RioOutdoors 4S-WPH User manual

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Installation Instructions
4S-WPH
Surface Mount Wall-Mount Partial Hexagon 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.
Figure 1: Items included in the kit, (
#
).
Items not included in this kit: wood, tools, some hardware.
•
Thoughtfully engineered Brackets eliminate all wood-joinery skills requirements.
•Skills required: leveling ground, 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 2 hours.

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Table of Contents
1.1 SAFETY AND WARNING INFORMATION ........................3
1.2 TOOLS REQUIRED...................................................4
1.3 CONTENTS OF KIT #4S-WPH...................................5
1.4 LIST OF MATERIALS THAT YOU WILL SUPPLY,OR ARE
RECOMMENDED................................................6
1.5 SURFACE MOUNT SYSTEM........................................7
1.6 GENERAL LUMBER REQUIREMENTS INFORMATION..........9
1.7 OVERALL PERGOLA SIZE .........................................10
1.8 SIDE ELEVATION DIAGRAM .....................................11
1.9 HEADERS AND FOOTERS PREPARATION ..................... 12
1.10 HEX PERGOLA ASSEMBLY WORK OUTLINE .................. 14
1.11 CREATING THE POST ASSEMBLIES............................. 22
1.12 POST TOP #4C1L BRACKET INSTALLATION ................ 28
1.13 SECURING THE HEADERS ................................. 30
1.14 SECURING HEADERS TO THE POST-TOP HEX ELBOWS .... 34
1.15 SECURING THE #4FA FLOOR ANCHOR BRACKETS ......... 36
1.16 SECURING VERTICAL POSTS TO THE WALL................... 38
2.1 CONDITIONS ...................................................... 40
2.2 EXCLUSIONS....................................................... 40
2.3 LIMITATIONS OF LIABILITY ..................................... 41
2.4 HOW TO OBTAIN WARRANTY SERVICE ..................... 41
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
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.

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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 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.

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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
3/32” Drill
Bit
Drill pilot holes for ¼”
lag screws in soft
wood.
All pergola types
½” X 4”
Masonry
Drill Bit
Drill ½” X 2” deep holes
in concrete pads or
concrete footings.
Surface Mount styled
pergola
Circular
Saw/Miter
Saw
Cut headers to length;
cut rafters to length. All pergola types
Crescent
Wrench
Tighten down nut on
concrete anchors. Surface Mount Pergolas Image not available.
Hammer Various. All pergola types.

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1.3 CONTENTS OF KIT # 4S-WPH
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 Hex Elbow Bracket
SKU# 4HL
(The hardware required to mount each bracket are taped
to each bracket)
3
4x4 1-Way Elbow Bracket
SKU# 4C1L
(The hardware required to mount each bracket are taped
to each bracket)
2
4x4 Fixed Floor Anchor Bracket
SKU# 4FA
(The hardware required to mount each bracket are taped
to each bracket)
3
4x4 Wall Mount/ Wall Post Hugger Bracket
SKU #4WM
(The hardware required to mount each bracket are taped
to each bracket)
2
Wall Anchor Bracket
SKU #1WAB
(The hardware required to mount each bracket are bulk
packaged)
4
¼ x 1-1/4” Lag Screw
(This Qty shows the total of this item included in this kit) 76

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1.4 LIST OF MATERIALS THAT YOU WILL SUPPLY, OR ARE RECOMMENDED
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
Post Lumber (You
determine length) 3
Header Lumber (You
determine length) 4
1/2” X 2-3/4” (1/2-13
threads) Vibration Resistant
Hammer-On Stud Anchor
for Concrete.
McMasterCarr.com SKU
92188A305
12
3/8” x 3” SS Lag Screws (for
deck mounting).
McMasterCarr.com SKU
92351A636
12
50-lb Sandbags 6
Tape, for marking drill bit
depth 2” NA
Grand Total Cost ($)
NA

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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. If adding a solid roof option on top of this pergola, you will need to add additional post supports for the pergola
posts directly underneath and extending down to the ground to a footing surface.
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.

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1.5.2 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.
1.5.3 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.

