0x0 Trellis Pergola ASSEMBLY GUIDE Ver.0-7
Table of Contents PAGE Introduction & Overview...................................................... Pergola Materials Overview.............................................................. Pergola Materials Breakdown............................................................ Pergola Additional Materials List.................................................. Side Panel Trellis Assembly........................................................ 7.. Corner Post Assembly.............................................. 8 Vinyl Beam Assembly..................................... 9.. Vinyl Rafter Assembly................ 0 Vinyl Beams & Rafters Placement................ Pergola Brace Assembly Placement................ Shade Slat Assembly & Installation................ Pergola Mounting................ 0 Wood Post Layout & Installation for In-Ground Application..................... Pergola Installation on Deck (with access to under the deck) 8 Pergola Installation on Deck (with no access to under the deck)........... 9 Pergola Installation on Existing Concrete Pad................................................................... 0.. Additional Installation Note......................................................................................... / in / in 9 7/8 in 88 / in 0 / in 90 / in 0 / in 88 in 8 in 9 in in 0 in in in 0 in Top View Front View Side View
Introduction & Overview Getting Started First off, allow us to say thank you for the investment you have made in one of our fine pergola kits. This kit is designed to be assembled and installed ideally by two people with basic carpentry knowledge and tools. Do not attempt alone, especially during the installation stage. Should you decide to moderately modify the dimensions of your pergola from the standard kit size, a circular saw with a sharp fine-tooth blade is all that is needed to cut, shorten or modify the vinyl components. When assembling components place on a non-abrasive surface (ie: shipping box) to avoid scratching. We recommend a x area for unobstructed assembling. You should not need to use excessive force when assembling any components. Planning & Preparing Because this project is made to stand independent of your home, you can either locate it near your house or let it stand alone in the garden. By keeping it unattached from your home you will not have to deal with moving existing gutters or matching eave heights. If you plan to build your pergola close to the house, please keep the outer extremities of the pergola a minimum of inches back from your eaves. Restriction of Use This product is not designed to carry additional weight loads such as swings, people or other objects. Please take the time to read this instruction guide thoroughly prior to the construction of your pergola. If you have any questions, feel free to contact our technical dept by calling 800 8 9, ext #0 (Mon to Fri 8:00 A.M to :00 P.M. EST). It is critical before you start that you consider the current slope of elevation where the pergola is planned - if there is any. Also utility or sprinkler line location is important to identify prior to excavating holes if necessary. You should also check to verify local building codes, ordinances, neighbourhood covenants, or height restrictions regarding this type of structure.
Materials Overview. Posts - Long (8). Posts - Short (). Pergola Beams (8). Pergola Rafters (8). Rafter & Beam Decorative End Caps (). Rafter & Beam Joiners (8) 7. Trellis Posts () 8. Trellis Vertical Slat (8) 9. Trellis Horizontal Rails - Middle (0) 0. Trellis Horizontal Rails - Top and Bottom (). End Caps - 7/8 x / (0). Braces (8). Brace Brackets (8). End Caps - x / (). Shade Slat Decorative End Caps (). Shade Slats () 7. Shade Slat Joiners () 8. Aluminium Stiffener for Beams / Rafters (8) 9. Aluminium Stiffener Inserts for Beams (8) 0. Mounting Plates - Left (). Mounting Plates - Right (). Mounting Stakes () 7 0 7 8 9 0 9 8
Materials Breakdown Check Boxes (Total of ) for These Contents In the event of missing or defective parts please call our customer service dept. at 800 8 9, ext #0 (Mon. to Fri. 8:00 AM to :00 PM EST). 7 8. Posts - Long (8). Posts - Short (). Pergola Beams (8). Pergola Rafters (8). Rafter & Beam Decorative End Caps (). Rafter & Beam Joiners (8) 7. Trellis Posts () 8. Trellis Vertical Slat (8) 9. Trellis Horizontal Rails - Middle (0) 0. Trellis Horizontal Rails - Top and Bottom (). End Caps - 7/8 x / (0). Braces (8). Brace Brackets (8). End Caps - x / (). Shade Slat Decorative End Caps (). Shade Slats () 7. Shade Slat Joiners () 8. Aluminium Stiffener for Beams / Rafters (8) 9. Aluminium Stiffener Inserts for Beams (8) 0. Mounting Plates - Left (). Mounting Plates - Right (). Mounting Stakes () 9 9 0 0 8 7 Not to Scale
