RioOutdoors 4S-DC User manual

1 | Page
Installation Instructions
4S-DC
4x4 Surface Mount Single Cubic Pergola Kit
Pergola Kits
WARNING: If the information in these instructions is not followed exactly, weakening or failure of the erected
structure may result causing property damage, personal injury, or loss of life.
All brackets designed and sold by RioOutdoors.com are to be used for building pergolas only and are not to be used for
other structure construction purposes.
•
Thoughtfully engineered
Brackets eliminate all wood-
joinery skills requirements.
•Skills required: drill holes
in concrete and hammer
in anchors, drilling pilot
holes and driving lag
screws into lumber.
•Easy lift and place U-
channels eliminate need
for lifting equipment.
Super-easy assembly
work.
•Self-aligning design
squares up structure
automatically.
•Estimated Assembly
Time is less than 1-1/2
hours.
Figure 1: Items included in the kit, (

 ).
Items not included in this kit: wood, tools, some hardware.

2 | Page
Table of Contents
1.1 SAFETY AND WARNING INFORMATION ........................3
1.2 TOOLS REQUIRED...................................................4
1.3 CONTENTS OF KIT #4S-DC ......................................5
1.4 LIST OF MATERIALS THAT YOU WILL SUPPLY ..................6
1.5 SURFACE MOUNT SYSTEM........................................7
1.6 SIDE ELEVATION DIAGRAM..................................... 10
1.7 FLOOR ANCHOR BRACKETS INSTALLATION....... 11
1.8 INSTALLING PERGOLA POSTS........................... 13
1.9 POST-TOP BRACKETS INSTALLATION ........................ 15
1.10 POST TOP 2-WAY EXTENSION BRACKET INSTALLATION 18
1.11 4X4HEADERS INSTALLATION ................................. 20
2.1 CONDITIONS ...................................................... 23
2.2 EXCLUSIONS....................................................... 23
2.3 LIMITATIONS OF LIABILITY ..................................... 24
2.4 HOW TO OBTAIN WARRANTY SERVICE ..................... 24
Proper pilot hole diameter and hole depth for various lag screws and wood types
Lag Screw Type
Wood Type
Pilot hole drill diameter and hole depth
¼” X 1-1/4” Lag Screw
McMasterCarr.com SKU 92351A546
Soft Wood 3/32” drill bit diam., 1-1/4” depth
Hard Wood 3/16” drill bit diam., 1-1/4” depth
3/8” X 3” Lag Screw
McMasterCarr.com SKU 92351A636
Soft Wood 11/64” drill bit diam., 3” depth
Hard Wood ¼” drill bit diam., 3” depth
A properly sized pilot hole must be drilled before you attempt to drive lag screws into any pergola lumber member.
See Table, below. Driving lag screws into lumber, without first drilling a pilot hole, can prevent the lag screw from
driving fully into the wood or can lead to crack formation while driving the lag screw in, or later, as the wood dries
naturally. This can result in a weakened pergola structure.

3 | Page
GENERAL INFORMATION
1.1 SAFETY AND WARNING INFORMATION
1.1.1 Building Permit & Inspection Requirements
We recommend that you consult with your local building permit office and obtain advice and any required building permits and
inspection approvals from the local building inspection department or the local jurisdiction having authority over building codes.
1.1.2 Other Cautions
CAUTION: Adhere to all safety requirements. Wear safety glasses/goggles when working. Wear safety gloves
when handling brackets, hardware, and lumber. Wear hearing protection when using a circular saw, miter
saw, table saw, or hammer drill.
INSTALLER: Leave this manual with the consumer. CONSUMER: Retain this manual for future reference.

4 | Page
1.2 TOOLS REQUIRED
Listed below, are common tools required for pergola projects. These tools are not included in this kit. Your pergola project may
not require all tools. Select and acquire the tools for your project from the “Required for” column in this table.
Description
Tool Purpose
Required for
Reference Image
Tape
Measure
Measure and verify
lengths. All pergola types
Framing
Level Verify Level/Plumb All pergola types
Hammer
Drill
Drill holes in concrete
pads or concrete
footing for securing
floor anchor brackets.
Drill pilot holes for lag
screws.
All pergola types
Ratchet
Socket
Driver
Drive lag screws into
Pergola lumber
members.
All pergola types
7/16” Hex
Socket
Drive ¼” X 1-1/4” Hex
Hd. lag screws. All pergola types
9/16” Hex
Socket
Drive 3/8” X 3” Hex Hd.
lag screws.
Raftered pergola (single,
dual, quad headers)
3/32” Drill
Bit
Drill pilot holes for ¼”
lag screws in soft wood. All pergola types
11/64” Drill
Bit
Drill pilot holes for 3/8”
lag screws in soft wood.
Raftered pergola (single,
dual, quad headers)
½” X 4”
Masonry
Drill Bit
Drill ½” X 2” deep holes
in concrete pads or
concrete footings.
Surface Mount styled
pergola
#2 Phillips
Screwdriver
Bit
Attaching pergola
rafter ties to rafters
and headers.
Raftered pergola (single,
dual, quad headers)
Circular
Saw/Miter
Saw
Cut headers to length;
cut rafters to length. All pergola types
Jig Saw
Cut rafter tail designs.
Raftered pergolas
Image not available.
Crescent
Wrench
Tighten down nut on
concrete anchors. Surface Mount Pergolas Image not available.
Hammer Various. All pergola types.