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1.6 GENERAL LUMBER REQUIREMENTS INFORMATION
We have designed the corner elbow brackets to provide automatic alignment of the header 4x4s. By making certain all
header 4x4s are of the same length and not warped, following the instructions properly, and securing the 4x4s to the elbow
brackets as instructed, you will achieve a perfect hexagonal shape for your pergola. All you have to do is select the size you
desire for your pergola and pick the correct header lengths. See section 1.8, below, for overall sizes and living area based on
the length of the headers.
1.6.1 Dimensional lumber size requirement
The pergola brackets are designed to be used with 4x4 dimensional
lumber which has actual measurements of 3.5” (89 mm) X 3.5” (89
mm).
1.6.2 Maximum lengths for Posts and Headers
We recommend a maximum header length of 12 feet for 4x4
headers. Longer 4x4 lumber is available in the market. However,
longer lumber is more vulnerable to warping and twisting as it dries.
This can lead to warping and deformation of the pergola structure.
1.6.3 Selecting Lumber members at the lumberyard
Due to intolerances in manufacturing processes, variations do occur
in the lengths lumber. The length of lumber delivered to stores can be
longer than the labeled length but will never be less than the labeled length dimension. To
gain more flexibility, we suggest that you measure each lumber member before adding to your cart at the store. Select
lumber members which are slightly longer than the labeled length. Example: if buying 96” length 4x4s. Measure and select
member which exceed 96”. Some pieces can have lengths as long as 96-3/8”. The extra length will provide flexibility if you
need to trim the ends for squaring or cleaning purposes.
1.6.4 Plan ahead to save money and to minimize wood waste
We provide all the detailed information for you to plan your project. Use the information wisely and make wise judgements
about the header lengths which directly drive the overall pergola size. Check with local lumber yards for available lengths of
4x4 lumber. Example: if you decide upon a 60” (1524 mm) length header, instead of buying 96” 4x4 lumber and cutting off
36” (914 mm), you may be able to buy 72” (1829 mm) long 4x4s and cut-off only 12” (305 mm). Or, you may be able to buy
120” (3048 mm) and be able to yield 2 full 60” (1524 mm) long pieces.

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1.7 OVERALL PERGOLA SIZE
We have designed the corner elbow brackets to provide automatic alignment of the floor floating s and the header s. By
making certain all outer perimeter “Header Lengths” are of the same length, following the instructions properly, and
securing the s to the elbow brackets as instructed, you will achieve a perfect hexagonal floating deck base for your pergola.
All you have to do is determine the size you desire for your pergola. See table, below, for Living Area based on the Header
Length.
We recommend a maximum header length of 12 feet for headers. Before you start assembly, study the table, below, and
determine the length of the s you will need. Remember that both the floor s and header s must be of the same lengths. The
length of the Front Frame Member is determined by the length of the other headers and are shown as DIM A, in the table
below.
HEADER
LENGTH
(in.)
DIM A (in.) DIM B (in.) AREA (sq. ft.)
60
9 ft. 8 in.
7 ft. 10 in.
54
72
11 ft. 5 in.
9 ft. 4 in.
78
84
13 ft. 2 in. 10 ft. 10 in.
106
96
14 ft. 10 in. 12 ft. 4 in.
139
108
16 ft. 7 in. 13 ft. 10 in.
175
120
18 ft. 4 in. 15 ft. 4 in.
216
132
20 ft. 1 in.
16 ft. 10 in.
262
144
21 ft. 10 in. 18 ft. 4 in.
312
Note: Increasing the length of the “Header Length” by 12 inches increases DIM A by, approximately, 20-3/4”. This is provided
as a general guideline to determine the outer maximum dinension of the hexagon pergola. Increasing the “Header Length”
by 12” increases DIM B , overall depth, by 18”.

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1.8 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
(in.)
DIM A
(in.)
96
92 1/2
108
104 1/2
120
116 1/2
132
128 1/2
144
140 1/2
The Post Height, above, equals the outer height of the pergola. Dim A is the inner ceiling height of the pergola. Dim A is
measured to the bottom surface of the header member.

