Odd shape, pocket sleeve, hem, grommet & pinch pleat

Odd shape custom panel quotes are available with sketch

Best practice is to specify overall dimension at least 6 inches smaller than the trellis framework or cable perimeter interior dimension to allow for trampoline-style lacing with rope from grommets and wiggle-room for any variance. Denser knits have very little stretch under normal tension and the sewn perimeter hem will not stretch at all, but it certainly pays to provide space to lace odd shape panels properly. No need to over-tighten, stretch and distort a panel, but it should be taut to avoid wind movement, per installation guidelines. Production will do a fine job as always, but please note odd shape panels are not warranted for return, refund, or free replacement for any errors at quoted price.

Single odd shape panels are a minimum $175 delivered price. An economical alternative for odd shape canopy covers is to purchase plain cloth (no hem or grommet) and then cut on-site for optimal accuracy and install plastic locking clips. Cut fabric six to eight inches larger than finish dimension you are looking for and fold edges over several times. Cut edges can be sewn on a home sewing machine, but in practice sewing is not necessary when cut edges are folded over two or three times and clips placed every foot. Our commercial-duty locking clip anchors act as a grommet plus they allow for attaching directly to chain link fencing or running cable along the edge.

Sewn perimeter hem and grommet work

Brass grommets are standard industry practice for many reasons, primarily longevity. We experimented with other choices over the years, but negative feedback reinforced the use of brass. Black grommets shed their colorant, quickly becoming an eyesore. Aluminum grommets are much too soft, quickly degrading from rubbing abrasion against fasteners, cable and rope. And stainless steel is too dense to properly crimp closed unless produced so thin that they degrade nearly as fast as aluminum. Beware of grommet choices other than brass if you are concerned at all about longevity. Brass takes on a dark patina over time, blending in nicely with the black perimeter hem tape. Black color perimeter hem tape is the only choice available. When we offered color choices, the hem tape never identically matched fabric color and faded at different rates, displeasing clients. The black hem tape gradually fades to a softer gray-black, blending nicely with any color knit. 

Grommeted Pinch Pleats are standard practice on larger covers

Brass #4 grommets are installed one every foot along pinch pleat, just like the perimeter hem/edge. This additional lashing (tying to structure) with GPP eliminates lofting and sailing (rising in the wind) and sagging in the middle (pillowing) on larger shade panels. Movement and abrasion against the structure are what eventually causes material failure, not simple exposure to the sun, so keeping a panel taut is the key to longevity. It is not possible to overlap GPP in middle of panel (crossing one over the top of another) and GPP are not available with double layer panels. Exact spacing of GPP is not warranted and special grommet placement is not possible to specify. Professional installers begin large panel installations by lacing the center grommeted pinch pleat to central frame member (ridge beam, cable, conduit, or pipe) and then pulling pergola cover taut across width sides and finally tension across length, towards two ends in-turn.

Open End Pockets for inserting rod, pipe, or board through side

Finish dimension and installation tips

Description on the automated quoting form is overall FINISH outside-edge to outside-edge corner measurements that we do our best to make for you. Panels are cut down from larger roll widths, allowing extra inches of fabric to fold and sew hem for finish dimension specified. Quoting form description alerts when ordering stock roll width and finish dimension is anticipated to be less than entered. Sewn perimeter hem tape webbing installed on all four sides of canopy does not stretch. Denser knits have minimal interior 'pillowing' stretch under normal, adequate tension. Panel covers are generally ordered at least 6 inches overall smaller than interior of framework (or cable perimeter) and then laced with rope from every grommet, around all four sides. For instance: framework (or cable network) 12 foot by 12 foot interior measurement would normally see panel ordered no more than 11 foot 6 inch by 11 foot 6 inch overall. Perimeter gap area allows trampoline-style rope lacing and wiggle-room for possible production variance.

Avoid 'static fastening' directly through hem or grommets with staples, screws, hooks, or zip-ties since there is no room for variance and adjusting tension. Static fasteners are unyielding under stress from movement and often damage hem and grommets. If you do choose static fastening, we recommend using 1+ inch diameter fender washers to spread stress out evenly, across entire grommet. To avoid abrasion damage, best practice is to hang panels underneath the trellis, rather than stretch canopy cover across the top of your pergola. Mounting panels atop the trellis or pergola is only preferred engineering when cover is left up all winter in a snowy climate or with flat installations in areas of heavy rainfall. Recommend installing grommeted pinch pleats to support across middle or center. GPP provide critical lashing points to stop 'pillowing' and movement, greatly increasing longevity. Panels are single, one-piece construction never any exposed 'factory seam'. Our 20, 26 and 32 foot wide fabrics always have center loom splice covered with GPP for stability and optimal longevity. READ THIS PAGE for sizing guidelines, pegola cover installation tips, and design details.

