Backyard Living Structures PERGOLA User manual

PERGOLA
INSTALLATION
GUIDE
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2
TOOLS NEEDED
INSTALLATION
TOOLS FOR ASSEMBLY
•Drill(s)
•Miter or Circular Saw with
carbide blade (cut slowly)
•5/8″
•Drill Bit
•5/16″ Magnetic Driver(s)
•3/8″ Magnetic Driver(s)
•6″ Drill Extension(s)
•12″ Drill Extension (2x8 option only)
•Phillips bit for Drill
•Level
•Hammer
•Tape Measure
•String Line
•Hammer Drill if necessary, for
concrete or footing mounts
•Wrench for Anchors on post
•Composite shims
•Sawhorses
•Quick Clamp(s)
•Step Drill Bit (Vari–Bit®)– For
reaming holes in aluminum
•PVC Pipe de-burring tool (optional)
TOOLS FOR DIGGING AND SETTING PIER TYPE FOOTINGS
•Hand diggers/Auger
•Scrap Lumber
(for making forms)
•Concrete stakes
(for holding forms)
•Wheel barrow or small
concrete mixer
•Shovel
•Trowel
Post/Column
Beam
Rafter
Purlin Holder NOTE:
All fasteners for beams, rafters, purlin
holders and purlins are included in kit.
Fasteners NOT provided in kit:
Post mount attachment, Ledger
plate attachment, Column
base to surface fasteners
Purlin
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STEP 1
LAYOUT
A NOTE ON
PERGOLA SIZES
Sizes are dened by the total
width and depth of the roof. For
example, a 12’ x 16’ pergola will
have a roof area of 12’ x 16’ and
a post spacing of 10’ x 14’.
ALL PERGOLA
KITS CAN BE
CUT TO SIZE.
The beams and rafters supplied
in the kit are NOT pre-drilled. This
is to allow the width and depth to
be customizable for each kit. Our
standard sizes are designed around
a 1’ overhang on each end. This is
merely a rule of thumb and can
be adjusted during installation.
View CAD drawings and
photos of installed pergolas at
Heartlandpergolas.com
MEASURE
a. Determine necessary height,
post locations and overhangs
based upon site – Make note of
the following measurements
as you will want these later:
1. Desired outside to outside
dimensions of your posts
2. Desired height to the top of
your beam (same as height
to bottom of your rafter)
b. Ensure posts are square
with each other and/or
any adjoining structure
1. Post and beam spacing is
adjustable to t installation
site and any obstructions.
Beam and rafter overhangs
should not exceed 36″, purlins
should not exceed 24″.
2. NOTE: If adding to existing
slab or patio do not assume
that they are built square!
c. It is common that existing
concrete and paver patios are
installed with a certain degree
of slope. If slope is minimal
(less than 1″ in 10’) you can
simply disregard it. If slope is
more pronounced, consider
that your posts may be diering
lengths to allow pergola roof
to be level to horizon.
d. Maximum span of 2x6 beams
and rafters is 16’. 2x8 beams
and rafters can span 22’
e. Note that purlin holders do
not have to run under any
roof overhangs on your site.
This allows maximum head
clearance for your rafters.
f. For challenging sites, custom
fabrication of pergolas to
your unique site is available,
please contact [us].
NOTE:
All fasteners for beams, rafters, purlin
holders and purlins are included in kit.
Fasteners NOT provided in kit:
Post mount attachment, Ledger
plate attachment, Column
base to surface fasteners
EXAMPLE:
If you have a patio that is 10'-6"
deep x 13' wide you would want
a roof that was at least 12'-6"
deep x 15' wide. You would order
the next size up, a 14' deep x 16'
wide and trim the beams and
rafters to your desired overhang.
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STEP 2
INSTALL POST MOUNTS
2A MOUNT TO DECK
a. Add blocking below deck ooring under
each post mount. Minimum blocking
thickness of 3” (this is two 2x10’s thick)
b. Inset mount as necessary to ensure post
skirt does not overhang edge of decking
•Minimum 6.25” inset from edge to center
of mount for a 10” round column
•Minimum 5.25” inset from edge to center of
mount for a 7” square or 7” round column
•Minimum 3.25” inset from edge to
center of mount for 5x5 post
c. Detail on nailing blocking – Minimum
4 nails on each side of 2 by block
d. Mount Fasteners – Carriage Bolts or ledger
attachment screw (5” Recommended)
e. Use composite shims as necessary to
plumb mount. Tighten fasteners.
