New England !VALON User manual

10 x 10 Flat Top
Louvered Pergola
ASSEMBLY GUIDE
OPTIONAL ACCESSORIES
s!RCH+IT3YSTEM (2 Arches)
s0RIVACY&ENCE0ANEL3YSTEM (2 Panels & Middle Post)
s0RIVACY7ALL (2 Panels & Middle Post)
s"OLT$OWN"RACKET+IT(4 for Pergola)
s0ERGOLA0LANTER
6ER
-ODELS!VALON
www.newenglandarbors.com

Table of Contents
210 x 10 Flat Top Louvered Pergola
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10 x 10 Flat Top Louvered Pergola
INTRODuCTION & OVERVIEW……………………………xx…
0ERGOLA MATERIALSOVERVIEW…………………………
0ERGOLA MATERIALS"REAKDOWN………………………x 
0ERGOLA !DDITIONALMATERIALS,IST………………………………
7OOD0OST LAYOuTINSTALLATION fOR)NGROUND!ppLICATION………………………………
7OOD0OST LAYOuTINSTALLATION uSING"OLT $OWN0OST"RACKETSfOR CONCRETEOR 7OOD3URFACE……………
VINYLCOLUMN !SSEMBLYAND)NSTALLATION OVER 7OOD 0OSTS…………………………………………
-AIN3UPPORT"EAM !SSEMBLY………………………
RAfTER !SSEMBLY……………………………………… 
-AIN3UPPORT"EAMSRAfTER0LACEMENT …………………………
LOuVER!SSEMBLY …………………………………………………………
TuRN"AR HOLDERINSTALLATION x……………………………………
OpERATIONS ………………………………………………………… 
MODIFICATION …………………………………………………………
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Top View
Front ViewSide View
90 in
110 in
120 in
34
151 in
151 in
92.5 in
110 in
104 in
120 in
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Introduction & Overview
3
10 x 10 Flat Top Louvered Pergola
Getting Started
&IRST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 $O NOT
ATTEMPTALONE,ESpECIALLYDURINGTHEINSTALLATIONSTAGE 3HOULD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 7HENASSEMBLINGCOMpONENTSPLACEONA
NONABRASIVE SuRfACE(IE SHIPPINGBOx) TO AVOID SCRATCHING 7ERECOM
MENDA’ x’ AREAfORUNOBSTRuCTEDASSEMBLING YOu SHOULD NOTNEEDTO
USEExCESSIVEfORCE
WHEN ASSEMBLINGANYCOMpONENTS
Planning & Preparing
THE!VALON0ERGOLAISMADETOSTANDINDEpENDENT Of YOUR HOMEAND YOu
CAN
EITHERLOCATEITNEARYOURHOUSEORLETITSTANDALONEINTHEGARDEN "YKEEP
ING
ITUNATTACHED fROMYOURHOMEYOu WILL NOT HAVETO DEAL WITH MOVINGEXIS
TING 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
4INCHESBACKFROMYOUREAVES
7HAT LOOKS LIKETHETOUGHESTPART OFTHISPROjECTISACTUALLYTHEEASIEST,THE
GRACEFUL,SOLIDLOOKINGCOLUMNS 7E’VEDESIGNEDTHESECOLUMNSTOSIMPLYBE
SLIPpEDOVERTREATEDXWOODpOSTSTHATAREEITHEREMBEDDEDINCONCRETEOR
DIRECTLYMOUNTEDTOACONCRETEORWOODSURFACEUSINGOURBOLTDOWNBRACKETS
3EEPAGES,ANDfORMOREDETAILS
ITISCRITICAL BEfOREYOu STARTTHAT YOu CONSIDERTHECURRENTSLOpEOFELEVATION
WHERETHEpERGOLAISPLANNEDIFTHEREIS ANY !LSO 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 thoroughly prior 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).
(Avalon Pergola Shown)
www.newenglandarbors.com
Introduction & Overview

