Suncast PA1012 User manual

© 2011 Suncast Corporation, Batavia, IL 0660092B
OWNER'S MANUAL
This assembly manual was created to assemble an 8' x 10', 10' x 10', or 10 x 12' Suncast Pergola. The unit size used for these instructions is the 8' x 10' size.
The assembly process is the same for each Pergola size, but some pictures will differ slightly depending on the size you have purchased.
PA1012 Pergola
WARNING
• Repair or replace broken parts immediately.
• Suncast is not responsible for damage caused by weather or misuse.
• Avoid excess heat from any auxiliary source.
Before you begin...
Read instructions prior to assembly. This product contains parts that can be damaged if
incorrectly assembled. Once assembled, the pergola cannot be taken apart without breakage.
Please follow instructions. Suncast is not responsible for replacing parts damaged due to
incorrect assembly.
Avoid scratching finish. For steps where parts are placed upside down, place parts on a smooth
surface to avoid scratching finish. Flatten cardboard from carton to create a smooth work surface.

2
• Consult your local authorities for any permits required to construct pergola.
Prior to the construction of your pergola, check with the local building code official to review any required permits or building
limitations.
• COMPLETE SITE PREPARATION AND FOUNDATION CONSTRUCTION BEFORE UNPACKING ALL PARTS.
A level and sturdy foundation is required before pergola construction can begin.
• Read instructions thoroughly prior to assembly.
This kit contains parts that can be damaged if assembled incorrectly or in the wrong sequence.
• Please follow instructions.
If you have questions or concerns with this product DO NOT return to store. Assembly questions? Missing parts? Call 1-800-846-2345
or 1-630-879-2050.
• Assistance is required.
Due to the size of the parts, at least two people are required to handle, fit and secure pergola components.
• Foundation mounting hardware varies with each application.
Read manual first and contact your local building supply retailer for recommendations for your application.
Before You Begin...
• Pergola not intended for use in extreme weather conditions.
• Do not stand, sit, or hang items from pergola structure.
• Handle carefully in extreme temperatures.
• Repair or replace broken parts immediately. Call 1-800-846-2345 or 1-630-879-2050 for replacement parts.
• Suncast is not responsible for damage caused by weather or misuse.
• At regular intervals inspect your pergola to make sure that assembly integrity has been maintained.
• Periodically check that the location you have chosen to set your pergola is still level.
• Avoid excess heat from any auxiliary source.
• Any additional holes drilled into parts could cause unsafe conditions.
• Follow manufacturer safety instructions when using ladder.
• Do not anchor to paver bricks. Foundation must be a solid surface.
• Exercise caution using a lawn mower, edge trimmer or other yard equipment near pergola.
• Do not attempt to cover overhead structure.
CAUTION
TOOLS REQUIRED
• Screw Gun or Drill with Screw Bit or Phillips Screwdriver
• Ladder
• Tape Measure
• Hammer
• Level
• Square
• Assistance is required during assembly.

3
A
B
DE
F
G
H
I
J
K
L
P
Q
R
S
C
MNO
PARTS - 8' X 10', 10' x 10' , 10' x 12'
AA
AAA BBB CCC
DDD EEE
FFF
GGG
HHH
BB CC DD EE FF GG HH
HARDWARE / QUINCAILLERIE / TORNILLERÍA
RAFTERS, STRINGERS and TRIM - 8' X 10' ONLY
#0630632
2 1/2" Screw
x46
#0630638
3 1/2" Screw
x124
#0630635
2" Screw
x150
#0630636
Angle Bracket
x4
Left Beam Trim
Right Beam Trim
#0W00180
Left Beam Trim
x2
#0W00184
Right Beam Trim
x2
Short Stringer
Long Stringer
#0630637
Stake
x4
#0630633
3" Screw
x120
#0W00197
Post Trim
x8
#0W00191
Stringer
x16
#0W00188
Rafter Top
x9
#0W00201
Rafter Bottom
x18
#0670057
Post Base
Bottom Trim
x4
#0670056
Post Base
Top Trim
x4
#0W00196
Post Base Side A
x8 #0W00187
Post Base Side B
x8
#0670055
Post
x4
#0W00189
Small Post Brace
x4
#0W00183
Interior Left Beam
x2
Interior Left Beam
#0W00182
Exterior Left Beam
x2
Exterior Left Beam
#0W00185
Exterior Right Beam
x2
Exterior Right Beam
#0W00181
Interior Right Beam
x2
Interior Right Beam
#0W00186
Interior Center Beam
x2
#0W00190
Large Post Brace
x4
#0W00198
Post Base Corner
x16
#0630634
1.5" Finishing Nail
x70
#0630639
2" Finishing Nail
x36