Minimum
4 Nails
per Joist 2"x10" (T YP)
BLOCKING
JOIST JOIST
5x5 Post or Column Sleeve
Aluminum Post Mount
Aluminum Mounting Plate
Carriage Bolt or Ledger Screw (4)
(not included)
5x5 Post Skirt or
Column Base
BLOCKING
FLOORING
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2B
MOUNT TO SLAB OR
LANDSCAPE COLUMN TOP
a. Inset mount as necessary to ensure post skirt does
not overhang edge of slab or column top
•Minimum 6.25″ inset from edge to center of
mount for a 10″ round column
•Minimum 5.25″ inset from edge to center of mount
for a 7″ square or 7″ round column
•Minimum 3.25″ inset from edge to center of mount for 5x5 post
b. Mount Fasteners - 3/8″ hot dipped galvanized wedge or
screw type anchors, minimum 2 1/2″ embedment.
c. Use composite shims as necessary to plumb mount. Tighten anchors.
5x5 Post or Column Sleeve
Aluminum Post Mount
Aluminum Mounting Plate
Concrete Anchor (4)
(not included)
5x5 Post Skirt or
Column Base
CONCRETE SLAB OR
LANDSCAPE COLUMN TOP
NOTE:
FOR A POURED SLAB,
concrete must be a
minimum 4" thick.
FOR A LANDSCAPE
COLUMN, we recommend
a one-piece cap of
concrete or natural stone
(4000 psi or greater).
It is important that the
column is constructed on
a sound foundation. For
a compacted gravel base,
this means minimum two
courses below grade, for
a concrete base, be sure
to attach footing to base
course with plenty of
landscape adhesive. For
construction of column
we recommend either
masonry or a high quality
concrete product installed
with plenty of landscape
adhesive. In the case of
adhesive, more is usually
better. In windy areas we
have even had customers
ll the pillar(s) with concrete
to add weight and rigidity.
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2C
MOUNT TO
FOOTING
10"ROUND,
7" ROUND, OR 7"
SQUARE COLUMN
a. The main goal in this method is
to isolate the pergola posts from
the patio area without looking like
it. This allows the patio to move
up and down over the seasons
while the pergola posts stay rock
solid. To do this properly you
need to make sure you know
the nished grade of the patio.
•If there is an existing patio, you
can simply remove blocks as
necessary to form and pour
footings to the height of the
existing patio surface. Use a
concrete saw to cut the paver
blocks to t around the column
once the forms are removed.
•If the patio is not yet installed,
you MUST establish the
desired patio surface height
prior to forming and pouring
your footings. The end goal
is that the patio block will t
neatly around the column
base without tting under it.
This allows the patio to freely
move up and down without
squeezing or crushing parts of
the pergola column.
NOTE: It is common that
the patio will have some
slope. This is no problem.
Simply set the top of your
forms to follow the desired
slope. The roof of the pergola
can still be installed level.
b. Determine post locations
and layout with strings
and tape measures.
c. Minimum footing size = 12″ round
- with top 4″ of footing formed
to match the size of column
base (see sizes above). Note:
Column bases are xed and do
not slide up and down the post.
d. Dig footings to frost line, making
sure to remove excess loose dirt
from the bottom of the hole.
e. Build, steak and level forms over
your holes. Ensure your forms
are installed square to patio
or structure. It is often helpful
to set string lines to double
check the locations as well as
desired height of the footings.
f. Fill holes with concrete to top
of forms and trowel smooth
g. Once cured, attach post mounts
to footings using 3/8″ dia. hot
dipped galvanized wedge or
screw type anchors, minimum 2
1/2″ embedment. Use composite
shims as necessary to plumb
mount. Tighten anchors.
Column Sleeve
Aluminum Post Mount
Column Base
10½" sq. - 7" Column
12½" sq. - 10" Column
PAVER
DIRT
FOOTING
GR AVEL
Top of Footing
at Patio Height
Footing to Frost Line
or 36" Minimum Depth
Concrete
Anchor (4)
(not included)
Fixed Column Base
(does not slide up/down)
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2D
MOUNT IN FOOTING
(5X5 POST)
a. The 5x5 post comes with a movable post skirt and
(optional) trim ring. These can slide up or down the
post and allow you to nish your patio height at
any level and simply slide the skirt down to meet
the nished surface. Because the trim will move
up and own with ease, you can set your posts and
build your patio around them. Make sure to leave
the top of your footings low enough that they do not
interfere with the patio being installed around them.
b. Dig a 12″ round footing to frost depth making sure to
clean any loose dirt from the bottom of your hole.
c. Fill holes with concrete to top of
forms and trowel smooth
d. Once cured, attach post mounts to footings
using 3/8″ dia. hot dipped galvanized wedge
or screw type anchors, minimum 2 1/2″
embedment. Use composite shims as necessary
to plumb mount. Tighten anchors.