Avalon Pergola Materials Overview
410 x10 Flat Top Louvered Pergola
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1. 0OSTCAPS(4)
2. MAINCOLUMN TOPS(4)
3. 0OST TRIMS(8)
4.
RAfTER& "EAM$ECORATIVE%ND CApS (20)
5. MAIN3UPpORT"EAMS(8)
6. "EAMRAfTERJOINERS(10)
7. MAINCOLUMN"OTTOMS (4)
8.
RAfTERS (12)
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8
6
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9. /NE 7AY 4”x4 “ INTERNAL 7OOD0OSTGuIDES (4)
10. LOUVER TuRN "AR (1)
11. TuRN"AR HOLDER(1) - Found in Box 7
12.
0REASSEMBLEDLOUVER "ARS  7ITHLONGLOUVER"AR(6)
13. 3TEEL HOLDER "RACKETS (36)
14. LOUVER"OARDS (72)
15.
0 REASSEMBLEDLOUVER"ARS 7ITH3HORTLOUVER"AR3)
16. 0 REASSEMBLEDLOuVER"ARS 7ITH .O LOUVER "AR (3)
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Check Boxes (Total of 7) for These Contents
INTHEEVENT OFMISSINGORDEfECTIVEPARTS pLEASECALLOURCUSTOMERSERVICE
DEPT AT 1 800 282 9346 (Mon. to Fri.8:00 AM to 4:00 PM EST)
1. 0OSTCAPS (4)
2. MAINCOLUMN TOPS(4)
3. 0OST TRIMS(8)
4.
RAfTER& "EAM$ECORATIVE%NDCAPS (20)
5. MAIN3UPpORT"EAMS (8)
6. "EAMRAfTERJOINERS (10)
7. MAINCOLUMN"OTTOMS (4)
8.
RAfTERS (12)
9. /NE 7AYvX “ INTERNAL 7OOD0OSTGUIDES (4)
10. LOuVER HANDLE"AR (1)
11.
0REASSEMBLED LOUVER "ARS  7ITHLONGLOUVER"AR (6)
12. 3TEEL HOLDER"RACKETS (36)
13. LOuVER "OARDS (72)
14.
0 REASSEMBLEDLOUVER"ARS 7ITH3HORTLOUVER"AR (3)
15. 0 REASSEMBLED LOuVER "ARS 7ITH.O LOuVER "AR (3)
Avalon Pergola Materials Breakdown
5
10 x 10 Flat Top Louvered Pergola
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Not to Scale
3x
3x
Note the distant to
the first louver bracket

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. 1 1/2”Self-Auguring Stainless Steel Screws (40) (for Beam and Rafter Joiners )
D. 2 1/2”Self-Auguring Stainless Steel Screws (32) (to lock the Main Column Bottom
and Tops to the Wood Posts )
E. 2 1/2“ Self-Auguring Stainless Steel Screws (2) (to fasten Turn Bar Holder to post)
F. 4“ Self-Auguring Stainless Steel Screws (32) (to lock Beams to the Posts)
G. 4”
Self-Auguring Stainless Steel Screws (40) (to lock Rafters to the Beams)
H. 9”Stainless Steel Bolt Assembly with Nuts and Washers (4)
(to lock the Column Tops and Beams together)
I. 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 (4) (purchase at local building center)
K . 4x4 Bolt Down Bracket Kit (purchase from www.newenglandarbors.com or a
retailer of our products)
1/4”x 2 3/4”Concrete Screws (12) and Wood Screws
3/16”Concrete Drill bit.Min 3” long (1)
1/2“ x 3 1/2”x 12“ Wood Post Shims (32)
If Mounting Pergola in Ground
L.
4x4x12 Pressure-Treated Wood Posts (4) (purchase at local building center)
M. Concrete Ready Mix (4) (purchase at local building center)
Rafter/ Beam Support (Required)
N. 2x6x10 Pressure-Treated Boards for Beams and Rafters (10) (purchase at
local building center)
Tools You Will Need
s,EVEL
s2UBBER-ALLET(AMMER
s4APE-EASURE
s3TRING,INE
s7OOD3TAKES(4)
(temporary support for
string line)
s3TEP,ADDERS (2)
s#ORDLESS$RILL
sv7OOD$RILL"IT
s#IRCULAR3AWWITH&INE4OOTH"LADE
s&RAMING,EVEL
s&RAMING3QUARE
s7RENCH3OCKET3ET Not to Scale
610 x 10 Flat Top Louvered Pergola
NJ ,
Purchase
Separately
Purchase
Separately
Purchase
Separately
M
CONCRETE - Ready Mix
Purchase Separately
Purchase Separately
K
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C D E G&B HA
I

