Pergolas Direct FREE STANDING User manual

Pergolas Direct
Instruction Manual
Free Standing
© Copyright 2010 Pergolas Direct. All rights reserved
PergolasDirect.com

FREE STANDING
STEP-BY-STEP INSTRUCTION PROCEDURES
COMPONENTS ............................................................................................................. 1
TOOLS NEEDED .......................................................................................................... 1
INTRODUCTION ........................................................................................................... 2
PERGOLA LAYOUT ...................................................................................................... 3
LAYOUT OF THE SUPPORT POST ............................................................................ 3
INSTALLING SUPPORT POST .................................................................................... 4
INSTALLING POST BASES.......................................................................................... 6
INSTALLATION OF SUPPORT POST FOR CONCRETE PATIOS & DECKS ............ 9
INSTALLATION OF 2” X 6” SUPPORT BEAM ............................................................. 10
INSTALLATION OF JOIST AND JOIST BEAM BRACKETS ........................................ 11
INSTALLATION OF JOIST ............................................................................................ 12
INSTALLING 3” SHADE SLATS ................................................................................... 13
INSTALLATION OF EXTERNAL COMPONENTS ........................................................ 13
© Copyright 2010 Pergolas Direct. All rights reserved. Reproduction in whole or in part without permission is strictly prohibited.

Fasteners and Hardware Provided:
Vinyl Glue
Tools Required:
Tape Measure
Framing Level
Framing Square
Circular Saw (Fine Tooth Blade)
Drill and Drill Bits
1/2” Masonry Bit (Concrete Patios)
1/2” Wood Bit (Wood Decks)
1/8” Drill Bit (Pre-drill holes for Joist Beam Brackets)
Framing Square (Patios Attached To House)
(2) Step Ladders
String Line or Chalk Line
Crescent Wrench (Concrete and Wood Patios)
Hammer
80 lb. Ready Mix Concrete
(Pergolas installed in ground)
5” Post
Cap
2” x 6”
Pergola Cap
2” x 6”
Joist
Hanger
Brackets
Vinyl Glue
Cap For 5”
Ledger Lock
Screw
5” Ledger
Lock
Screw
1 1/2” Self
Tapping
Screw
(For Shade
Slats)
1 1/2” Self
Tapping
Screw (For
Joist Beam
Brackets &
Joist Hanger
Brackets)
Shade Slat
Picket End
2” x 6” End Cap
Joist
Beam
Bracket
Decorative Post Base
Ring (For Concrete &
Wood Patios)
“L” Bracket

2
PERGOLA
FREE STANDING
Thank you for purchasing your new pergola from PergolasDirect.com. We have spent numer-
ous hours in developing an installation manual which we hope will provide simple and concise
instructions to help you build a beautiful new addition to your back yard. Enjoy!
This instruction booklet will provide a step-by-step process for installing your new pergola.
Should you decide to 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 on your pergola.
Please read these instructions thoroughly prior to the construction of your pergola.
DETERMINING PERGOLA HEIGHTS AND LAYOUT
The average height of a pergola is 8’, measured from the ground level to the bottom of your
support beam.
The height of your pergola will be based on several factors. For example, the height may
be determined by the height of the roof line on single-story homes, or the heights of existing
doors and windows.
Layout of your pergola is just as important as height. You will need to consider post location,
slope of concrete patios and wood decks and sprinkler or utility lines if it is an in-ground
pergola.
Note: It is recommended to verify local building codes, ordinances, neighborhood
covenants, or height restrictions regarding this type of structure and heights.

3
PERGOLA LAYOUT
PROJECTION AND LENGTH
On our standard kits, the maximum
projection distance is 14’. Projection
is the distance from the outside of the
post to the ouside of the next post,
running to direction of the joists
(See Diagram 1).
On “attached” pergolas the projection
is distance from the attachment point
on the house to the outside of post.
The length of your pergola is mea-
sured from outside edge of the sup-
port post. Length is also the direction
your support beam runs. Length of a
pergola is unlimited. With maximum
spans between posts of 14’, you can
have several posts in the length of
your pergola, if the length exceeds 14’.
LAYOUT OF THE SUPPORT POST
Post location is the most important part of
the installation process. Take your time
measuring and analyzing window and
door heights, location of electrical and
phone lines, etc., prior to the layout of
your post.
Note: The patio cover you order
will be based on the measurements
from outside edge to outside edge of
the posts in both the projection and
length.
STEP 1
Measure and temporarily mark the pro-
jection and length of the pergola (See
Diagram 2 and 2A).
DIAGRAM 1
DIAGRAM 2