Pergola Additional Materials List Hardware (in plastic bag) NOTE: WE HAVE INCLUDED 0% EXTRA SCREWS BEYOND WHAT IS IDENTIFIED BELOW. All Screws Included with this Kit are Self-Auguring. A B E G H A. Vinyl Weld Glue () C F B. / Self-Auguring Stainless Steel Screws () D (To fasten trellis assembly to pergola posts) C. / Self-Auguring Stainless Steel Screws () (For brace brackets) D. / Self-Auguring Stainless Steel Screws () (To fasten shade slats to rafters) E. / Self-Auguring Stainless Steel Screws () (For beam and rafter joiners) F. / Self-Auguring Stainless Steel Screws () (To fasten braces to beams / rafters) G. Self-Auguring Stainless Steel Hex Head Tek Screws () (To fasten posts to mounting plates) H. / Self-Auguring Stainless Steel Screws (8) (To fasten beams / rafters to posts) I. Self-Auguring Stainless Steel Screws () (To fasten rafters to beams) J. /8 x Drill Bit () (to pre-drill holes on bottom of joiner to penetrate aluminium inserts as necessary) K L M I J CONCRETE - Ready Mix Purchase Separately Extra Materials You will Need We have provided mounting plates with stakes to mount your pergola into the ground. You may, however, follow one of the options below to better suit your need: If Mounting Pergola with Wooden Posts (in ground) K. xx0 Pressure-Treated Lumber () (purchase at local building center) x Lumber will need to be ripped down to / x / dimensions to fit into the hollow posts. L. Concrete Ready Mix () (purchase at local building center) If Mounting Pergola onto Deck (with access to under the Deck) M. / Bolts with Washers and Locking Nut () (purchase at local building center). Length of bolts will depend on thickness of decking material. If Mounting Pergola onto Deck (with no access to under the Deck) N. / - /8 Lag Bolts () (purchase at local building center) Length of Lag bolts will depend on thickness of decking material. If Mounting Pergola on existing Concrete Pad O. / x Sleeve Anchors () (purchase at local building center) N O Purchase Separately Purchase Separately Tools You Will Need Level Hammer Tape Measure Step Ladders () Cordless Drill Hex Nut Driver (/ or 8mm) Tools You May Need Circular Saw with Fine Tooth Blade Framing Level Framing Square Hacksaw (or a motorized cutting device designed to cut steel) / in / in Not to Scale Purchase Separately Purchase Separately
Pergola Assembly STEP ONE Side Panel Trellis Assembly One by one, insert five Middle Trellis Horizontal Rails over the Trellis vertical Slat as shown. Excess force should not be used. Slide the End Trellis Horizontal Rails over the assembly as shown. Note that there are only one side with a routed hole. Starting with one end, carefully walk the assembly into the Trellis Post while making adjustments. Note that the horizontal rails are tabbed; once inserted, the horizontal rails will lock into place. Starting with one end, carefully walk a Trellis Post over the assembly as shown. Pressure fit four end caps as shown. Repeat for other 7 side panel trellisses. x 8 www.newenglandarbors.com 7
Pergola Assembly STEP TWO Corner Post Assembly Lay ALL the posts on its side as shown and create a mark inches from the one end. Separate the LONG POSTS from the SHORT POSTS. Place one of the trellis assembly from the previous step on the narrow side of the long post and align the one end to the pencil mark. Fasten the trellis assembly to the post while ensuring that it is straight and level using four -/ screws through the pre-drilled holes. Using a helper, place the assembly onto another long post on its narrow side. Fasten the trellis assembly to the post using four -/ screws through the pre-drilled holes. 7 Repeat this for a total of panels. Align to pencil mark in 8 Align to pencil mark
9 STEP THREE Left and Right Corner Post Assembly There are Left and Right corner assemblies ( each) as shown aside: The assembly process is very similar, the only diference between the two is which post the second trellis assembly is attached to. (The left or right side of the assembly) Place a trellis assembly on one of the post and fasten with four -/ screws though the pre-drilled holes onto the / side. Make sure the trellis assembly is straight and level along the post. With a helper, stand the assembly upright and attach a SHORT post against the trellis assembly and fasten with four, -/ screws through the pre-drilled holes onto the / side. You could also use the mounting plates to stand the posts upright at this point. Pressure fit three post caps per corner assembly. Left Corner Post Assembly Right Corner Post Assembly