4
POST ASSEMBLY
PRE-ASSEMBLY
Select a level location with good drainage for your pergola. Place pergola kit as close to assembly site as possible.
Boxes are labeled #1 - #6. Each box will be referenced by its number during assembly.
Only unpack the boxes as called for in the instruction manual.
1. Open Box #2, #3, and #5.
Organize the parts by using the parts list to
indentify and separate each piece.
2. Locate two Post Base Side A (A), two Post Base Side B
(B) and four Post Base Corner (C) boards.
NOTE: Post Base Side A (A) is narrower then Post Base
Side B (B).
AC
B
box 2
box 3 box 5

5
3. Take one Post Base Corner (C) and note the two grooves
running the length of the board.
4. Slide one Post Base Side A (A) into either groove on the side
of Post Base Corner (C).
Align the bottom of the Post Base Corner to the bottom of the
Post Base Side.
5. Attach the corner to the side using three 2" Screws (AA)
through the pre-drilled holes.
C
grooves
AA
x3
C
A
align at bottom

6
6. Slide one Post Base Side B (B) into the remaining groove on
the Post Base Corner (from step 2 - 5).
Align the bottom of the Post Base Corner to the bottom of the
Post Base Side.
7. Attach in the same manner as step 5.
B
align at bottom

7
A
A
B
B
8. NOTE: It is very important to place Post Base Side A (A) boards
opposite each other.
Continue assembling the rest of post base using the remaining three
Post Base Corners, one Post Base Side A, and one Post Base Side B.
completed post base
NOTE: The A and B
sides will protrude
on one end. This
will be the ground
end of the post base
assembly.

8
9. Locate one Post Base Bottom Trim. The Post Base
Bottom Trim (D) has thinner trim boards than Post Base
Top Trim (E). See photo.
10. Position Post Base Bottom Trim (D) with recessed edge
over raised edge of ground end of post base assembly.
11. Attach the trim to post base assembly using four 2"
Finish Nails (EE) installed over the side boards at the
center of each side, as shown.
12. Flip post base assembly. Locate and position one Post
Base Top Trim (E) with wide end of molding at top.
Center the trim over post.
DE
x4
EE
install nails over side boards
recessed edge
raised edge
wide end at top
D
E

9
15. This pergola includes brackets to anchor the posts. Anchoring
the pergola to a firm, level surface is recommended. If you are
not going to anchor the posts, proceed to step 16.
Locate the four Posts (F). On the opposite side of the long
board, attach Angle Bracket (GG) to bottom of Post using two
2 1/2" Deck Screws (CC). See diagram.
14. Repeat steps 4 - 13 to assemble remaining three post
bases.
long board
x2
CC
GG
13. Attach top trim using four 2" Finish Nails (EE) installed
over the side boards at the center of each side.
x4
EE
F

10
16. Locate the four Posts (F). With long board at top, insert
one Post into each post base assembly, as shown.
F F F F
2. Locate one Rafter Top (G) and two Rafter Sides (H). Position
the three pieces on a flat, level, clean surface, as shown.
Use a tape measure to find the center of the Rafter Top (G).
Align inner ends of Rafter Bottoms with center of Rafter Top
(G).
RAFTER ASSEMBLY
1. Open Box #4.
Organize the parts by using the parts list to indentify
and separate each piece.
G
H
H
box 4
3. Attach the rafters using four 3" Screws (BB) through the
pre-drilled holes in the Rafter Sides and four 3" Screws
(BB) through the pre-drilled holes in the Rafter Top. x8
BB
measure to find center
align ends at center

11
4. Repeat step 2-3 to assemble the remaining rafters.
The 8' x 10' pergola uses a total of 8 rafters.
The 10' x 10' pergola uses a total of 8 rafters.
The 10' x 12' pergola uses a total of 9 rafters.
2. Arrange one Interior Left Beam (I), one Interior
Right Beam (J), one Exterior Left Beam (K), and one
Exterior Right Beam (L) in positions shown. The two
boards with the post notch must be in the top row
with the post notch facing up.
NOTE: The 10' x 10' and 10' x 12' pergola use five
boards per beam and have a different layout. The
construction method remains the same. Use the
diagram below to assemble the beam for the 10' x
10' and 10' x 12' pergola.
BEAM ASSEMBLY
J
I
L
K
1. Open Box #1.
Organize the parts by using the parts list to
indentify and separate each piece. box 1
10' x 10' and 10' x 12' beam components and layout
NOTE: Post notches must face up.
post notches
post notch
top row
AAA BBB CCC
DDD EEE