Post
Location
Diagonal Distance
Projection
Projection
Length
String or Chalk Lines
4
STEP 2
Using string lines or chalk lines layout the pergola dimensions. Measure the diagonal dis-
tance from corner to corner (See Diagram 2A). Diagonal distances must be the same to
ensure a square installation. Adjust the lines until the diagonal distances are square. The
inside corner of the string lines will be the post location.
INSTALLING SUPPORT POSTS
Pergolas can be installed in the ground, on concrete patios or wood decks.
IN GROUND CONSTRUCTION
Pergolas installed in the ground require different installation procedures than concrete patios
and decks.
STEP 1: DIGGING HOLES
After you have determined where the posts will be located, you are now ready to dig each
post hole. Post holes (piers) are dug 12” in diameter and 30” deep (See Diagram 3).
DIAGRAM 2A

STEP 2
After all holes are dug and cleaned,
place a post into a hole, level and mea-
sure the post height to determine the
amount of excess post which will be cut
from the bottom. The recommended
height of the pergola is 8’ from the
ground level to the bottom of the support
beam (See Diagram 4).
Note: The depth of the hole and slope
of the ground (if any) will affect the
post length prior to installation. Not
all posts will be cut to the same mea-
surements.
Note: Heights of windows, roof over-
hangs, or other factors may change
the recommended height. Make sure
you calculate heights and distances
before cutting off any excess post.
STEP 3: CONCRETING POST
With the first post cut to exact height,
insert the 8’ galvanized steel post base
inside the bottom of the 5”x5” support post,
place the post with the insert down into the hole
and add ready mix concrete all the way to the
top. Check to make sure the slots in the holes
are facing the correct position to accept the
support beams. Level the post and smooth off
top of concrete. Let your concrete set up for
at least 48 hours prior to installing your support
beams.
Note: The best way to mix your concrete is in
a wheelbarrow. Do not make the mixture too
soupy. This will affect the concrete strength
and cause the concrete to be brittle in time.
A thick sludge is ideal, plus it will hold the
post in place while concrete is setting up.
STEP 4
Go to the opposite hole, place a post into the
hole. With the help of another person, place
a 2x6 support beam up against the first post
where the beam is even with the support beam
hole and up against the other post.
DIAGRAM 3
DIAGRAM 4
5

6
STEP 5
With both post and support beam
leveled (using a framing level),
make a mark on the side of the
post where the top of the beam is
level with the post (See Diagrams 5
and 8).
STEP 6
Cut off your excess post, and insert
the 8’ post base and concrete this
post. Once you have concreted
the post, check for levelness again.
STEP 7
Repeat steps 2 through 7 for the
other outside posts.
Note: The post base ring can
be installed on the post before
or after the posts are installed.
INSTALLING
POST BASES
ON CONCRETE PATIOS
After you have determined where each post will be located on
your concrete patio, you are ready to install 36” galvanized steel
post bases (See Diagram 6 and 6A).
DIAGRAM 5
DIAGRAM 6

7
Note: You will determine where to cut off excess post for proper height once post
bases are secured (See: INSTALLATION OF SUPPORT POST on page 9).
DIAGRAM 6A
1) Layout the locations for the post.
2) Take surface plate (A) and use as a tem-
plate, mark the four corner holes for the (4)
3/8” x 4-1/2” threaded rod (O).
3) Drill the marked holes using a 7/16”
masonry drill bit. Drill the hole into the
concrete surface to a depth of 3-1/2”.
Thoroughly clean the holes of dust and
debris.
4) It is recommended to use chemical
anchoring epoxy (epoxy not included) with
threaded rod (O) per ASTM standards.
*For information regarding chemical anchor-
ing contact: Powers Fasteners at 800-524-
3244.
5) Align the surface plate (A) over the
threaded rods(O).
6) Position the optional base trim (D) over
the top of the surface plate (A).
7) Take leveling insert (F) and (4) 5/16” nuts
(T). Press nuts into hex shapes of leveling
insert (F). Align over holes of optional base
trim (D) and surface plate (A)
8) Take the post mount and place it into the
optional base trim (D) and over the threaded
rods (0).
9) Take four washers (P) and place one on
each threaded rod (O), then put nuts (Q) on
threaded rod (0). Hand tighten nuts (Q) to
allow leveling of the post.
10) Screw the (4) 5/16 x 1” leveling bolts
(E) into the (4) 5/16” nuts pressed into level-
ing plate (F). Adjust the leveling bolts (E) to
straighten the post. (See Figure 1) After post
has been leveled, tighten nuts (Q). (Do not
over tighten)
11) Slide vinyl support post over the post
mount until it seats into the optional base
trim (D) or meets the deck surface. The
post stabilizers (K) will secure the post into
its proper position.
A - Surface Plate (1)
D - Base Trim Optional
E - 5/16” x 1” Leveling Bolts (4)
F - Leveling Insert (1)
K - Post Stabilizer (2)
L - 2x2 Square Tubing (1)
O - 3/8” x 4-1/2” Threaded Rod (4)
P - 3/8” Washers (4)
Q - 3/8” Nuts (4)
T - 5/16” Leveling Insert Nuts (4)

