Attached Pergola ASSEMBLY INSTRUCTIONS Quality Control Number: Numéro de controle de qualitié: Número de control de calidad: © 2011 Suncast Corporation, Batavia, IL Includes instructions for 8' x 8', 8' x 12', 10' x 14', 10' x 16', 12' x 16', 14' x 14', or 14' x 20' pergola 0660108
Before You Begin... • Consult your local authorities for any permits required to construct pergola. Prior to the construction of your pergola, check with the local building code official to review any required permits or building limitations. • COMPLETE SITE PREPARATION AND FOUNDATION CONSTRUCTION BEFORE UNPACKING ALL PARTS. A level and sturdy foundation is required before pergola construction can begin. • Read instructions thoroughly prior to assembly.
Pergola Safety and Care • Wash pergola with garden hose or mild detergent solution and soft cloth. Do not use a stiff brush or abrasive cleaner as that could damage pergola. • Hot items, such as recently used grills, blowtorches, etc., must not be used in or near the pergola. Tools Needed for Installation 8' 8' Assembly Day Tips • Complete site preparation and foundation construction before unpacking parts and beginning assembly. • Take care when removing vinyl parts. Other parts are packed inside them.
Parts I G Post cover Top trim ring H F Top square post sleeve Round trim ring Temporary Beam Holder D A Vinyl column 4x4 wood post BB Temporary beam holder x2 CC Wood block x2 DD E B C Foot bracket Optional high-wind bracket Wood peg x2 Large base trim ring Pergola Size A B C D E F G H I 8x8 2 2 2 2 2 2 2 2 2 8x12 2 2 2 2 2 2 2 2 2 10x14 2 2 2 2 2 2 2 2 2 10x16 3 3 3 3 3 3 3 3 3 12x16 3 3 3 3 3 3 3 3 3 14x14 2 2 2 2 2 2
Parts R S Shade Shade trim T Shade splice O Rafter collar N GG Rafter sleeve End cap Q Rafter trim HH Rail mount L J P Beam sleeve 7' wood rafter insert Wood beam insert K 7' Wood beam insert M Beam trim Pergola Size J K L M N O P Q R S T GG HH 8x8 3 0 4 4 6 0 0 6 8 16 0 2 6 8x12 6 3 4 4 9 0 0 9 16 16 8 2 9 10x14 6 3 4 4 18 9 9 9 20 20 10 2 9 10x16 6 3 4 4 22 11 11 11 20 20 10 2 11 12x16 6 3 4 4 22 11 11 11 24
Hardware W X 5/16" x 4" Structural stainless steel white pan head screws #8 1" Screws V 3/16" Concrete drill bit Y 2 1/2" Stainless steel white pan head screws U 1/4" Wood drill bit AA 1/2" x 4" Concrete screws/bolts Z Concrete screws EE Washers FF Rafter clip II 5" Ledger board screws Note: These pieces shown at actual size.
Site preparation, unpacking, and platform construction (Materials NOT supplied with Pergola Kit) Note: Site preparation and platform construction and Support Post Installation steps may require professional assistance to be installed correctly. Please read all manual steps thoroughly before starting this project. Note: Site preparation and platform construction are required for this pergola. Placing the pergola on the ground without any type of foundation is not recommended.
Specs for post and beam layout Proper site preparation requires that the layout is square. Use the measurements on the chart provided to determine the correct spacing of the posts (A & B). The diagonal measurement (C) will ensure that the pergola is square.
Elevations Shade splice Shade trim 2x6 Rafters w/ wood fillers Hollow shades Rafters secured to beams w/ rafter clips Beam trim 2x8 Beams w/ wood fillers 4x4 Post 8' 9" Vinyl column 1' wood filler inside beams Foundation by others Beams (& 1' filler) secured to post w/ 4" structural screws ELEVATION A Rafter trim 8' 9" 2x6 Rafters w/ wood fillers Hollow shades Shades secured w/ 2.
Optional High-Wind Bracket Pre-Assembly 1 2 B x10 C A A If you have chosen to purchase the high-wind brackets (C), remove the screws in the existing brackets (B). Set brackets aside and save all screws for later. Slide the high-wind bracket (C) onto the bottom of the post (A), making sure that it is snug against the bottom. 3 C A Attach the high-wind bracket (C) using the screws that were removed in Step 1. The high-wind bracket uses an additional 14 screws that are included.
Support Post Installation " XX 'X 'X XX " 1 Using the chart on page 8, determine post layout. 2a Mark each post location. Each mark will be the exact center of the posts. 2b Standard bracket Optional high-wind bracket A A C B 1 1 2 2 For high wind areas, position post (A) and high-wind bracket (C) over mark and trace holes in bracket. Position post (A) and foot bracket (B) over mark and trace holes in bracket.
