New England Arbors Elysium User manual

12 x 12 Flat Top
Attached Louvered Pergola
ASSEMBLY GUIDE
Ver 1.0-113015
Model: Elysium
www.newenglandarbors.com
OPTIONAL ACCESSORIES:
• Bolt Down Bracket Kit • Privacy Wall • Pergola Planter
(2 for Pergola)

Table of Cont e nts
212 x 12 Flat Top Attached Louvered Pergola
3
12 x 12 Flat Top Attached Louvered Pergola
Introduction& Overview……………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .………. . . . . .
Pergola Materials Overview………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . …. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pergola Materials Breakdown………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .…. . . . . . . . . . . . . . . . . . . . . . .
Pergola Additional MaterialsList………………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wood PostLayout & Installation for In-Ground Application………………………………. . . . . . . . . . . . . . . . . . . . .
Wood PostLayout & Installation using Bolt Down Post Brackets for Concrete or Wood Surface……………
Vinyl ColumnAssembly and InstallationOver Wood Posts………………………. . . . . . . . . . ………………….
MainSupport Beam Assembly…………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Support Beam Assembly for Attached Wall Side …. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rafter Assembly………………………………………………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ledger Assembly and Main Support Beam Placement …………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Support Beams and Rafter Placement …………………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening Pergola ends and Caps ..……………………………………… . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAG E
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Top View
Side View
Front View
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14
90 in 103 7/8 in
144 in
134 in
140 5/8 in
92 1/2 in
1 1/2 in Gap For
2x6 Ledger Board
135 5/8 in
156 1/8 in
1 1/2 in Gap for
2x6 Ledger Board
175 in
42 in
Louver Assembly ………………. . . . . . . . . . . . . . . . . . . . . . . …………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Bar Holder Installation …………………………………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Operations ……………………………………………. . . ………. . . ………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Int ro duction & O ve r view
3
12 x 12Flat Top Attached Louvered Pergola
Getting Started
First off, allow us to say thank you for the investment you have made in one
of our fine pergolakits. This kitis 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 asharp 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) toavoid scratching. We recom-
mend a 15’ x 15’ area for unobstructed assembling.You should not need to
use excessive force when assembling any components.
Planning & Preparing
The Elysium Pergola is designed to be attached to an existing structure
such as your house. Please follow this instructions closely and plan ahead
to avoid confusions and issues during installation.
What looks like the toughest partof this project is actually the easiest, the
graceful, solid-looking columns. We’ve designed these columns to simply be
slipped over treated 4x4 wood posts that are either embedded in concrete or
directly mounted to a concrete or wood surface using our bolt down brackets.
See pages 7, 8 and 9 for more details.
Itis critical before you start that you consider the current slope of elevation
where the pergolais 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, neighbour-
hood covenants, or height restrictions regarding this type of structure.
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 thoroughlyprior to the construction
of your pergola. If you have any questions,
feel free to contact our technical dept by calling
1 800 282 9346,(Mon to Fri 8:00 A.M to 4:00 P.M.
EST).
www.newenglandarbors.com
Int ro duc tion & O ve r v ie w

Elysium Pergola Materials Overview
412 x12 Flat Top Attached LouveredPergola
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2
4
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1. Post Caps (2)
2. Main Column Tops (2)
3. Post Trims (4)
4. Rafter & Beam Decorative End Caps (12)
5. Main Support Beams (4)
7. Beam & Rafter Joiners (9)
8. Main Column Bottoms (2)
9.
Rafters - With Double Notches - (6)
11.
One Way 4”x4“ Internal Wood Post Guides (4)
5
8
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19
18
14
17
11
12. Louver TurnBar (1)
13. Turn Bar Holder (1) - Found in Box 7
14. Pre-assembled Louver Bars (Right) - With Long Louver Bar (3)
15. Pre-assembled Louver Bars (Left) - With Long Louver Bar (3)
16. Steel Holder Brackets (36)
17. Louver Boards (84)
18. P re-assembled Louver Bars - With Short Louver Bar (3)
19. P re-assembled Louver Bars - With No Louver Bar (3)
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15
10 20
12
67
6. Main Support Beams - Attached Side (With pre-drilled holes on top) (2)
10.
Rafters - Attached Side (6) 20. Rafter Hangers (6)

