Keller Mechanical & Engineering designed, fabricated, and installed a custom steel truss system with a cantilevered roof extension to cover the active wash tunnel and adjacent vacuum plaza. The solution enhances structural integrity, expands protected customer areas, and showcases Keller’s ability to engineer and fabricate complex, site-specific steel systems.
The Challenge
Provide durable, code-compliant overhead coverage across mixed-use bays—without heavy columns cluttering the vac area. The system needed to manage Florida wind loads, maintain clear customer flow, and interface cleanly with existing equipment and foundations.
Our Solution
- Structural Design & Engineering: PE-sealed analysis to applicable FBC wind criteria; connection design for primary trusses, purlins, and cantilever arms; anchorage strategy to existing structure and footings.
- Custom Metal Fabrication: Precision-cut steel trusses, plates, stiffeners, and connection hardware; shop-welded assemblies to accelerate site installation and quality control.
- Cantilever Integration: Tailored moment connections and bracing to support the roof extension over the vacuum plaza—maximizing coverage with minimal posts for an open, easy-to-navigate layout.
- Field Installation: Sequenced lifts and set-out to maintain operations and protect on-site systems; fit-up, bolt-up, and final alignment with inspection checkpoints.
Custom Metal Fabrication Precision-cut steel trusses, plates, stiffeners, and connection hardware; shop-welded assemblies form a roof over Wash tunnel
Tailored moment connections and bracing to support the roof extension over the vacuum plaza—maximizing coverage with minimal posts for an open, easy-to-navigate layout.
Benefits
- More Coverage, Fewer Obstructions: Cantilevered spans deliver shade and rain protection over the vac plaza without a forest of columns.
- Higher Uptime & Better Experience: Weather protection improves guest comfort and helps limit weather-related downtime.
- Built for Florida Conditions: Engineered for uplift and lateral loads, with robust connections and diaphragm continuity.
- Faster Install, Cleaner Finish: Shop-fabricated components reduced on-site time and ensured consistent quality.
More Coverage, Fewer Obstructions: Cantilevered spans deliver shade and rain protection over the vac plaza without a forest of columns.
Services Provided
- Structural design & PE-stamped calculations
- Connection design (moment/seat/clip plates, stiffeners, bracing)
- Custom steel truss fabrication (shop welding, QC)
- Cantilever arm fabrication & roof support integration
- On-site erection, bolt tensioning, and inspections
- Permitting support and closeout documentation
Project Facts
- Customer: Mister Car Wash (Clearwater, FL)
- Scope: Design, custom metal fabrication, and installation of a truss-and-cantilever roof system covering the wash tunnel and vacuum plaza
- System Type: Steel trusses with engineered cantilever; purlins/secondary members; moment and braced connections
- Delivery: Design-build self-perform (steel fabrication + erection) (General Contractor, Design + Build)
- Code/AHJ: FBC wind design; City of Clearwater inspections