3a 3b Standard bracket (3/16" drill bit) V Drill holes using the 3/16" concrete drill bit (V) provided. Optional high-wind bracket (1/2" drill bit) (not included) For high-wind areas, use a 1/2" concrete drill bit (not included) to drill holes a minimum of 5" deep. 4 5 1 A 1 A Position wood posts (A) so that they are parallel with each other. Using a string, align the tops of the posts. This will ensure that when the beams are attached, they will fit properly against the posts.
6a 6b Z Optional bolts AA x4 x2 Use four concrete screws (Z) to secure. Tighten securely. Do not proceed with post covers until all wood posts are plumb and mounted securely. 6c As an option, additional 1/2" x 4" concrete screws/ bolts (AA) can be installed. 7 Optional high-wind bracket Repeat Steps 2-6 for remaining post. AA x4 Use concrete screws/bolts (AA) to secure brackets. Tighten securely. Do not proceed with post covers until all wood posts are plumb and mounted securely.
Post Trim Installation 8 9 H D G F E Unpack post trim boxes and position trim close to each post in the order shown. Slide vinyl column (D) over wood post. Fit lower portion of vinyl column over wood spacers, until cover rests securely on concrete surface. 10 11 F E Slide the large base trim ring (E) over the top of the column until it rests on the concrete surface. Slide round trim ring (F) down column until it rests on the raised ledge.
12 13 G H Slide top trim ring (G) over column, making sure the rounded part is facing down and the square part is facing up. Slide top square post sleeve (H) over wood post. 14 Repeat Steps 10-13 for remaining post. This is how the top post trim should look.
15 16 CC BB 1 DD 2 2 Hook temporary beam holder (BB) on top of the square post sleeve, facing direction of post, which will be supporting the opposite end of the beam. Repeat for opposite post. Insert wood block (CC), making sure the two holes in the wood block are facing upward. Insert a wood peg (DD) in each hole. Repeat for opposite post. This is how the temporary beam holder should look when it is positioned to hold the beam during beam installation.
Beam Pre-Assembly 17 1 2 J K Keep logo plate with screws. Unwrap beam sleeve (J) with the Suncast logo. Unscrew logo and remove. Set logo plate and gold screws aside to be reattached later. 19 18 1 K 6" 2 Slide 7' wood beam insert (K) out until 6" of the filler piece is exposed. Re-attach one side of the logo plate to the beam which will face front.
20 1 21 J 2 For front facing beam, measure the placement of the existing screw in the logo plate and transfer the measurement to the other end of the logo plate. Insert and tighten remaining screw. Slip opposite beam sleeve (J) over wood beam insert. (For front facing beam, lift logo plate while sliding beam sleeve underneath.) The seam should be snug where two sleeves meet. 22 3" X 23 3" L X 1/4" J J L x2 Unpack wood beam inserts (L).
24 X 25 6" Fasten a 1" screw (X) on the top edge of beam, 6" from the end of the beam. Note: Top edge of beam is determined by the logo plate orientation. 26 7 1/4" Measure and mark a line 7 1/4" in from the end of beam. Repeat on other end of beam. Note: Bottom edge of beam is determined by the logo plate orientation. 27 5" Repeat Steps 18-26 for remaining beam. U Note: Logo plate steps only apply to the beam which will face front.
Ledger Board Pre-Assembly 28 29 6" 3" X 3" X 2 1 K J x2 Slide 7' wood ledger board insert (K) out until 6" of the filler piece is exposed. Slip opposite ledger board sleeve (J) over wood ledger board insert. The seam should be snug where two sleeves meet. 30 Measure 3" from the splice on both sides. Fasten two 1" screws (X) on the top of the ledger board. 31 L X 1 1/2" J J L Unpack wood ledger board inserts (L). Slide wood ledger board insert into hollow ends of ledger board sleeve (J).
Beam Installation 33 32 GG J J GG Apply cement to the flange of end cap (GG). Promptly insert end cap into the ledger board (J) that will be attached to the house. Repeat for the other end of the ledger board (J). Using the chart on page 8, position the ledger board against house below where it will be attached. Mark concrete floor at both ends of the ledger board.
36 II X x3 3 37 1 J X X II X 2 J X 4 Attach one rail mount (HH) to each end of the ledger board and one rail mount in the center over the ledger board splice. Secure with three 1" screws (X) on each mount. Pergola Size Rafter Spacing (on center) Number of Rafters 8x8 16 3/4" 6 8x12 16" 9 10x14 19" 9 10x16 17 3/8" 11 12x16 17 3/8" 11 14x14 19" 9 14x20 19 1/4" 13 Refer to the chart to determine rail mount spacing.