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8
7
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12
Check Boxes (Total of 7) for These Contents
In the event of missing or defective parts please call our customer service
dept. at 1 800 282 9346 (Mon. to Fri. 8:00 AM to 4:00 PM EST).
1. Post Caps (2)
2. Main Column Tops (2)
3. Post Trims (4)
4. Rafter & Beam Decorative End Caps (12)
5. Main Support Beams (4)
Elysium Pergola Materials Breakdown
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12 x 12 Flat Top Attached Louvered Pergola
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4
www.newenglandarbors.com
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Not to Scale
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18
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6
6. Main Support Beams - Attached Side (With pre-drilled holes on top) (2)
7. Beam & Rafter Joiners (9)
8. Main Column Bottoms (2)
9.
Rafters - With Double Notches (6)
11.
One Way 4”x4“ Internal Wood Post Guides (4)
12.
Louver TurnBar (1)
13. Turn Bar Holder (1) - Found in Box 7
14. Pre-assembled Louver Bars (Right) - With Long Louver Bar (3)
15. Pre-assembled Louver Bars (Left) - With Long Louver Bar (3)
16. Steel Holder Brackets (36)
17. Louver Boards (84)
18. P re-assembled Louver Bars - With Short Louver Bar (3)
19. P re-assembled Louver Bars - With No Louver Bar (3)
10.
Rafters - Attached Side (6)
20. Rafter Hangers (6)
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9
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Pergola Additional Materials List
Hardware (in plastic bag)
NOTE: WE HAVE INCLUDED 10% EXTRA SCREWS BEYOND WHAT IS IDENTIFIED BELOW
All Screws Included with this Kit are Self-Auguring.
A. Tube of Vinyl Weld Glue (2)
B. 5/8” Self-Auguring Stainless Steel Screws (72) (to lock Louver Assembly to Steel Holder
Brackets )
C. 5/8”Self-Auguring Stainless Steel Screws (24) (to lock Rafter Hangers to Rafter )
D. 1 1/2”Self-Auguring Stainless Steel Screws (36) (for Beam and Rafter Joiners )
E. 1 1/2”Self-Auguring Stainless Steel Screws (24) (to lock the Rafter Hangers to Attached Beam)
F. 2 1/2“ Self-Auguring Stainless Steel Screws (2) (to fasten Turn Bar Holder to post)
G. 2 1/2“ Self-Auguring Stainless Steel Screws (16) (to lock Top and Bottom Columns to Wood Posts)
H. 4” Self-Auguring Stainless Steel Screws (12) (to lock Rafters to the Beams)
I. 4” Self-Auguring Stainless Steel Screws (24) (to lock Beams and Rafters to Posts)
J. 9”Stainless Steel Bolt Assembly with Nuts and Washers (2) (to lock the Column Tops to Beams)
K. Turn Bar Holder (1) * Found in Box 7
Extra Materials You will Need
(Purchase separately from www.newenglandarbors.com or retailer of our products)
If Mounting Pergola on Concrete or Wood Deck
J. 4x4x8 Pressure-Treated Wood Posts (2) (purchase at local building center)
K . 4x4 Bolt Down Bracket Kit (purchase from www.newenglandarbors.com or a
retailer of our products)
Refer to bolt down bracket instructions for hardware requirements,
as they pertain to your application:
If mounting pergola onto an existing concrete surface:
• 1/2“ x 3 1/2”x 12“ Wood Shims (16)
• 1/4”x 2 3/4“ Cement Screws - Countersunk Head (6)
• 3/16”Concrete drill bit. Minimum 3“ long (1)
If mounting pergola onto a wooden/composite deck with AN ACCESSIBLE UNDERSIDE:
• 1/2“ x 3 1/2”x 12“ Wood Shims (16)
• 1/4”x ?“ Bolts and Nuts - Countersunk Head (6) (Length depends on blocking material)
• 1/4” Washers (6)
• 1/4” Wood drill bit. Minimum 3“ long (1)
If Mounting Pergola in Ground
L. 4x4x12 Pressure-Treated Wood Posts (2) (purchase at local building center)
M. Concrete Ready Mix (2) (purchase at local building center)
Rafter/ Beam Support (Required)
N. 2x6x12 Pressure-Treated Boards for Beams and Rafters (9) (purchase at
local building center)
O. 2x6x6 Pressure-Treated Boards (2) (purchase at local building center)
P. 3/8”x 3 1/2”Lag Screw with Washers (6) (purchase at local building center)
Q. 3/8“ x 3 1/2”Lag Screws (for wood wall) or Anchor Screws (for brick
or concrete wall) (6) (purchase at local building center, also purchase drill bit)*
*) Please consult your local building center for mounting anchors.These second set
of screws will be used to mount your wood beam / ledger onto your structure.
Refer to page 12 for more information.
Not to Scale
612 x 12 Flat Top Attached Louvered Pergola
www.newenglandarbors.com
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H I
GF
D E
CBA
K
M
CONCRETE - Ready Mix
Purchase Separately
Purchase Separately
KNJ L
Purchase
Separately
Purchase
Separately
Purchase
Separately
P