STEP FOUR Vinyl Beam Assembly Aluminium block should face up Insert two short aluminium stiffener into one long aluminium stiffener to create full length piece. Repeat so you have four full length beams. Insert one end of the beam into the joiner. Push firmly until the extrusion bottoms out inside the joiner. Insert one assembled aluminium stiffener (with aluminium block facing up), into the pocket of the vinyl beam past the joiner. Push until aluminium block is centered about the joiner. Slide a second beam over the aluminium stiffener and into the joiner. Screw the joiner to vinyl beams and aluminium insert using -/ screws. The bottom and top holes will need to be pre-drilled (use drill bit provided). Apply a bead of vinyl glue to the inside of the decorative end cap as shown and firmly attach to the end of the beam assembly. Note: Aluminium block should always face up and will affect the orientation of the end cap. 0
STEP FIVE Vinyl Rafter Assembly Insert one end of the rafter into the joiner. Push firmly until the extrusion bottoms out inside the joiner. Insert one aluminium stiffener (with aluminium block facing up), into the pocket of the vinyl rafter past the joiner. Push until aluminium block is centered about the joiner. Slide a second rafter over the aluminium stiffener and into the joiner. Screw the joiner to vinyl rafters and aluminium insert using -/ screws. The bottom and top holes will need to be pre-drilled (use drill bit provided). Apply a bead of vinyl glue to the inside of the decorative end cap as shown and firmly attach to the end of the rafter assembly. Note: Aluminium block should always face up and will affect the orientation of the end cap. Notches in rafter faces down.
STEP SIX Vinyl Beams & Rafters Placement Slide the four corner post assemblies over mounting plates as shown. Space the post assemblies out using dimensions shown. Measurements are taken between posts. 88 in 8 in With a helper, raise the beam assemblies (one at a time) and butt them up against the posts as shown. Center the beam between the two posts. Note that the top of the beam should be level with the short posts. Fasten beam assemblies to the posts using / Screws (8 screws per beam assembly). Flush
STEP SIX (Cont d) Vinyl Beams & Rafters Placement With a helper, place the rafter assemblies onto the beam assemblies. Excessive force should not be used. End rafters should butt up against the posts. Middle rafters should be spaced out 9 apart. Fasten the end rafters to the posts using -/ screws as shown (8 per end rafter) 7 Fasten all rafters to the beams using screws as shown ( per rafter) 9 in 9 in 9 in 7
STEP SEVEN Pergola Brace Assembly & Placement Insert the brace into the bracket as shown. Note the location of the two holes. Pressure fit the end cap onto the brace. Repeat for all 8 braces. Place brace assembly onto the post as shown. Brace assembly should be against the outer edge of the post (away from the pergola), and the top of the brace should be flush to the top of the beam / rafter. Mark the location of the bracket and temporarily remove the brace. Fasten the bracket onto the post as shown using two -/ screws. Beam Side Holes Re-install the brace and fasten into place using one -/ screw. 7 From the inside, fasten the brace to the beam/rafter using two screws through the pre-drilled holes. Rafter Side 8 Repeat for all four corners. x8 Flush Flush Against Edge Against Edge 7 7
STEP EIGHT Shade Slat Assembly & Installation Insert two shade slats into a shade slat joiner as shown. Apply a bead of vinyl glue to the inside of the shade slat end cap and firmly attach to the end of the shade slat Repeat for all shade slats. With a helper, place all six shade slat assemblies onto the pergola rafters. Distribute the shade slats evenly; the distance between the shade slats is ±7-/ apart. Fasten the shade slats onto the rafter using -/ screws (One at every junction of where the shade slat crosses over the rafter - screws per shade slat). x 7-/ in www.newenglandarbors.com
STEP NINE Pergola Mounting This pergola has been designed to be easy to install and anchor to the ground. If you are in a high wind location and require more stability, please see the next page on how to install the posts into the ground. Important step: ensure that your ground is level. This can be accomplished by a combination of building up the ground with soil and/or digging as necessary. Place the pergola at the desired location and pound the supplied mounting stakes with a hammer into the ground. If mounting onto concrete or decking material, please consult mounting options at the end of this instruction. Fasten the pergola with hex head tek screws provided at the locations shown. You will need to pre-drill the holes through the mounting plates first using the drill bit provided. / or 8mm x Note: A hex driver or wrench will be needed to fasten these screws.