5 | Page
1.3 CONTENTS OF KIT # 4S-DC
The contents of this kit are shown in the table, below. Before you begin your project, take an inventory of all items that you
received from us. If any items are missing, contact us directly via email at [e-mail]. Include your name and
shipping address and your order number, if available. We will respond within 24 hours with a resolution to your problem.
Item SKU #, Description
Item Qty
Item Image
4x4 Post-Top/Floor 2-way Elbow Bracket
SKU# 4C2L 4
4x4 Post-Top/Floor 2-Way Straight Extension
SKU #4SE 2
4x4 Fixed Floor Anchor Bracket
SKU# 4FA 6
¼ x 1-1/4” Lag Screw
96

6 | Page
1.4 LIST OF MATERIALS THAT YOU WILL SUPPLY
This is the list of required materials which are not included in this kit. You will acquire these items locally for your project. Use
this table to help you calculate your total project budget.
Item Description Item Qty
Item Cost
($)
Total Item
Cost ($)
Item Image
4x4 Post Lumber (You determine length) 6
NA
4x4 Header Lumber (You determine length)
6
NA
1/2” X 2-3/4” (1/2-13 threads) Vibration Resistant
Hammer-On Stud Anchor for Concrete.
McMasterCarr.com SKU 92188A305
24
3/8” x 3” Lag Screws (for deck mounting).
McMasterCarr.com SKU 92351A636 24
Tape, for marking drill bit depth
2”
NA
Grand Total Cost ($)
NA

7 | Page
1.5 SURFACE MOUNT SYSTEM
1.5.1 What is a Surface Mount system?
Surface Mount means that the vertical posts for a pergola are secured to the top of a concrete footings, concrete pad, or deck
cross-brace beams using Floor Anchor Brackets. You may bolt the floor anchor brackets directly on top of a concrete pad or on
top of a footing. If bolting on top of a deck, you must add cross-brace beams under the deck boards to fully support the weight of
the pergola.
For concrete footings, the required depth is determined by the maximum depth of the frost line for a particular area. The
diameter of the footing is determined by the weight that each footing is subjected to by the pergola structure. If you choose to
use concrete footings or to add this pergola on top of an existing wooden deck, consult your local building permit office to
determine the required footing depth and diameter and the cross-brace beam requirements. If you fail to follow local officials’
guidelines, permanent damage to the Pergola structure or the deck structure can render them unsafe for use.

8 | Page
1.5.2 Study the Floor Anchor Brackets layout requirements.
First, study the Flooor Anchor Brackets layout requirements. Spend some time planning, yourself, so you are fully familiar with the
final size you desire for your pergola. Determine the exact location for each pergola Floor Anchor Bracket based on your pergola
size. We have designed our pergola systems to eliminate the need to cut any 4x4 post or header members. Plan accordingly to
minimize your work requirements.
Mark each Floor Anchor Bracket location using colored chalk and tracing the outer profile of the Floor Anchor Bracket bottom
plate on top of the concrete pad or wood deck. Remeasure and verify the proper location for each post. If planning to use
concrete footings, mark the bracket locations on the ground using stakes or bright spray paint.
DIM A
DIM B
DIM C
DIM D
DIM E
DIM F
OVERALL
WIDTH
OVERALL
LENGTH
96
99 3/4
96
99 3/4
96
99 3/4
103 1/2
203 1/4
108
111 3/4
108
111 3/4
108
111 3/4
115 1/2
227 1/4
120
123 3/4
120
123 3/4
120
123 3/4
127 1/2
251 1/4
132
135 3/4
132
135 3/4
132
135 3/4
139 1/2
275 1/4
144
147 3/4
144
147 3/4
144
147 3/4
151 1/2
299 1/4

9 | Page
1.5.3 Call 811.
811 is the national call-before-you-dig phone number. Anyone who plans to dig should call 811 or go to their state 811 center's
website before digging to request that the approximate location of buried utilities be marked with paint or flags so that you don't
unintentionally dig into an underground utility line.
Consult with your local building permit office and obtain any required building permits and formal information related to
required footing depth and diameter for your locality.
1.5.4 Install the Surface Mount footing
system.
1. Excavate the required hole diameter and depth.
2. Pour concrete into the footing holes.
3. Work in 6” incremental depths. Tap concrete
with the tip of a trowel to remove air bubbles.
Work upward until you reach ground level or 1”
above ground level.
4. Along the outer 2-3 inches create a downward
tapered profile moving away from the footing
center in all directions on the concrete top
surface. This taper will help water flow away
from the post bracket.
5. Wait 7 days for the concrete footing to cure
before proceeding with the remaining
construction work. If quick-setting concrete is
used, cure times may be shorter; read the
information on the concrete bag or ask your
concrete supplier.
Figure 2: Tapered Footing Top
Surface.