Wood Post Layout & Installation
for In-Ground Application
Measure and mark out the location of the ergola osts using
string line and tem orary wood stakes. Diagonal distances must
be the same to ensur re 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.
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 ha e determined where the osts will be located,
exc ate 10” diameter x 36” d ost holes.
After holes are dug and cleaned, ace the 4x4 wood ost into
a hole ensuring it’s le re to string lines. The final ost
height should be no more than 102”out of the ground. If a ost
is higher because of obstructed exca ation of footings, lease
cut down in height accordingly.
ill the acant hole withre-mixed concrete all the way to
within 3” of the t he hole. Once the concrete has set, back
Re eat for all four osts.
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 T WO
Install Wood Supporting Posts Directly into the Ground
4
111 1/2 in.
283.2 cm
10”
36”
1
2
3”
3
7
10 x 10 Flat Top Louvered Pergola
Overhead View
157 11/16 in (400.5 cm.)
from corner of wood ost to corner of wood ost.
102“ (Maximum)
Note:
Shown is a 11’-6”length of wood, and since
the 4x4 Pressure Treated wood comes in
12’ lengths, do one of the following:
a. Cut the wood down to 11’-6”
b. Dig 42” tead of 36”
111 1/2 in.
283.2 cm
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Wood Post Layout & Installation
Using Bolt Down Brackets
for Concrete or Wood Surface
Measure and mark out the location of the Pergola Posts using
string or chalk line. 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 corner of the
Mark out the location of bolt down brackets 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.
bottom flange.
1
OPTIONAL STEP
2
3
3
With the four Post brackets installedPlumb,Proceed to set
the 4x4x8’ wood PoSTINPlace. Secure using wood screws.
RePeat for all 4 Posts.
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.
55
96 in
4
4
810 x 10 Flat Top Louvered Pergola
3“ (DEEP)
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2
Marker
2
Marker
1
* Orientate brackets
accordingly to reduce
OFFSETMOTIONOFPOSTS
(direction of arrows
denote flange
OPENING
**
*
*
110 3/8 in
280.4 cm
110 3/8 in
280.4 cm
156 in (396.5 cm)
&rom corner of bracket
(Bottom of flange)
to corner of bracket
6
)NORDERTOCREATEASNUGFITBETWEENTHEWOODPOSTSANDTHEINNER
CAVITYOFTHEVINYLPOSTSITWILLBENECESARYTOhBUILDOUTvTHEX
POSTSNEARTHEBOTTOMANDTHETOPUSINGvXvXvSHIMS
&OLLOWINSTRUCTIONSASILLUSTRATED
,EVEL
6
Shims to
“build out”
THEXPOSTS
on all four
sides
72 in
6 in

Vinyl Column Assembly & Installation
Over Wood Posts
9
10 x 10 Flat Top 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 predrilled holes at top of column are orientated
correctly for future beam and rafter placement. See diagram
at top of next page.
3a - If you also purchased base moldings (sold separately),they
should be inserted at this stage.
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 tOPANd bottom Post trim into Position. Use the bottom
Post trim to coVer the joint on the column. Slide the toPPost trim
intOAPProximate Position ±3” below the hole in the toPVInyl column
assembly.
)FREQUIRED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 bottom of two or more of your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.
Using tHEPredrilled hole as a temPLate, driVe a 1/2” hole
through the wood Post. Make sure to drill straight through
to the hole on thEOPPosite side of the Post.
1
2
4
STEP THREE
5
6
7
8
5
7
8
*Ensure that predrilled holes at top of
column are orientated correctly for
future beam and rafter placement.
3
3
*
2
4
3a
)FYOUPURCHASEDTHEBASEMOLDINGSSCREWDIRECTLY
ABOVETHEBASEMOLDINGS

Main Support Beam Assembly
1
1
2
STEP FOUR
10
10 x 10 Flat Top Louvered Pergola
At this stage, the columns should be properly
installed as per the following illustration,
with the columns 110” in. (279.4 cm) apart.
Also,notice that the holes at the top of each
post should be facing the same direction.
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110 in.
279.4 cm.
110 in.
279.4 cm.
Critical Note:
Note the location of the pre-drilled hole on beams as pictured
aside.These holes will align with the hole on the posts.
Both ends of beam section should extend approximately 6” over
the pressure treated wood.
Insert one 2x6x10’Pressure treated wood into aMAINSUPPORT
beam section followed by the joiner and another beam section.
Glue and attach the DecoratiVe End CAPs onto the ends as shown.