12
3. In the bottom row, push the ends of the Exterior Left
Beam (K) and the Exterior Right Beam (L) together.
4. Take the Interior Right Beam (J) from the top row and
set it on top of the right side of the bottom row.
J
L
K
bottom row
top row
right side

13
5. Take the Interior Left Beam (I) from the top row and set
it on top of the left side of the bottom row.
6. Align all edges of the boards, including the notches.
notches
7. Attach the boards using fourteen 2" Screws (AA)
through the pre-drilled holes.
NOTE: The 10' x 10' and 10' x 12' pergolas use twenty
2" Screws (CC) through pre-drilled holes.
x14
AA
Ileft side

14
8. Repeat steps 2 - 7 to assemble the second beam.
1. Arrange one beam assembly and two post assemblies in
positions shown.
Place the long board of each post into the post notch on
each side of the beam. Push post snug against beam.
Use a square to ensure posts are 90˚ to beam.
2. At each post, partially insert four 2 1/2" Screws (CC)
through pre-drilled holes in long board. Check that corner
is square. Adjust, if necessary, then tighten.
POST TO BEAM ASSEMBLY
long board
post notch
x8
CC
snug against beam
90˚

15
3. Repeat steps 1 - 2 for remaining beam and two post
assemblies.
4. NOTE: The long board side of each post and beam
assembly must face the interior of the pergola.
With at least two people, stand each post and beam
assembly upright.
CAUTION: Do not leave post and beam assemblies
unattended until two rafters are installed.
5. Line up the notches on one rafter assembly with the
notches on the far end of each post and beam assembly.
Push down on rafter to seat.
Check that rafter is fully seated on beam at both contact
points. If necessary, use a rubber mallet.
notches
fully seated at notches

16
6. Attach rafter assembly to both post and beam assemblies
using one 3" Screw (BB) through pre-drilled hole on each
side of beam, at angles shown.
7. Repeat steps 5 - 6 to install second rafter to opposite end.
8. Place pergola assembly in it's final location. A level and
sturdy foundation is required. Measure the distance
between the legs to ensure they are the same. Match
measurements of line to line, dashed to dashed, dots to
dots. Adjust, if necessary. See diagram.
x4
BB

17
9. Locate the Post Trim (M) boards. With rounded edges
facing out, align one Post Trim (M) to the outside of one
post and parallel to the beam.
10. Attach Post Trim to post with eight 1 1/2" Finish Nails (FF)
in positions shown.
M
x8
FF

18
11. With rounded edges facing out, align a second Post Trim
(M) to the inside of post and parallel to the beam.
Attach Post Trim to post in the same manner as step 10.
13. Locate one Large Post Brace (N) and place flush to arch
assembly and flush against post.
Attach using four 3 1/2" Screws (DD) through pre-drilled
holes, in positions shown.
12. Repeat trim installation for each post following steps 9 - 11.
M
N
x4
DD
flush to arch assembly
flush against post

19
14. Locate one Small Post Brace (O) and place centered on
post and flush to inside layer of beam assembly.
Attach using four 3 1/2" Screws (DD) through pre-drilled
holes, in positions shown.
15. Repeat steps 13 - 14 to install remaining Large and Small
Post Braces.
16. Repeat steps 5 - 6 to install remaining rafters.
O
x4
DD
flush to inside layer
centered on post

20
STRINGER INSTALLATION
2. Locate one Long Stringer (Q) and one Short
Stringer (P).
NOTE: The stringers for the 10' x 10' and 10'
x 12' pergolas will be the same length. The
construction method remains the same.
3. On one side of pergola assembly, place one Long
Stringer (Q) on top of rafters and align over beam.
Starting at the outside, align the notches in the
stringer to the notches in the rafters. Press down
on stringer to fully seat contact points in notches. If
necessary, use a rubber mallet.
Q
P
place stringer over beam
fully seat notch to notch
1. Open Box #6.
Organize the parts by using the parts list to
indentify and separate each piece.
box 6
Q