5x5 Post Sleeve
Aluminum Post Mount
5x5 Post Skirt.
(Measures 6½"sq.)
slides up and down
Top of Footing below
grade or patio height
PATIO
DIRT
GRAVEL
Footing to Frost Line
or 36" Minimum Depth
NOTE:
This type of footing is best when building
pergola in conjunction with a paver patio
or a concrete patio that is less than 4" thick.
This is also the best application if you have
any concerns of frost heaving the patio.
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STEP 3
INSTALL COLUMNS
OVER POST MOUNT
CUT POST MOUNT TO HEIGHT
a. Mark the desired top of beam
height on each post mount.
•Ensure the top of beam will be level. The
simplest way (short of using a laser level)
is to quick clamp your beams to your
post mounts and adjust until level.
b. Measure the distance from the ground
to this mark on each post.
Write these measurements here:
Post A
Post B
Post C
Post D
c. Cut each aluminum post mount 1″ below
recorded measurements above.
d. Drop wood post plug into top of each post mount.
•This provides a more solid beam
to post connection.
Wood Post Plug
Ground to
desired top of
beam height.
(Recommend
8' to 10')
Top of Beam height
1" Cut Aluminum Post Mount here
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3A INSTALL 5"X 5"POST
OVER POST MOUNT
a. Cut each 5x5 vinyl post sleeve to proper height.
•Cut post ½″ shorter than recorded measurements.
b. Install skirts and optional trim rings on to
your vinyl post sleeve, these t tight.
c. Slide vinyl post over the top of the
aluminum post mount.
•Your vinyl post should stick up 1″ taller
than the top of the aluminum mount to
allow room for pyramid post cap.
3B INSTALL COLUMN OVER
POST MOUNT (7"SQUARE/ 7"
ROUND/10"ROUND COLUMN)
a. Cut each vinyl column sleeve to proper height:
•Kits with a 6″ beam:
Cut column 8″ shorter than
recorded measurements.
•Kits with an 8″ beam:
Cut column 10″ shorter than
recorded measurements.
b. Slide column base, sleeve, and cap over post
mount (in that order), these t tight.
c. Slide the 5″ x 5″ vinyl post cover with cap
over the aluminum post mount.
•This slides through the hole in
the top of the column cap.
d. Secure column base to a deck with wood
deck screws; to a footing or slab with small
concrete screws (Tapcons®or similar)
Top of Beam height
½" Cut Vinyl Post here
Top of
Beam height
2" Cut Vinyl
Column here
Beam Width
(6"or 8")
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STEP 4
ATTACH LEDGER TO STRUCTURE [ATTACHED
PERGOLAS ONLY]
a. Secure ledger to structure ensuring it is centered on
pergola –
PRO TIP: layout and mark rafter hanger
locations prior to installation of ledger plate.
b. Fasteners – Necessary fasteners for Ledger
are NOT provided in kit. Requirements
determined by structure.
c. Minimum height for rafter attachment
without modication:
•2x6 Rafter - skirt is 7 ½″ tall, 1″x10″ Azek
Trim Ledger Plate is ¾″ thick x 9 ¼″ tall
•2x8 Rafter – skirt is 9 ½″ tall, 1″x12″ Azek
Trim Ledger Plate is ¾″ thick x 11 ¼″ tall
•NOTE: for a tight spot you can trim PVC
ledger Plate or rafter skirt to reduce the
overall height of rafter attachment.
d. Attach rafter hangers based on
your layout measurements.
NOTE:
If removing siding, ensure that ledger
plate is properly ashed and sealed.
If ledger is installed over top of siding, ensure
that top and sides are caulked adequately.