Wood Post Layout & Installation for In-Ground Application Follow these instructions to install this pergola in the ground. Post location and placement is the most critical step in the overall installation process. Please double check for the possibility of any underground utilities such as sprinkler, gas or telephone lines. STEP ONE in Overhead View / in / in / in 8 / in Measure and mark out the location of the pergola posts using string line and temporary wood stakes. Diagonal distances must be the same to ensure a square installation. Adjust string lines accordingly. The inside corner of the string lines will be the post location. Please Note: Should you decide to moderately modify the dimensions of your pergola from the standard kit size, a circular saw with a sharp fine-tooth blade is all that you need to cut, shorten or modify the vinyl components. The steel stiffeners for the main beams and rafters can be cut down using either a hacksaw or a motorized cutting device designed to cut metal. / in 88 / in /8 in from corner of wood post to corner of wood post. STEP TWO in Install Wood Supporting Posts Directly into the Ground After you have determined where the posts will be located, excavate 0 diameter x deep post holes. After holes are dug and cleaned, place the x wood post into a hole ensuring it s level and square to string lines. The final post height should be no more than 8 out of the ground. If a post is higher because of obstructed excavation of footings, please cut down in height accordingly. Fill the vacant hole with pre-mixed concrete all the way to within of the top of the hole. Repeat for all posts. Please Note: Some x pressure treated posts can be larger than / x / square due to twisting or cracking. We have allowed a tolerance for this in the internal one way. However, in extreme cases you may need to shave down the top of the x wood post slightly to get the vinyl post started over the wood post. Before installing your wood posts in the ground, please check to confirm this and correct at this stage if necessary.! IMPORTANT! If mounting in ground with wood posts, the wood pergola posts will need to be installed first. The rest of the pergola will then be assembled according to the rest of the instructions. 0 8 (Maximum) 7
Pergola Installation on deck (with access to under the deck) Pergola installation with this menthod can and should be done AFTER the pergola is fully assembled. STEP ONE Place the fully assembled pergola (including the mounting plates) to the desired location and make sure pergola posts are standing square relative to each other. To distribute the weight of the pergola, we recommend using x supports directly below the mounting plates as shown. Drill / holes ( per mounting plate) through the deck and x supports as shown. Insert a / bolt assembly into each of the hole and fasten nut into place. x Supports 8
Pergola Installation on deck (with no access to under the deck) Pergola installation with this menthod can and should be done AFTER the pergola is fully assembled. STEP ONE Place the fully assembled pergola (including the mounting plates) to the desired location and make sure pergola posts are standing square relative to each other. Drill /8 holes (or lag bolt manufacturer s suggestion) - per mounting plate through the deck and x supports as shown. Fasten / lag bolt into each of the hole. 9
Pergola Installation on Existing Concrete Pad Pergola installation with this menthod can and should be done AFTER the pergola is fully assembled. STEP ONE Place the fully assembled pergola (including the mounting plates) to the desired location and make sure pergola posts are standing square relative to each other. Using a masonary bit and a hammer drill, drill /8 holes (or as per sleeve anchor manufacturer s suggestion) - per mounting plate as shown. Clean the holes and insert the sleeve anchors. Following the manufacturer s instruction, expand the anchor by tigthening nut or head. 0
Additional Installation Note If there is too much sway in the pergola, you may also purchase ready-mix cement and pour it down the posts - DRY - and then add water down the posts (consult cement packaging for cementwater ratio). This will help lock the posts and footings together. One bag of ready-mix cement should be used for each corner ( posts) for a total of bags. CONCRETE - Ready Mix Purchase Separately Post caps are removable. Pry cap with butter knife or putty knife.