Wood Post Layout & Installation
for attached Pergola
Measure and mark out the location of the pergola posts using
string line and temporary wood stakes. 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.
1
This pergola can also be installed on a pre-existing wood or
concrete surface using our bolt down bracket system with
a 4x4 wood post (sold separate). See page eight for more details.
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
After you have determined where the posts will be located,
excavate 10”diameter x 36”deep post holes.
After holes are dug and cleaned, place the 4x4 wood post into
a hole ensuring it’s level and square to string lines. The final post
height should be 84”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 3” of the top of the hole.
Once the concrete has set, back fill the remaining 3” with soil.
Repeat for both posts.
Please Note:
Some 4x4 pressure treated posts can be larger than 3 1/2 x 3 1/2
square due to twisting or cracking. We have allowed a tolerance
for this in the internal one way and two way 4x4 wood post guides
(see page 8). However in extreme cases you may need to shave down
the top of the 4x4 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.
1
2
3
STEP TWO
Install Wood Supporting Posts Directly into the Ground
4
136 3/8 in.
346.3 cm.
135.5 in.
344.2 cm.
10”
36”
84”
1
2
3”
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12 x 12 Flat Top Attached Louvered Pergola
Overhead View
Wall

Wood Post Layout & Installation using
Bolt Down Brackets for Concrete or
Wood Surface for Attached Pergola
Measure and mark out the location of the bolt down brackets using
string or chalk line. Adjust string lines accordingly. The inside
corner of the string lines will be the corner of the bottom flange.
Mark out the location of bolt down brackets accordingly using
the base of the bracket accordingly.
Using a 3/16” masonry drill bit, drill 3“ deep holes
to allow installation of 2 3/4”concrete screws (Not included)
Proceed to install three 2 3/4”concrete screws into the bottom
base of the bolt down bracket.(Not included)
Please Note:
Concrete patios generally have sloped surface for water run-off.
If this is the case,when you secure the bolt down bracket to the
concrete, the bracket may be at an angle. This can be corrected
for level using galvanized steel washers (not provided), acting
as shims underneath the base to level - VERY IMPORTANT OR
PERGOLA BEAMS AND RAFTERS WILL NOT BE LEVEL.
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1
OPTIONAL STEP
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3
3
With the two post brackets installed plumb, proceed to set
the 4x4 x7’ wood post in place. Secure using the same concrete
screws included in the kit. Repeat for both posts.
Posts should be 84” in height.
In order to create a snug fit between the wood posts and the inner
cavity of the vinyl posts, it will be necesary to “build out” the 4x4
posts near the bottom and the top using 1/2” x 3 1/2” x 12” shims.
Follow instructions as illustrated.
Please Note:
Some 4x4 pressure treated wood posts can be larger than 3 1/2 x
3 1/2 square due to twisting or cracking. We have allowed a
tolerance for this in the post brackets and the internal one way and
two way 4x4 wood post guides. However in extreme cases, you
may need to shave down the end of your 4x4 wood post slightly
to allow access.
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6
3“ (Deep)
4
4
812 x 12 Flat Top Attached Louvered Pergola
7
84”
56
Level
6 in
72 in
Shims
7
2
Marker
Wall
* Orientate brackets
accordingly to reduce
offset motion of posts.
(direction of arrows
denote flange
opening)
*
*
135 3/4 in
344.9 cm
134 3/8 in
341.3 cm

Vinyl Column Assembly & Installation
Over Wood Posts
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12 x 12 Flat Top Attached Louvered Pergola
1
Using the vinyl weld glue, insert the One Way 4”x4” Internal
Wood Post Guide in the one end of the main column posts.
This step is only applicable if your wood 4x4 post are embedded
into the ground. If your pergola is going to be installed on
wood or concrete surface, please dispose of these four pieces.
Using a step ladder, guide the bottom vinyl columns over the
wood 4x4 posts .
Using a step ladder guide the top vinyl columns over the
wood 4x4 posts.
Please Note:
Ensure that holes at top of column are orientated correctly for
future beam and rafter placement. See diagram at top of next page.
Connect the bottom and top vinyl column by using vinyl weld
and sliding together. Please Note: Vinyl Weld Glue has about a
sixty second cure time and about a 20 minute dry time.
Slide the bottom post trim into position to cover the joint on
the column.
Slide the top post trim into approximate position just below the
bottom routed hole on the bottom of the top vinyl column assembly.
If necessary, adjust post heights accordingly to ensure future
level installation of beams and rafters as necessary. If slope is
severe causing a height difference between the posts, you may
need to trim down the bottoms of the vinyl columns as
necessary.
Secure the vinyl columns to the wood posts using 4 – 2 1/2“
self-auguring stainless steel screws at 8”up from the base
of the posts, and 4 – 2 1/2”self-auguring stainless steel screws
just above the trim cap as illustrated. This will prevent possible
uplift during high winds, etc.
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2
4
STEP THREE
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6
7
8
2 3 4
567
Slope?
8
8“
*Ensure that hole at top of column
are orientated correctly for
future beam and rafter placement.
*
3