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1.9 HEADERS AND FOOTERS PREPARATION
The diagram, below, provides detailed information about all lumber headers required to build this structure. Prepare the
specified lumber members by following the table and diagrams in this section. See section 1.6 Overall Pergola Size to determine
the overall size and applicable lengths for items A, and B.
1.9.1 Details of header lumber members
The table, below, provides the end treatment details for each lumber member type. It is your responsibility to, first, decide upon
the overall size of the structure you desire. The overall size of the structure drives the lengths of items A, and B. Once you
determine the lengths of A, and B, cut the required number of each item to the determined length, and apply the end treatments
as shown, below.
Lumber Member ID Length End 1 Treatment End 2 Treatment
You Decide
15 degree miter and
1/2" corner chamfers
15 degree miter and
1/2" corner chamfers
You Decide
15 degree miter and
1/2" corner chamfers
Straight 90 degree cut
A
B

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1.9.2 Preparing lumber member “A.”
Follow the steps, below. Cut and prepare two (2) identical lumber members to be used as item
1.9.3 Preparing lumber member “B”
Follow the steps, below. Cut and prepare two(2) identical lumber members to be used as item

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1.10 HEX PERGOLA ASSEMBLY WORK OUTLINE
1.10.1 Brackets application depiction
This image shows where all brackets are used.

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1. Create three post assemblies by adding post-bottom #4FA floor anchor brackets and post top #4HL hex elbows to three
posts of equal lengths. See section 1.9.1 and 1.9.2 Create two post assemblies by adding post-bottom #4FA floor anchor
brackets and post top #4C1L elbow brackets. See Section 1.11 and 1.12.
2. Study the posts layout, below. You will be erecting the posts in the numerical order given below. While you will be building
this structure against a wall, the wall is not shown here for clarity.

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3. Stand two posts, Post #1, and Post #2 (both with
Hex Elbow Brackets) in designated locations and
hold them securely in place by placing two
sandbags on two sides of the #4FA floor anchor
brackets.
4. The distance between posts should be measured at
the two inner corners. This distance must be close
to the length of the headers you will be installing.

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5. Place a header (type “A”) loosely between the two posts in the U-channels of the hex elbow brackets.
6. Adjust position of posts until the header fits snugly between the two post top hex brackets.
7. Stand a third post, Post #3 with a Hex Elbow Bracket, in its designated location and place two sandbags on two sides of #4FA
floor anchor bracket.
8. Measure and adjust the distance between the second post and the third post. See step 3, above.
9. Place header loosely between post #2 and post #3 in the U-channels of the hex elbow brackets.

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10. Adjust position of post #3 until the header fits snugly between the #2 and #3 post top hex brackets.

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11. Next stand Post #4 (with a 1-Way Elbow). Rotate the header receiver U-channel in its 1-way elbow towards the open U-
channel on the top of Post #2.
12. Measure for header distance between the 1-way elbow’s face and the corner in the hex elbow bracket. Adjust as necessary.
13. Place a header (“B”) between Post #2 and Post #4. Adjust location of Post #4 until header is snug between the two posts.
14. Repeat steps 10-12 for Post #5 and the header between Post #5 and Post #3.

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15. Verify that the structure is as you desire it, all posts are plumb, and that all headers are in their proper positions.
16. Make certain that all pergola posts are plumb and located in the proper positions and check for level on top of all headers. If
level is not proper, you may be required to place some shims under the #4FA floor anchor brackets. Use thin gage sheet
metal shims, if required. Do not use wood shims as they will rot away.
17. Drill pilot holes in required locations through 5/16” holes on the vertical faces of the post top hex elbow brackets and the
post top 1-way elbow brackets and secure the headers in place by employing a ratchet and a 7/16” socket and driving ¼” x 1-
1/4” Lag Screws. Tighten the Lag Screws. See sections 1.13.1 and 1.13.2.
18. Repeat step 16 for all pos -top hex elbow brackets (Post #1, Post #2, and Post #3).
19. Remove the sandbags.
20. Drill ½” holes into the concrete footing, concrete pad, or concrete blocks through the 9/16” holes in the base of the #4FA
floor anchor brackets, hammer-in Stud Anchor for Concrete into the holes and secure the #4FA floor anchor brackets to the
floor. See section 1.15.
21. Secure the two posts butted against the wall using two #1WAB brackets on each wall. See section 1.16.