Rafter and
Aluminum Insert
Heavy Bead
Silicone Caulk
Attach Rafter to Rafter Hanger with
(4) 5⁄16"x1"Hex Screws
3⁄8"x1"
Hex Screw
Skirt with Locking Tabs (tabs MUST point down)
5⁄8"plugs
Required:
Rafter Hanger attached with
(6) Heavy Shank Screws
(not provided)
Framing of Structure
(studs, headers,
wall plates, or similar)
Siding
Sheathing
PVC Ledger Plate 1"x10" or 1"x12"
Optional:
½" LedgerLOK®
or equivalent 16" OC
(not provided)
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STEP 5
INSTALL BEAMS
There are two methods of
attaching a beam to the post:
a. TRADITIONAL METHOD - use
the template provided with each
kit to mark and drill a 4-hole
pattern for each beam to post
attachment location and screw
beam to post with fasteners
provided. Holes in beam are
then covered with plugs.
b. BEAM ATTACHMENT BRACKETS
-These brackets are powder
coated stainless steel and are
installed with matching self-
drilling screws. They are an
additional option on each kit
add slightly to the cost. The
benet is that these brackets
eliminate the need to pre-drill
the 4-hole pattern for each
beam to post attachment.
This saves installation time
and makes for a slightly more
DIY friendly installation.
TRADITIONAL
METHOD
a. Determine desired beam
length and overhangs. Trim
beams if necessary.
b. Mark and drill OUTSIDE FACE
ONLY of beam and aluminum
insert with 5/8″ diameter bit. Four
holes per beam connection.
NOTE: Ream holes larger
in ALUMINUM ONLY for
easier plug installation.
c. Attach beam to post with
provided heavy 3/8″ x 2″ hex
screws and cover with 5/8″ plugs.
BEAM ATTACHMENT
BRACKETS
a. Determine desired beam
length and overhangs. Trim
beams if necessary.
b. Secure rst beam to top of
post with a clamp. Fasten beam
attachment brackets with
provided fasteners.
IMPORTANT: The shorter
fasteners go into the beam; the
longer fasteners go into the post.
c. On second beam, measure
and mark location of beam
attachment bracket.
d. Install beam attachment
bracket to beam.
e. Raise beam into place and attach
beam attachment bracket to post.
PRO-TIPS:
If at caps are desired on
ends of a beam, cut aluminum
insert short by ½" per end
to allow for insert of cap.
Ream holes larger in ALUMINUM
ONLY for easier plug installation.
5⁄
8
" Plugs
3⁄8"x1"
Hex Screw
(2) 3⁄8"x1" Hex Screw
Column
5"x5" Post Sleeve with
Aluminum Mount
2"x6" or 2"x8" Beam
with Reinforcement
White Panhead Screw
into each Purlin
(8) 3⁄8"x2" Hex Screw 5⁄8" Plugs
Column Cap
Cap
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STEP 6
RAFTER ATTACHMENT
6A ATTACH RAFTERS TO BEAM
a. Set rafter on top of beam with desired
overhang. Trim rafters if necessary. Mark
hole locations directly above each beam.
b. Drill through TOP ONLY of rafter with step bit,
directly over center of both beams – This is
safest to do on sawhorses at ground level.
Attach rafter to each beam with 3/8″ x 1″ hex screws.
6B ATTACH RAFTERS TO
LEDGER
[ATTACHED PERGOLAS ONLY]
a. Install rafter hangers to ledger
plate per desired layout.
b. Slide rafter hanger skirt over rafter. Note: Skirts
are directional and need to be slid on with the
four locking tabs in the downward direction.
c. Attach rafter to hanger with
5/16″ x 1″ hex screws ensuring that
screws penetrate aluminum insert.
d. Slide skirt to cover hanger bracket.
e. PRO-TIP: If structural wall is bowed, adjust rafter length
as necessary to ensure uniform overhang over beam. PRO-TIPS:
If pergola is attached to a structure always attach
rafters to ledger before securing them to the beam.
If at caps are desired on ends of a rafter
cut aluminum insert short by ½" per
end to allow for insert of at cap.
Aluminum
Post Mount
Brackets attach to beam first,
then into aluminum post mount
BEAM ATTACHMENT BRACKETS:
No pre-drilling through Face of Beam
2x6 Beam
2x6 Beam
Brackets hide
between beams
Aluminum
Post Mount
TRADITIONAL METHOD:
Drill and Screw through face of beam
2x6 Beam
2x6 Beam
5⁄8" Plugs
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STEP 7
ATTACH PURLIN
HOLDERS
a. For maximum shade, determine
primary direction of sun
and install purlin holders to
angle purlins accordingly.
b. Determine desired length
of purlin holders. Note:
holders must be held back a
minimum of 1 ½″ from end
of rafter to allow installation
of curved rafter end cap.
c. If necessary, cut purlin holders
to desired length, ensuring
that you cut between holes.
d. PRO-TIP: For easiest purlin
installation make sure that
holes in purlin holders line up.