11
10 x 10 Flat Top louvered Pergola
Main Support Beam Assembly
Using four 1 1/2”screws provided, fasten the Beam Joiners,
Beams and Wood together as shown.
Now that the wood is secured in place, use the predrilled holes
as templates and drill 1/2”holes through the wood as shown.
Make sure to drill straight through to the other side of the beam.
Repeat for all four beams.
3
4
5
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3
4
Rafter Assembly
1
STEP FIVE
To accomodate the notches on the rafters, first the wood inserts
must be notched out as shown below:
Six will be needed.
7 in (min)
3½ in
120 in
3½ in
7 in (min)

12
10 x 10 Flat Top louvered Pergola
Rafter Assembly
Insert one of the notched 2x6x10 pressure treated wood into a beam
section follow by the joiner and another beam section. Make sure the
notch is at the bottom as shown.
Glue and attach the Decorative End Caps onto the ends as shown.
Using four 1 1/2”screws provided, fasten the Rafter Joiners,
Rafters, and Wood together as shown.
Repeat for all six rafters.
2
3
4
5
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3
4
Note:
Ensure the wood insert is not
protruding into the notched
area of the Rafter.

Main Support Beam & Rafter Placement
13
10 x 10 Flat Top Louvered Pergola
1
1
2
3
STEP SIX
2
Using a helper and two ladders proceed to complete the
following steps:
Raise one Main Support Beam Assembly at a time and insert
the Bolt Assembly into the holes to hold into place as shown.
Some force may be required to get the bolt through.
Do not tighten the nuts until all four beams are in place,
instead, simply hand-tighten them.
Once all four main support beams are in position, use
two wrenches to lock the beams into place.
Fasten the main support beams onto the Posts using the 4”
screws provided. (8 screws per post)
Place the rafters onto the main support beams as shown. Space
the middle two rafters 34” apart (Critical for louver placement)
3
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Main Support Beam & Rafter Placement
14
10 x 10 Flat Top Louvered Pergola
Fasten the Rafters to the Posts using the 4”screws provided
(4 per post).
Fasten a 4”screw at each intersection where the Beams
and Rafters intersect as shown. 24 screws will be needed.
4
5
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4
5
5
*Important: Make sure the distances between rafters are 34”.

Louver Assembly
15
10 x 10 Flat Top 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 SEVEN
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
16
STEP EIGHT
10 x 10 Flat Top Louvered Pergola
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

Louver Assembly
17
10 x 10 Flat Top Louvered Pergola
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 Brackets in place at this point.
Fasten the Short Louver Bar using two nuts as shown.
Do not over tighten.
You will need to raise the middle section momentarily
to do this step.
5
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Steel Holder Brackets
6
6
Note: check that the holes are closer to
the bottom as shown.
Install in order (one row at a time)

18
10 x 10 Flat Top Louvered 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 steel brackets.
Another 12, 5/8” screws will be needed.
Louver Assembly
7
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8
8
7
Bottom View
9
9

Louver Assembly
19
10 x 10 Flat Top Louvered Pergola
Repeat for other two rows.
Place the Post Caps onto the posts.
10
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11
11
10

Turn Bar Holder Installation
1
1
2
STEP EIGHT
20
10 x 10 Flat Top Louvered Pergola
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The Turn Bar Holder can be found with in Box 7 and is
designed to provide a place to keep the Turn Bar when not in use.
Pick a location that is easily accessible and out of the way of the
louvers operation.The post is recommended as the 2 1/2” screws
are used to protrude into the wooden post, providing a secure
mounting support.
Mount with the slot on the top and closer to the post as shown.
Fasten with two 2 1/2” screws provided.
Hang the Turn Bar as shown.
3
2
Slot on the top and
closer to the post.
3