134 in.
340.4 cm.
135 5/8 in.
344.4 cm.
Main Support Beam Assembly
Insert one 2x6x12 pressure treated wood into a beam followed
by the joiner and another beam section.
Critical Note:
Note the location of the pre-drilled holes on the end of the main
support beams. As pictured aside, the holes should be away from
the joiners.
Screw the joiner to vinyl beams and wood insert using 1 1/2”
screws.
Using a 1/2”drill bit, drill through the pre-drilled holes through
the 2x6 wood as shown.
Repeat for second Main Support Beam assembly.
1
2
3
STEP FOUR
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12 x 12 Flat Top Attached Louvered Pergola
At this stage,the columns should be properly
installed as per the following illustration,
with the columns 134” in. (340.4 cm) apart.
Critical: Note the opening direction
of the holes on the top of the posts.
2
1
Pre-drilled hole
at the end of the
main support beam
Pre-drilled hole
at the end of the
main support beam
3
4

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12 x 12 Flat Top Attached Louvered Pergola
www.newenglandarbors.com
Main Support Beam Assembly for Attached
Wall Side
Insert one 2x6x12 pressure treated wood into a beam followed
by the joiner and another beam section.
Critical Note:
Note the location of the pre-drilled holes on the top of the main
support beams.The cluster of four pre-drilled holes needs to be
away from the jointer as shown.
Screw the joiner to vinyl beams and wood insert using 1 1/2”
screws.
Fasten the Rafter Hangers to the beam assembly as shown.
Each rafter hanger will require two 1 1/2”screws from the top
and two 5/8”screws through the side.
1
STEP SIX
2
3
1
2
3
1 1/2”
Screws
5/8”
Screws
Pre-drilled holes
at the top of the
main support beam

Rafter Assembly
1
STEP SEVEN
To accomodate the notches on the rafters, first the wood inserts
must be cut down and notched out as shown below:
Six will be needed.
143 in
3 1/2 in
13 in (min)
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Insert one 2x6x12 pressure treated wood from the previous
step into a beam followed by the joiner and another beam section.
Note the orientation of the notch on the wood insert.
Screw the joiner to vinyl beams and wood insert using 1 1/2”
screws.
Repeat for all six rafters.
2
3
4
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12 x 12 Flat Top Attached Louvered Pergola
2
3

Ledger Boards and Main Support Beam
Placement
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12 x 12 Flat Top Pergola
Using a helper and two ladders proceed to complete the
following steps:
Position and place the two main support beams onto both
sides of the posts.
Fasten the two beams to the post by using the bolt assembly
that comes with the hardware kit. You’ll need two wrenches
to fasten the nuts and bolt.
Mount the two 2x6x6’ pressure treated wood pieces (sold se-
parate) on your wall surface. Please consult your local hardware
store regarding methods of mounting.We recommend 6 lag
screws if mounting to a wood siding or concrete/brick anchor
if you are mounting to a brick wall. Screws heads should be
recessed flush with the wood beam.
To locate the position of your wood beams;
A. Measure half way between the two vinyl posts (67”)
B. Mark and draw a string line square to the wall.
C. Measure up 98 1/2” and mark with pencil
D. Measure 3.25” on either side of the mark. This would
be the top corner of the two wood beams as shown.
1
2
STEP SEVEN
1
Front View
3
3
2
67”
90°
90°
A
B
C
98.5”
3.25” 3.25”
D
98.5”
(Distance to
top of wood
beams)
6.5” (Distance between wood beams)
72 in
(Wood Beam Length) 72 in (Wood Beam Length) Verify 3 1/4” distance
between the edge of the
wood beams to the face
of the vinyl post

