Bespoke Canopy for a Coach House

Canopy installation on a restored 1850s coach house

Along with our porches and verandas, all of ZAC’s door canopies are made by hand in our factory in Croydon, Surrey. This means they can be made to fit perfectly onto a wide range of property styles and substrates. This blog shows the manufacture and installation of a bespoke canopy made for a restored 1850s coach house located in the heart of a conservation area and area of outstanding beauty in Westerham, Kent.

The customer wanted their canopy to be clad in natural zinc and for it to span fully over their glass entrance way, which meant it needed to be just over 3 meters wide. They asked that its design complemented the beautiful arched windows and the overall exterior of the property. A design was agreed that would have a mix of convex and concave curves, and multiple panels that would be finished with folded caps. It was also agreed that the canopy would extend out by 1 meter so that it would overhang the outside step to ensure that it gave shelter from the elements.

The first part of the manufacturing process is to build the steel frame for the canopy. In reality, this means cutting, curving and welding the individual metal bars and finishing it off by sanding and powder-coating. The below shows the frame after these stages of the manufacturing process. You will also see four of the holes drilled into the frame, which will be used when fixing the canopy.

Steel frame of a canopy sitting on a bench.

Once the frame was completed, our tinsmiths set about cutting and fitting the natural zinc cladding.  The picture below shows the first three panels fitted onto the frame.  You may see our tinsmith Vinny in the background cutting the next panel to be fitted.

The panels of natural zinc installed onto the steel frame of a door canopy.

Once all of the panels and capping strips were fitted, it was delivered to site.

Zinc clad canopy being delivered on a flat bed truck.

As is normal in canopy installations, appropriate holes needed to be drilled into the wall that lined up with the pre-drilled holes in the canopy. Once the substrate had been assessed, it was agreed to use chemical fixings, which were appropriately installed. The customer had chosen to have stepped flashings, so the wall also had to be chased out for these. Once all of the preparation had been completed, the canopy was lifted into position using a genie lift. The picture below shows the canopy now in position and fixed to the wall.

Zinc clad door canopy lifted into position above glass doors.

It was then ready for the finishing touches to be added by the installation of the stepped flashing.

Man fitting step flashing onto the newly installed zinc clad door canopy.

Looking at the finished project below, I am sure you will agree that the canopy looks perfectly at home on this restored 1850s coach house.

Zinc clad door canopy over the doorway on a restored coach house.
View of zinc clad door canopy looking over at Westerham green.

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