Solid waterproof tarpaulin tent covers and toxic UV coatings

We do not sell any solid waterproof 'tarpaulin' or tent covers since they are not as effective at keeping a patio or pergola cool. Without holes in the fabric, like our knitted shade fabric, heated air cannot pass back up through. Trapping heat underneath like a tent and allowing rainwater to puddle atop decreases longevity. A knitted shade panel will dramatically slow rain down, but even when installed taut on a steep slope over 45 degrees, not all of the rainwater is going to run off the sides. Given the relatively short life expectancy of solid waterproof poly tarps that allow rainwater to puddle, we recommend roofing the pergola or trellis instead when you require 'waterproof'. Metal and Lexan roofing panels are lightweight, economical, and much longer-lasting than tarpaulin, but they can be insanely noisy in a rainstorm. Canvas tent tarps are expensive, dirty and a pain to keep oiled. And 'heavy-duty waterproof poly tarpaulin' are lucky to last a year in direct sunlight with cheap heat-seamed joints and edges, not fully sewn hems like our knit shade panels. Beware of 'UV resistant coatings' which are invariably toxic and flake off constantly as the tarp ages. Fire resistant tarpaulin coatings are even more toxic.

Locking clip fasteners attach any fabric on cable, fence, rope or nails

We do not sell grommet kits or nailing plates, since these locking clip anchor fasteners are so much more effective and long lasting on plain cloth panel pergola covers. Our commercial grade locking clips are heavy duty with longer barbs than 'residential grade' locking clips found in big box stores. These professional-duty commercial grade UV stabilized plastic locking clips are 1-1/2" wide by 1" tall and will easily penetrate at least two or three layers of thick material for a nice strong folded hem. With sewn reinforced hems, a scratch awl is best used to punch starter holes for the main barbs. Specifically designed for tying guy wires off or wrapping the fabric onto chain link fence, cable, or rope (up to 5/16 inch diameter). Large surface area ensures your material will not be damaged when pulled taut. They have TWO front holes for maximum versatility, a small 3/16" hole at top for hook (pictured) or screws and a larger 5/16" hole in middle for lag bolt (pictured). The pass-through opening across top/center will hold up to 5/16" diameter cable or rope (red rope pictured). Top image is a clip being installed, showing several options. Note we do not supply the S hooks, lag bolts, or rope pictured. Bottom image is front and back of a locking clip. You can even put one on each side of fabric, instead of folding over the edge, for a center-mounted fastening point in the middle of a panel. Fold cut edge of material over two or three times and and snap clip into place. Barbs on one side lock into holes on the other side of fastener. These anchor clips are very effective on chain link fences to stop movement in the wind.

Repairing a torn shade panel typically requires sewing

There are not any adhesive 'repair tapes' or patches available that will stand up to sunlight exposure and tensional stress for any length of time. Short small cuts on knit shade covers are best pulled together and chain-stitched by hand with needle and thread. Any local sewing or craft store will stock spools of heavy-duty black #90 UV upholstery thread and #18 chenille hand needles. Knit fabric is not prone to unraveling once properly sewn together, so it's not necessary to melt or sear cut edges. A little silicone or butyl caulk can be applied to better protect the repair, but never present an open flame anywhere near a panel. Longer tears and larger holes are best reinforced with 'hem tape' batten webbing (not adhesive) on a home sewing machine with a #16 or #18 ball-point needle. It might be possible to create a flat sewn 'patch' by laying one piece of webbing on both sides of the panel, but a 'pinch pleat' is much stronger and longer lasting. For a pinch pleat, the fabric is 'pinched' into a creased 'pleat' with solid webbing folded atop and sewn. Always test your sewing machine tension settings on a folded piece of webbing before stitching. We do not sell batten webbing in less than full 300 foot long rolls (see below) but you can search online for: "3 inch wide black polypropylene webbing strap". Note that nylon and polyester webbings do not have the same inherent UV sunlight resistance as polypropylene. Black is a better choice for longevity since it does not contain any added colorants which tend to break down in direct sunlight. Beware of fire retardant coatings.

Heavy-duty hem tape webbing for sewing reinforced batten edges