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RioOutdoors 4S-WPH Installation Instructions Manual Download Page 9

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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. 

Summary of Contents for 4S-WPH

Page 1: ... building pergolas only and are not to be used for other structure construction purposes Figure 1 Items included in the kit 𝑆𝑆𝑆𝑆𝑆𝑆 𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄𝑄 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 channe...

Page 2: ...ERTICAL 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 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 dia...

Page 3: ...n 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 C...

Page 4: ...e 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 X 1 1 4 Hex Hd lag screws All pergola types 3 32 Drill Bit Drill pilot holes for lag screws in soft wood All pergola types X 4 Masonry Drill Bit Drill X 2 deep holes in concrete pa...

Page 5: ...age 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 hardw...

Page 6: ...culate 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 bi...

Page 7: ...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...

Page 8: ...e 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 t...

Page 9: ...ber 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 s...

Page 10: ...able 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...

Page 11: ...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 ...

Page 12: ...elow 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 Lengt...

Page 13: ...g 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 ...

Page 14: ...14 P a g e 1 10 HEX PERGOLA ASSEMBLY WORK OUTLINE 1 10 1 Brackets application depiction This image shows where all brackets are used ...

Page 15: ...ee 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 ...

Page 16: ...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 ...

Page 17: ...etween 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 ...

Page 18: ...18 P a g e 10 Adjust position of post 3 until the header fits snugly between the 2 and 3 post top hex brackets ...

Page 19: ...l 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 ...

Page 20: ...he 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 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 holes into the concrete footing concrete ...

Page 21: ... structure is now complete Consider adding some decorative elements which are shown below A lattice fence upper lattice border or other elements of your choice can substantially increase the aesthetic value of your living space ...

Page 22: ... 4FA 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 ...

Page 23: ...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 ...

Page 24: ...6 Using a ratchet driver and a 7 16 socket drive one x 1 1 4 Lag Screw through all four pilot holes you drilled 7 Tighten all lag screws 8 Repeat steps 1 6 and add a 4FA floor anchor bracket to all remaining posts ...

Page 25: ...ore you begin note which faces of the 4FA floor anchor bracket s tube face inside the pergola When adding the Hex elbow bracket to the post top make certain that the same faces of the 4FA floor anchor bracket s tube point inside the pergola Be consistent Randomness does not provide a desirable cosmetic effect ...

Page 26: ...he bracket all the way down on top of the post If you feel resistance tap lightly on top of the elbow bracket until it slides all the way 2 Wrap a piece of electrical tape around the 3 32 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 ...

Page 27: ... 4 deep pilot holes at the center of four 5 16 Holes Locate pilot holes at the center of each 5 16 hole 5 Drive one x 1 1 4 SS 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 all post top brackets ...

Page 28: ...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 If you feel resistance tap lightly on top of the elbow bracket until it slides all the way down 2 Identify the four 5 16 holes which are on two sides of square tube ...

Page 29: ...Locate pilot holes at the center of each 5 16 hole 4 Drive one x 1 1 4 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 5 Repeat same procedures for the other open end post top 4C1L elbow bracket ...

Page 30: ...r into the U channels between post 1 and post 2 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 Repeat for the opposite end of the header ...

Page 31: ...ould touch the bracket s corner square tube face or be close to touching the tube face 4 Drive one x 1 1 4 SS Lag Screw through each 5 16 hole into the pilot holes you drilled using a 7 16 Socket and Rachet driver Tighten down each screw Repeat for opposite side of the U channel and the opposite end of the header 5 Repeat steps 1 4 for the second A header which sits between post 1 and post 3 ...

Page 32: ...4 and one header B between post top 2 5 The miter cut ends of header B are to be positioned against post 3 and post 2 2 At both ends of header B identify the 5 16 holes which are on the sides of the U channel in the elbow brackets Holes exist on both inside and outside faces of the brackets ...

Page 33: ... both sides Locate pilot holes at the center of each 5 16 hole Perform this step for both B headers 4 Drive one x 1 1 4 Lag Screw through each 5 16 hole into the pilot holes you drilled in step 3 using a 7 16 Socket and Rachet driver Tighten down each screw 5 Repeat step 4 for the B header on the opposite side ...

Page 34: ... 6 Locate the two 5 16 holes on the vertical faces of the U channels holding the header Drill 3 32 X 1 1 4 deep pilot holes at the center of eight 5 16 Holes Four holes inside the pergola and four holes outside Locate pilot holes at the center of each 5 16 hole ...

Page 35: ... Rachet driver drive one x 1 1 4 Hex Lag Screw through each 5 16 hole and into the pilot holes you drilled in step 1 Tighten down each screw Repeat for opposite side of the U channel 8 Repeat steps 1 3 for all post top hex elbow brackets ...

Page 36: ...e bracket to the concrete footing or pad 2 Drill into the concrete through the four holes in the bracket bottom plate and into the concrete using a hammer drill and 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 3 Using compressed air blow out the drilling dust...

Page 37: ...mit 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 additional support posts directly under the pergola posts which will transfer the pergola load to the ground At the ground level a concre...

Page 38: ...l posts Use appropriate hardware based on wall structure type to secure the wall anchor brackets to the wall If securing to a masonry wall first place the wall anchor bracket in its desired location against the side of the post mark the shape of the long open slot in the bracket face on the wall Predrill a hole close to the center of the long slot mark on the wall After drilling the required hole ...

Page 39: ...uction project went for you Was it easy to do Did parts fit easily and properly Do you like the quality of our products and design styles Is your pergola structure sturdy and strong Please go to RioOutdoors com and provide us with your review Thank you for being a RioOutdoors com customer ...

Page 40: ...n for evaluation Incomplete claims may be rejected All pergola brackets must be installed according to all manufacturers instructions as per the installation instruction manual by a RioOutdoors com All Local and National required codes must be met Repair replacement parts purchased by the consumer from RioOutdoors com after the original coverage has expired will carry a 90 day warranty valid with ...

Page 41: ...R ANY INCIDENTAL OR CONSEQUENTIAL COMMERCIAL DAMAGES OR DAMAGES TO PROPERTY TO THE EXTENT PERMITTED BY APPLICABLE LAW RioOutdoors com MAKES NO EXPRESS WARRANTIES OTHER THAN THE WARRANTY SPECIFIED HEREIN THE DURATION OF ANY IMPLIED WARRANTY IS LIMITED TO DURATION OF THE EXPRESSED WARRANTY SPECIFIED ABOVE IF IMPLIED WARRANTIES CANNOT BE DISCLAIMED THEN SUCH WARRANTIES ARE LIMITED IN DURATION TO THE ...

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