A - Surface Plate (1)
B - Deck Board Example
C - Reinforcement Board Example
D - Base Trim (Optional)
E - 5/16” x 1” Leveling Bolts (4)
F- Leveling Insert (1)
G - 3/8 x 4-1/2” Bolts (4)
H - Bottom Plate (1)
K - Post Stabilizer (2)
L - 2 x 2 Square Tubing (1)
R - 3/8” Nuts (4)
S - 3/8” Washers (4)
T - 5/16 Leveling Insert Nuts (4)
8
INSTALLING POST BASES
ON WOOD DECKS
After you have determined where each post will be located on your wood deck, you are ready
to install the 36” galvanized steel post bases (See Diagram 6B).
DIAGRAM 6B
Note: You will determine where to cut off excess post for proper height once post
bases are secured (See: INSTALLATION OF SUPPORT POST on page 9).
1) Layout the locations for the post.
2) Take surface plate (A) and use as a tem-
plate, mark the four corner holes.
3) Thickness of wood deck and reinforce-
ment board underneath deck should be a
minimum 2-1/2î.
4) Drill four 7/16” holes through the marked
holes, drilling through the deck board (B)
and the reinforcement board (C).
5) Align the surface plate (A) over the
drilled holes.
6) Position the optional base trim (D) over
the top of the surface plate.
7) Take leveling insert (F) and (4) 5/16”
nuts (T). Press nuts into hex shapes of lev-
eling insert (F). Align over holes of optional
base trim (D) and surface plate (A)
8) Take the post mount and place it into the
optional base trim (D) lining up the holes.
9) Next insert the (4) 5/16” x 4-1/2” bolts
(G) into the drilled 7/16” holes.
10) Take bottom plate (H) and line up with
bolts under the deck as shown in diagram.
Add (4) washers (S) and (4) nuts (R). Hand
tighten nuts (R) to allow leveling of the post.
11) Screw the (4) 5/16 x 1” leveling bolts
(E) into the (4) 5/16” nuts pressed into lev-
eling plate (F). Adjust the leveling bolts (E)
to straighten the post. (See Figure 1) After
post has been leveled, tighten nuts (R). (Do
not over tighten)
12) Slide vinyl support post over the post
mount until it seats into the optional base
trim (D) or meets the deck surface. The
post stabilizers (K) will secure the post into
its proper position.

INSTALLATION OF SUPPORT POST FOR
CONCRETE PATIOS AND DECKS
STEP 1
With the post bases secured, place the vinyl support posts over the post bases. Use a
2”x6” (hollow) joist and place up against the outside of each post at a distance of 8’ from the
ground level to the bottom of the 2”x6” joist (See Diagram 8).
Note: 8’ is the recommended height of the pergola from the ground level to the bottom side of
the support beam. Due to heights of windows, roof overhangs, or other factors, heights may
vary. Make sure you calculate heights and distances before cutting off any excess post.
STEP 2
With the joist and posts both leveled, make a mark on the post at the top of the 2”x6”.
STEP 3
The distance between this mark and top of the support beam slot is the amount of post you
will need to cut off (the bottom slot is for support beam, top slot is for the joist to extend
through) (See Diagram 8).
STEP 4
With the post cut to exact measurements, place your decorative post base ring over the post
base.
STEP 5
Slide the support post over the post base and down into the post base ring (both will snap in
place).
DIAGRAM 8
9