This is what the string line in
the tool list is for. Install the two
outside purlin holders and run
a tight string between them.
Place all other purlin holders
almost touching string. DO NOT
depend on rafters or face of your
structure to be perfectly in line.
e. Using provided 5/8″ holes screw
holders to rafter with 3/8″ x 1″
hex screws. If purlin holder was
cut down it may be necessary to
drill a new 5/8″ mounting hole.
f. Plug holes with 5/8″ plugs.
STEP 8
INSTALL PURLINS
a. If necessary, measure and cut
purlins to desired length.
b. PRO-TIP: Purlin overhang from
holder should not exceed 24”.
c. Install cap on both ends of
purlins. These caps help
guide purlins through the
holes and make purlin
installation MUCH simpler.
d. Slide purlins into secured
holders ensuring that the ends
have a uniform overhang.
e. Fasten purlins through top of
purlin holder with tan or white
1 ½″ phillips pan head screws.
f. PRO-TIP: It is only necessary
to screw purlins through one
holder as long as purlins have
not been cut or spliced.
g. PRO-TIP: If is it necessary to
splice a purlin, measure and cut
to allow for the splice in the center
of the purlin holder; this is the
best area to screw the purlins, as
any extreme cold temperatures
will not pull the splice apart.
STEP 9
CAPS AND
FINISHING
a. Glue on beam and
rafter end caps.
b. Glue in plugs for column bases.
c. Wipe o any construction marks.
d. PRO-TIP: Window cleaner and Mr.
Clean Magic Erasers®work excellent
on any hard to remove marks.
STEP 10
ENJOY THE SHADE!
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FAN MOUNT
OPTIONAL
a. Use a qualied electrician for rough in during pergola construction. You will need a loop of
electrical wire pulled into one of the rafters that the fan mount will be attached to.
b. NOTE: The mount can be installed anywhere from the top to the bottom of the rafter. For
more head clearance with the fan, install hangers towards the top of the rafter. Ensure
that you leave enough room for the skirt to slide over the rafter hanger.
c. Once height is determined, attach rafter hangers horizontally with (4) 5/16″ x 1″ hex screws (silver).
d. Carefully drill through the center hole in the rafter hanger into the rafter to access the loop of wire for the fan.
e. Pull wire through the hole in the rafter hanger.
f. Measure the clearance between the rafter hangers.
g. Cut aluminum and vinyl 2x6 piece 1/8″ shorter than the distance between hanger plates, to ensure
enough room to t the 2x6 into place. Test t the 2x6 between the hangers, trim if necessary.
h. Once 2x6 is the proper length, mark and drill a hole for the wire to come through the 2x6.
i. Slide skirts over each end of the 2x6 and test t the mount in place.
j. NOTE: The skirts must be turned the correct way to t properly into the rafter hangers. If they do
not lock into place, covering the hanger, try removing them and ipping them 180 degrees.
k. Fish wire through and out of the 2x6 carefully to avoid damaging the sheath.
l. Fasten each end of the 2x6 with (2) 5/16″ x 1″ hex screws (silver)
m. Slide the skirts into place.
n. The mount is now ready for your fan.
Rafter Hanger
Attached w/ (4) 5⁄16"x1"
Hex Screws
Wires for Power
Attach fan mounting bracket directly to 2x6 rafter
Skirts Slide
over Hanger
2x6 Rafter
with Aluminum
Purlin
Holder
Shade
Purlin
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HURRICANE CLIPS
OPTIONAL
These clips, when installed properly, dramatically increase your pergola’s uplift resistance under extreme
wind loads. Refer to your warranty for more information regarding our residential lifetime wind warranty.
Clips are designed to be installed at each rafter to beam intersection in one of three ways:
1. On the inside of the double beam (as shown in diagram, least visible)
2. On top of the beam (works well when a post or column is in the way)
3. On the outside of the beam (most visible, not recommended)
The screws provided are self-drilling. Along with the right angle drill attachment (provided
with hurricane clip kit), this makes installation on the inside of the beams easy.
a. Hold the clip in the desired place, in between the beams and under the rafter.
b. Install two screws into the underside of the rafter.
c. Attach the right angle drill adaptor.
d. Install one screw though the clip into the beam.
e. Repeat at each rafter and beam intersection.
f. Where a post or other obstruction prevents attachment in between the beams,
mount the clip on top of the beam and into the side of the rafter.
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