and scrap the idea of closing in the existing roof. I'm still waiting for bids to come in from contractors who agreed that a new roof is best. It's looking like I'll have to deal with the lack of space for a while yet while I save up the money for other options.

 

[txvwnut]

Rip the carport roof off, then get 24 or 26' lumber, 2x8 or 2x10's. Then you start the new roof at the peak of your old roof and take it down to your header. Then you build a knee wall off of the outside garage wall to come up in the middle of the 2x's to help spread the load.

This right here is the way I would do it.

 

[DOUGD]

Does the roof leak now? It looks like fairly new construction. If you want to go low dollar and save the labor of removing it, I would suggest setting additional posts and building a header to support the inboard peak. What you have now is a future disaster with a heavy wet snow load. Don't spend the money on concrete with this structure. Simply add treated 2x6s around the perimeter attached to the posts and fill with fine 1/2" crusher run gravel to create a firm and level floor. Install horizontal purlins to the aft wall and outboard wall skin these with pre painted metal R-panel or similar to the two outboard walls and call it done. This will give you valuable dry storage space at a low cost. Save your money and build a proper metal building for your shop in the future.

 

[CraigStu]

Rip the carport roof off, then get 24 or 26' lumber, 2x8 or 2x10's. Then you start the new roof at the peak of your old roof and take it down to your header. Then you build a knee wall off of the outside garage wall to come up in the middle of the 2x's to help spread the load.

I would be concerned that the new roof is way to heavy to be supported by whatever is holding up the peak of the existing roof. The existing roof was designed to hold itself up. This would be asking it to also hold up 50% of a 24x24 roof made from 2x10s.

 

[txvwnut]

I would be concerned that the new roof is way to heavy to be supported by whatever is holding up the peak of the existing roof. The existing roof was designed to hold itself up. This would be asking it to also hold up 50% of a 24x24 roof made from 2x10s.

With the knee wall the weight from the ridge to the wall will be the same as the original design.

 

[ford33]

If you are running a fabrication business out of a one car garage and need more space, that is a good problem to have. Here are some other options which solve your immediate issue without spending a dime.

1. You stated you need more space but cash flow is the issue. That is a temporary issue and you are attempting to resolve it with a permanent and expensive fix by spending money to add space. Work with this temporary situation and save the soon to be received profits until you can resolve your space problem correctly.

2. Find a local business that has unused space and ask to lease it. Many companies begin by leasing unused office or industrial space from other companies. The rate is usually lower than market.

3. Clean and organize your space to accommodate your needs. A one man shop does not need much space to work.

4. Focus instead on growing your business profits. Charge a fair rate and value your time correctly. If you work on increasing your profits, you will have enough money to build or lease the needed space.

5. Get your receivables under control. If you have cash flow issues and the problem is people who late pay you, get that fixed now. Your are running a for-profit business not a charity. The accounting process is just as important as the manufacturing process.

Good luck with your business.

 

[rayra]

You can either shore that roof junction with post and beam, or I would suggest deconstructing the carport roof and re-using the materials as much as practicable, after you pour your slab extension WITH a good perimeter footing that will take your wall and roof load.

And consider putting a post and beam setup on that midline anyway and make it the base of some new roof trusses that relocate the peak of your roof to the center of your new structure. You'll gain a lot of storage height and it won't cost much more. Should still be within your budget, if you do most of the work yourself. I include in that the new slab. It isn't difficult to do it properly. Especially a slab that size.

 

[MadeByMiller]

Rip the carport roof off, then get 24 or 26' lumber, 2x8 or 2x10's. Then you start the new roof at the peak of your old roof and take it down to your header. Then you build a knee wall off of the outside garage wall to come up in the middle of the 2x's to help spread the load.

How would you tie the new 2x's into the peak of the existing rafters?

 

[MadeByMiller]

If you are running a fabrication business out of a one car garage and need more space, that is a good problem to have. Here are some other options which solve your immediate issue without spending a dime.

1. You stated you need more space but cash flow is the issue. That is a temporary issue and you are attempting to resolve it with a permanent and expensive fix by spending money to add space. Work with this temporary situation and save the soon to be received profits until you can resolve your space problem correctly.

2. Find a local business that has unused space and ask to lease it. Many companies begin by leasing unused office or industrial space from other companies. The rate is usually lower than market.

3. Clean and organize your space to accommodate your needs. A one man shop does not need much space to work.

4. Focus instead on growing your business profits. Charge a fair rate and value your time correctly. If you work on increasing your profits, you will have enough money to build or lease the needed space.

5. Get your receivables under control. If you have cash flow issues and the problem is people who late pay you, get that fixed now. Your are running a for-profit business not a charity. The accounting process is just as important as the manufacturing process.

Good luck with your business.

You bring up some wise points. I definitely wont make a hasty decision here, I'm exploring my options. Something that I forgot to mention in the post is that I also have some machining equipment and things I would prefer be out of the very dirty welding shop. Grinding dust gets everywhere and I don't want it getting in my machines. I do keep them covered with sheets at the moment, but that's still not ideal. As far as cash flow, I don't really believe I have a problem, I'm just a small business and prefer not to take out loans for anything and can't justify spending $40,000 to build a shop at the moment. I have no overdue invoices, my clients pay on time always. I agree with you absolutely that I don't need a lot of space, and a reorganization and better shop layout would certainly help, but it doesn't solve the issue of the dirty environment my tools are in. I've considered building a wall down the middle of the shop to separate the two, but that would leave me with 2 14'x12' spaces.

Thank you for your reply and insight, I appreciate the reminder to prioritize my spending and focus on what's important.

 

[jshillin]

How would you tie the new 2x's into the peak of the existing rafters?

You remove the shingles, but leave the sheeting, then you put down a 2x12 the width of the roof to spread the load. The new joists will have a long angle cut. The 2x12 won't be wide enough to support it all, so then you'll do the same thing with 2x's for the width of the cut. Then you build a couple other supports down to your existing wall, that's where you build the knee wall to put the load on it.