10
Note: Before you cut off post on the other support beam side you need to make sure
the joists will be level when they extend over the support beams. Sometimes a con-
crete patio or wood deck is not level and without making adjustments on your post
heights your pergola will be at a slight angle. To check to see if your patio or deck is
level, place a large contractors level on the surface of the patio or deck.
INSTALLATION OF 2”x 6” SUPPORT BEAM
The support beam will consist of a 2”x6” vinyl hollow beam and galvanized steel insert.
The inserts come in two pieces if the beam length is greater than 9’. The two-piece inserts
telescope into each other in order to extend to the proper length inside the vinyl beam. Make
sure that these inserts extend the full length of the beam. Sometimes in shipment they slip
inside each other and you will have to re-adjust the length.
STEP 1
Support beams extend 6” past the outside edge of the outside support posts
(See Diagram 9).
STEP 2
Slide the vinyl beam (with inserts inside) through both holes of the 5” post and through both
holes of the other 5” post. Install Pergola “L” brackets for the beam (See Diagram 9).
Note: With length spans greater than 15’, you will have additional support posts to
support beams. If this is the case, you will have a two piece beam. If you do have a
two piece beam, make sure they are spliced in the middle of the post (See Diagram 10).
DIAGRAM 9

11
INSTALLATION OF JOIST AND
JOIST BEAM BRACKETS
The 2”x6” joists come in lengths longer the projection of the pergola. Joists are cut to extend
a minimum of 6” past the outside edge of the post.
STEP 1
Insert a 2”x6” joist through each top slot on the support post. These joists are the primary
joists. Install Pergola “L” brackets under the joist (See Diagram 9).
Note: With the primary joist in place, you will need to find appropriate spacing for
the joist beam brackets on the support beam and mark where each bracket will be
installed.
The number of joists provided in your kit is calculated based on the length of your pergola.
The joist brackets and joist hangers need to be installed approximately every 16” on center,
starting from the center of each post. Your goal is that when you look up at the pergola, the
spacing of the joist looks even to the eye.
DIAGRAM 10

12
STEP 2
Install each joist beam
bracket with two 1
1/2” white self-tapping
screws, screwing into the
vinyl sleeve and steel
insert(s). Pre-drilling
the holes will make it
easier when you prepare
to install the brackets,
especially if you are
going through two layers
of steel insert.
STEP 3
Install the joist brackets
on the otherbeam using
the same measurements
as you did on the first
support beam.
INSTALLATION OF JOIST
You are now ready to install the 2”x6” joists.
STEP 1
Place the joist in the front and rear joist beam brackets.
STEP 2
Secure the joist to the brackets by screwing one 1 1/2” white self-tapping screw on each side
of the bracket.
STEP 3
Repeat steps 1 through 4 on all remaining joists.
DIAGRAM 11

13
INSTALLING 3” SHADE SLATS
The 3” shade slats are cut to extend 6” further than your pergola length. Your kit will contain
enough shade slats for adequate coverage using a 3” gap between slats.
On pergola lengths over 15’ splicing will be required. Additional slat material will be included
to allow a splice in the middle of a 2”x6” joist. On lengths greater than the 15’ all slats will
need to be custom cut. Allow for a minimum of 6” overhang past the outside 2”x6” joist.
STEP 1
Install slats on both sides of support posts using one 1 1/2” self-tapping screw (use tan snap
caps with tan pergolas) per joist. Be careful not to over-tighten screw.
STEP 2
Using a 3” slat as a template, mark slat locations working from the support post towards
the building. As you approach the last four or five rows, you want to adjust your marks to
achieve as close to a 3” gap as possible. (For example, in the last four rows you may have a
gap which is more or less than 3”.) Your goal is to have the slats look visually good to the eye
when looking up at the pergola.
Note: The number of slats that come with your kit is based on no less than a 3” gap.
STEP 3
Install 3” slats working from the building back towards the support posts.
Important: Before installing the first slat at the house, confirm proper slat placement to
achieve slat spacing.
INSTALLATION OF EXTERNAL COMPONENTS
The last installation required is installing the post caps, pergola caps, ledger lock caps, ledger
end caps and shade slat pickets.
STEP 1
With the vinyl glue that comes with the kit, apply a small dab of glue on each component and
install the pieces listed above. Do not apply glue on total surface area if for some reason you
want to remove these pieces at a later date.