10 | Page
1.6 SIDE ELEVATION DIAGRAM
Based on the height of the post used, the diagram below provides the side elevation profile for this pergola system.
POST HEIGHT
DIM A
DIM B
96
96
92.5
108
108
104.5
120
120
116.5
132
132
128.5
144
144
140.5
Dim A, above, is the height of the post used. Dim B is the inner ceiling height of the pergola. Dim B is measured to the bottom
surface of the header member.

11 | Page
1.7 FLOOR ANCHOR BRACKETS INSTALLATION
1.7.1 Concrete Footing or Concrete Pad Anchoring
1. Place a floor anchor bracket at the designated location and orient it in the proper way.
2. Apply tape to the drill bit to mark the 2” depth required for the 2-3/4” Vibration Resistant Hammer-On Stud Anchor you
will be using to anchor the bracket to the concrete footing or pad.
3. Drill into the concrete through the four holes in the bracket bottom plate and into the concrete using a hammer
drill and ½” masonry drill bit. Drill minimum 2-1/4” deep and maximum 2-3/8” depth. Do not drill less than 2-1/4”
depth as the anchor will not pinch the bracket down fully if the hole is less than 2” deep.
4. Using compressed air, blow out the drilling dust out of all holes. Compressed air cans are available at most stores.

12 | Page
5. Hammer in one concrete anchor (1/2” X 2-3/4”) into each hole you drilled through the hole in the Floor Anchor
floor bracket.
6. Tighten down the nut using a crescent wrench.
7. Repeat steps 1-6 for all Floor Anchor Brackets.
1.7.2 Anchoring on existing deck
Consult your local building permits office. Do not proceed without consulting your building permit office. It is important
to be cautious when installing a pergola on top an existing wooden deck. You must plan to add extra cross-support
beams for low weight pergolas, like cubic shaped pergolas. For heavier pergolas, like raftered pergolas, you must plan
and add new support posts directly under the pergola posts which will transfer the pergola load to the ground. At the
ground level, a concrete footing must be added per local code requirements to provide permanent support to the
posts. Your building permit office is the best free information source.

13 | Page
1.8 INSTALLING PERGOLA POSTS
1. Slide one 4x4 post inside a Floor Anchor. Let gravity pull the post all the way down.
2. Identify the 5/16” holes in two opposite faces in the floor anchor square tube (two holes in each face).

14 | Page
3. Drill 3/32” x 1-1/4” holes at the center of each 5/16” hole (four holes total, see step 2).
4. Drive a ¼” X 1-1/4” lag screw through each pilot hole using a rachet and 7/16” socket. Tighten down all lag screws.
5. Repeat steps 1 to 4 for all vertical posts.

15 | Page
1.9 POST-TOP BRACKETS INSTALLATION
1. Slide the 2-way elbow bracket’s tube over the 4x4 post top after aligning the header receiver u-channels in the proper
direction. Let gravity work and pull the bracket all the way down on top of the post.
2. Identify the four 5/16” holes which are on the sides of the gussets in the bracket.

16 | Page
3. Wrap a piece of electrical tape around the drill bit, spaced 1-1/4” from the drill bit tip. This will act as a hole depth indicator
when you drill each pilot hole. Pilot holes should be drilled at least 1-1/4” deep. A little bit deeper is acceptable but do not
drill less than the required 1-1/4” depth.
4. Drill 3/32” X 1-1/4” deep pilot holes at the center of four 5/16” Holes. Locate pilot holes at the center of each 5/16”
hole.

17 | Page
5. Drive one ¼ x 1-1/4” Hex Lag Screw through each 5/16” hole into the pilot holes you drilled in step 4, using a 7/16”
Socket and Rachet driver. Tighten down each screw.
6. Repeat steps 1 through 5 for each post top bracket.

18 | Page
1.10 POST TOP 2-WAY EXTENSION BRACKET INSTALLATION
The post-top extension bracket is to be mounted to the top of the middle support post. It will receive two headers running in
opposing directions.
1. Orient the post-top 2-way extension bracket’s U-channels in the desired direction and slide the square tube over the top
of the center post. Let gravity pull it down. If it resists, tap the top lightly with a mallet.
2. Locate two 5/16” holes on two opposing sides of the tube, adjacent to the gussets (4 holes total). Drill 3/32” x 1-1/4”
deep pilot holes in the center of the 5/16” holes.

19 | Page
3. Using a 7/16” socket and ratchet driver, drive a ¼” X 1-1/4” Lag Screw through each pilot hole you drilled.

20 | Page
1.11 4X4 HEADERS INSTALLATION
1. Lift and place one 4x4 header into the U-channels of adjacent post-top bracket.
2. Locate the two 5/16” holes on each vertical face of the U-channels holding the 4x4 header. Drill 3/32” X 1-1/4”
deep pilot holes at the center of four 5/16” Holes. Locate pilot holes at the center of each 5/16” hole.