Main Support Beams & Rafter Placement
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12 x 12 Flat Top Attached Louvered Pergola
Using a helper and two ladders proceed to complete the
following steps:
Mount the main support beam which has the rafter hangers
onto the wood beam as shown.The top of the wood beam
should be flush with the top of the support beam.
Fasten the main support beam attached to the wall so that
it’s centered to the main support beams attached to the vinyl
columns.
To fasten, use a minimum of six 3½” lag screws through the
main support beam and wood beam. Space the lag screws
between the rafter hangers.
Place the six rafters into the rafter hangers & beams.
Ensure that they are pushed all the way in the rafter hangers.
Fasten into the rafter hanger using four - 5/8” screws as shown.
Fasten the rafters onto the main support beams using 4” screws
as shown.
Finally, adjust the main support beam and rafters ensuring the
overhang past the column is equal. Using 4“ screws, lock the
main support beams and rafters into position inside the posts
by driving in 4 screws from the front and back each,
and 2 screws from the sides of each column.
1
2
STEP EIGHT
1
3
2
3
4
4
2 Screws from
the each side of
the column.
4 Screws from
the front and
back of the column.
Screw Pattern
Screw Pattern

Fastening Pergola ends and Caps
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12 x 12 Flat Top Attached Louvered Pergola
Install decorative pergola end caps using vinyl weld.
Final position your post trims.
1
2
STEP NINE
1
To position post trim in place:
1. Slide the post trim down.
2. Apply a generous amount of vinyl glue around the post
3. Slide the post trim back up to the desired location and
allow a few minutes for glue to cure.
To glue decorative end caps place:
1. Apply a generous amount of vinyl glue to the decorative end caps as shown.
2. Slide the decorative end caps into the beam/rafter and allow a few minutes
for glue to cure.
3

Louver Assembly
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12 x12Flat Top Attached Louvered Pergola
This kit contains four different pre-assembled Louver Bars as shown
below and aside:
3 x Pre-Assembled Louver Bars (plain)
6 x Pre-Assembled Louver Bars with Long Louver Bar*
3 x Pre-Assembled Louver Bars with Short Louver Bar
*) There are two variations of Louver Bar Assemblies with Long Louver Bar.
Identify and layout the twelve louver bars assembly as shown below:
1
STEP TEN
6 x Pre-Assembled Louver Bars (plain)
Pre-Assembled Louver Bars with Long Louver Bar
Pre-Assembled Louver Bars with Short Louver Bar
Note:
The short louver bar assembly will be
packaged as such. You will need to
remove these two nuts and re-
position the short louver bar.
Note:
Reposition the short louver bar as shown but
do not bolt to the adjacent louver assembly at this point.
Important ! : the holes on the louver bars are offset. ensure
the holes are at the bottom as shown.
Do not re-attach nuts
Note the distance to the first bolt;
the larger gap would go at the outside whereas
the smaller gap would go towards the middle bar assembly.
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Ensure all brackets are facing
the same direction.
Note the difference in distance to the first Louver Bracket

3
STEP EIGHT
Insert the Louver Boards one by one. Make sure each board is
inserted completely into the brackets.
Attach the matching Pre-assembled Louver Bar. Pressure fit
the boards one by one.
Repeat for all six sub-sections. At this point, you should have
three full sections of Louvers as shown below:
Louver Assembly
22
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3
The ends of the louver bars with large
space should be at the same end.
4
Do not attach with nuts at this point
Ensure that the holes in the louver
holder brackets are all on top of the
louver bars assembly
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12 x 12 Flat Top Louvered Attached Pergola

Louver Assembly
Place twelve Steel Holder Brackets as shown below and care-
fully lower the Louver assembly onto the steel brackets.
Do not screw the Steel Holder Bracketsinplace at this point.
Fasten the Short Louver Bar using two nutsasshown.
Do not over tighten.
You willneed to raise the middle section momentarily
to dothis step.
5
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Steel Holder Brackets
6
Note: check that the holes are closer to
the bottom as shown.
Install in order (one row at a time)
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12 x 12 Flat Top Louvered Attached Pergola

Slide the Steel Holder Brackets to a spot which will not
interfere with the operations of the louvers.‘Open’ and
‘Close’ the louvers to test and make sure the steel
brackets are not constraining the operation.
From the top, fasten the steel brackets in place using
5/8”screws. A total of 12 screws will be needed.
Repeat for the underside of the steelbrackets.
Another 12,5/8”screws will be needed.
Louver Assembly
7
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8
8
Bottom View
9
9
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12 x 12 Flat Top Louvered Attached Pergola

Louver Assembly
Repeat for other two rows.
Place the Post Caps onto the posts.
10
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12 x 12 Flat Top Louvered Attached Pergola