40 39 1 1 J 1 FF FF 1 J 2 2 X Place the two beams (J) that will be attached to the posts next to the ledger board. Use the rail mounts on the ledger board and mark the two beams on both sides of the rail mount. Attach rafter clips (FF) on the marks of both beams using two 1" screws (X) on each clip. 41 42 J Position two 8' step ladders next to two posts. Double check the orientation of the temporary beam holders and make sure they are positioned to support the beams.
43 44 U W Make sure that the beam is resting on top of the vinyl column and pressed securely against the 4" square posts. Secure with two 4" pan head screws (W) through the beam and into the post. Repeat on opposite end of beam. Using the pre-drilled holes that you drilled in Step 26, drill a 1/4" pilot hole into the post. The pilot hole should go through the post vinyl sleeve and into the wood 1/4". 45 J The installed beam should look like this.
46 47 1 I 1 DD I BB 3 CC 2 H Remove wood pegs (DD) and slide out wood blocks (CC) to remove temporary beam holders (BB). Reinstall them, as needed, on remaining posts. Apply cement to the flange of post cover (I). Promptly slip post cover over the top of the top square post sleeve (H). Repeat for remaining posts. Note: It may be necessary to loosen the top of the beams to allow the cover to fit securely on post sleeve.
Rafter Pre-Assembly 49 50 1 1/2" N P X N 42" Insert a 1" screw (X) 1 1/2" from the end of the rafter sleeve (N). Slide the 7' wood rafter insert (P) out of the rafter sleeve (N) until it protrudes 42". 51 52 N 1 P P O 1 N 2 X Slide rafter collar (O) onto 7' wood rafter insert (P) so that half of it rests on the rafter sleeve (N). Slide rafter sleeve (N) over 7' wood rafter insert (P) until the two vinyl sleeves are touching. Insert a 1" screw (X) next to the collar.
54 53 Repeat steps 49-52 to assemble remaining rafters. At this point in the assembly process, all of the posts, beams, and rafter clips should be permanently installed. All of the rafters should be assembled and ready to be installed. Rafter Installation 56 55 1 1 N 2 Line rafter up with mark on house. Ensure the rafter is level, then mark the top of the rafter. Repeat for opposite side. Position two step ladders between the post and the existing structure.
58 57 1 1 2 II Lay ledger board against house directly below where it will be attached. Determine stud locations, mark and pre-drill holes into the ledger board. Note: The ledger board needs to be attached to solid material behind the surface of the house. Attach ledger board to house using 5" ledger board screws (II). Note: The ledger board should be attached securely, keeping the top of the ledger board the same height as the top of the rafter, and be able to hold the entire weight of the pergola.
62 61 X x4 Using four 1" screws (X), secure rafter to the rafter clips. Place one end of the rafter on top of the beams and slide the other end into the rail mount. 64 63 Repeat steps 60-62 to secure rafter to rail mount and rafter clips. 4" Before moving on, measure the beams at the seam to make sure the spacing between the beams is 4". If needed, temporarily insert a 4" spacer while attaching remaining rafters.
65 Position the remaining rafters, fitting them inside the rail mounts, and securing each one as you go, until all have been installed. Secure opposite end of the rafters to the rafter clips on top of the beam. After rafters have been installed the pergola should look like this. Shade Pre-Assembly 66 67 R R 1 T 1 T R 2 2 X X Slide the shade splice (T) halfway into shade (R). Insert a 1" screw (X) about 1" from end of the shade.
Shade Installation 69 68 R R 1 1/2" 1 1/2" Measure 1 1/2" from each end of the outermost rafters to establish the location of the two outside shades. Lay the two outside shades (R) on top of rafters. Make sure that the splice (where the two shades come together) is directly centered over the middle rafter. X X 12 1/ 8" 12 1/ 8" 12 1/ 8" 12 1/ 8" 70 Measure and mark rafters 12 1/8" from the center of the first shade for remaining shades.
71 72 Secure remaining shades to rafters. Y After positioning the shades, begin at the corner and fasten shades using 2 1/2" pan head screws (Y). Ensure screws go through the top of the shade and into the rafter. Decorative Trim Installation 73 M M Multi-purpose cement is provided to install decorative trim. 32 Apply cement to inside ring of beam trim (M). Promptly tap beam trim into place, so that trim is snug and level. Repeat for remaining beams.
74 75 S Q S Q Apply cement to inside ring of rafter trim (Q). Promptly tap rafter trim into place, so that trim is snug and level. Repeat for remaining rafters. Apply cement to inside ring of shade trim (S). Promptly tap shade trim into place, so that trim is snug and level. Repeat for remaining shades.
Congratulations! Your pergola is now ready to enjoy.
Warranty Suncast® Corporation, 701 North Kirk Road, Batavia, Illinois 60510 (Manufacturer) warrants to the original purchaser only that the enclosed product is free from material and workmanship defects under normal, household use at time of purchase. Defective product or part must be returned, freight prepaid, to the Manufacturer's address (Attention: Parts Department) along with proof of purchase.
