RioOutdoors 6S-H User manual

1 | Page
Installation Instructions
6S-H
6x6 Surface Mount 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.

2 | Page
Table of Contents
1.1 SAFETY AND WARNING INFORMATION............... 3
1.2 TOOLS REQUIRED ..................................................... 4
1.3 CONTENTS OF KIT #6S-H.......................................... 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 SELECTING YOUR PERGOLA SIZE ................................ 10
1.8 SIDE ELEVATION DIAGRAM ....................................... 11
1.9 HEX PERGOLA ASSEMBLY WORK OUTLINE .................... 12
1.10 PREPARATION........................................................ 13
1.11 CREATING THE POST ASSEMBLIES ............................... 19
1.12 PLACING HEADERS IN U-CHANNELS............................ 25
1.13 SECURING THE HEADERS .......................................... 26
1.14 SECURING THE FLOOR ANCHOR BRACKETS ................... 28
2.1 CONDITIONS.......................................................... 31
2.2 EXCLUSIONS .......................................................... 31
2.3 LIMITATIONS OF LIABILITY........................................ 32
2.4 HOW TO OBTAIN WARRANTY SERVICE ....................... 32
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.

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 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
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.

5 | Page
1.3 CONTENTS OF KIT # 6S-H
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
6x6 Post-Top/Floor 2-way Hex Elbow Bracket
SKU# 6HL
(The hardware required to mount each bracket are taped
to each bracket)
6
6x6 Fixed Floor Anchor Bracket
SKU# 6FA
(The hardware required to mount each bracket are taped
to each bracket)
6
¼ x 1-1/4” Lag Screw
(This Qty shows the total of this item included in this kit) 88
1/2” X 2-3/4” (1/2-13 threads) Vibration Resistant
Hammer-On Stud Anchor for Concrete.
McMasterCarr.com SKU 92188A305
(This Qty shows the total of this item included in this kit)
24

6 | Page
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
6x6 Post Lumber (You
determine length) 6
6x6 Header Lumber (You
determine length) 6
3/8” x 3” SS Lag Screws (for
deck mounting).
McMasterCarr.com SKU
92351A636
16
50-lb Sandbags 12
Tape, for marking drill bit
depth 2” NA
Grand Total Cost ($)
NA
Note: The sandbags will be used to hold down the pergola posts floor anchor brackets while you loosely assemble the pergola
structure.

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. 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.

8 | Page
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.

9 | Page
1.6 GENERAL LUMBER REQUIREMENTS INFORMATION
We have designed the corner elbow brackets to provide automatic alignment of the header 6x6s. By making certain all
header 6x6s are of the same length and not warped, following the instructions properly, and securing the 6x6s 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 1.7, 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 6x6 dimensional lumber which has actual measurements of 5.5” (140
mm) X 5.5” (140 mm)
1.6.2 Maximum lengths for Posts and Headers
We recommend a maximum header length of 12 feet for 6x6 headers. Longer 6x6 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 6x6s. 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
6x6 lumber. Example: if you decide upon a 60” (1524 mm) length header, instead of buying 96” 6x6 lumber and cutting off
36” (914 mm), you may be able to buy 72” (1829 mm) long 6x6s 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.

10 | Page
1.7 SELECTING YOUR PERGOLA SIZE
We have designed the corner elbow brackets to provide automatic alignment of the floor floating 6x6s and the header 6x6s.
By making certain all outer perimeter 6x6s are of the same length, following the instructions properly, and securing the 6x6s
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 length of the headers.
We recommend a maximum header length of 12 feet for 6x6 headers. Before you start assembly, study the table, and
determine the length of the 6x6s you will need. Remember that both the floor 6x6s and header 6x6s must be of the same
lengths.

11 | Page
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
90 1/2
108
102 1/2
120
114 1/2
132
126 1/2
144
138 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.

12 | Page
1.9 HEX PERGOLA ASSEMBLY WORK OUTLINE

13 | Page
1.10 PREPARATION
1.10.1 Posts Preparation
Measure and prepare six posts of equal lengths. Use a power miter saw to cut the posts to equal lengths.
1.10.2 Headers Preparation
After you determine the final size for the hexagon, determine the applicable header lengths and prepare six headers of
equal lengths by following the steps, below.
a. Cut six 6x6 members to the header length.
b. Cut a 15-degree angle at each end of the headers.
c. Chamfer four vertical corners as shown. Cut (1/2” X 1/2”) chamfers.

14 | Page
2. Create six post assemblies by adding post-bottom floor anchor brackets and post-top hex elbows to six posts of equal
lengths. See section 1.9.
3. Stand two posts in designated
locations and hold them securely
in place by placing two sandbags
on two sides of the floor anchor
brackets.

15 | Page
4. The distance between posts should be measured at the two outer corners. This distance must be close to the length of the
headers you will be installing.
5. Place a header 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 in its designated location and place two sandbags on two sides of floor anchor bracket.
8. Measure and adjust the distance between the second post and the third post. See step 3, above.

16 | Page
9. Place header loosely between post #2 and post #3 in the U-channels of the hex elbow brackets.
10. Adjust position of post #3 until the header fits snugly between the #2 and #3 post top hex brackets.
11. Repeat standing and adding headers for all six posts.
12. Verify that the structure is as you desire it, all posts are plumb, and that all headers are in their proper positions.

17 | Page
12. 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 floor anchor brackets. Use thin gage sheet
metal shims, if required. Do not use wood shims as they will rot away.
13. Drill pilot holes in required locations through 5/16” holes on the vertical faces of the post-top hex 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 section 1.10.
14. Repeat step 13 for all post-top hex elbow brackets.

18 | Page
15. Remove the sandbags.
16. Drill ½” holes into the concrete footing, concrete pad, or concrete blocks through the 9/16” holes in the base of the floor
anchor brackets, hammer-in Stud Anchor for Concrete into the holes and secure the floor anchor brackets to the floor.
See section 1.11.
17. Your pergola project is now complete.

19 | Page
1.11 CREATING THE POST ASSEMBLIES
1.11.1 Adding Floor Anchor Bracket
1. Lay a post on the ground.
2. Lift one end of the post up and slide a floor anchor bracket, all the way over the post end.
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.

20 | Page
4. Locate four 5/16” diameter holes, two holes in each opposing face of the floor anchor’s square tube.
5. While holding the floor anchor tightly against the post end, drill 3/32 X 1-1/4” pilot holes through the center of four 5/16”
holes.