The concept of stapling fabric into an aluminum frame is the most durable method of awning and canopy fabrication. Generally all staple-in frame systems have these things in common: An extruded aluminum tube with one open side, A thin interior web inside the tube to receive staples, and a PVC insert that seals the open channel once the fabric has been stapled into the web. A 1" x 1" tube size has evolved into the standard for staple-in awning frames, with sidewall thickness varying to address the required wind and snow load demands of various awning configurations.

The mechanics of the system are quite simple. (See illustrations at left) The fabric is pulled tight across the top of the member into which it will be stapled. The narrow nose on the staple gun pushes the fabric down into the channel and holds it near the surface of the web. The staple gun then drives the staple through the fabric and the web. The elasticity of the aluminum "squeezes" the staple creating friction forces that hold it in place. Anywhere from 1 to 4 staples per second can be driven into the channel depending on the skill level of the operator. There are normally about two staples per inch of seam. This process of stapling joins the fabric panels together and tensions the panels as they are joined to the frame. It is a very fast and efficient method of attaching covers.

By design, the staple-in system has a frame member everywhere that there is a fabric seam. This is because the frame is part of the seam. It is desirable to have the fabric attached to each frame member for structural reasons. According to industry standards, sewn covers are also supposed to be attached to each frame member. However, few sewn covers actually have this feature. In many cases, the cover is only attached to the frame around the perimeter of the awning shell. This is undesirable because it prevents the fabric from transferring upward loading pressures into the rafters.

The staple itself is either galvanized or stainless steel. This prevents electrolytic corrosion that is common when steel and aluminum are in direct contact with each other. Once the PVC insert is installed, the fabric seam is protected from the environment.
(See Frame Fabric illustration below)

• Corrosion resistant aluminum frames - eliminates rust stains
• Tight cover attachment to each frame member, with smoother frame edges minimize fabric wear from wind vibration
• Increased production speed results in shorter lead times
• Damaged fabric panels can be replaced individually, on the job site without removal of the entire cover - Frames can be re-stapled multiple times
• Exclusive PVC Flashing Strip affords Watertight connections to building surfaces - Eliminates sealant-to-fabric contact
• Watertight fabric-to-frame seams and awning module seams
• Greater geometric flexibility- for design of complex shapes