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Suncast Free Standing Pergola, Assembly Instructions Manual

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Suncast Free Standing Pergola Assembly Instructions Manual Download Page 25

25

Position two step ladders next to two posts.  
Place each end of a rafter (N) into the outer most 
rafter clips on the beams.

N

49

48

At this point in the assembly process, all of the 
posts, beams, and rafter clips should be  
permanently installed. All of the rafters should be 
assembled and ready to be installed.

Repeat steps 43-46

to assemble remaining

rafters.

47

Installing the Rafters

46

X

N

P

1

1

2

Slide rafter sleeve (N) over 7' wood rafter insert (P) 
until the two vinyl sleeves are touching. Insert a  
1" screw (X) next to the collar.

Summary of Contents for Free Standing Pergola

Page 1: ...Y INSTRUCTIONS Quality Control Number Numéro de controle de qualitié Número de control de calidad 2011 Suncast Corporation Batavia IL 0660110 Includes instructions for 8 x 8 8 x 12 10 x 14 10 x 16 12 x 16 14 x 14 or 14 x 20 pergola ...

Page 2: ...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 th...

Page 3: ...ys when temperature is below 32 degrees Set aside appropriate amount of time to completely assemble pergola See the chart below for approximate assembly times 8x8 8x12 10x14 10x16 12x16 14x14 14x20 5 hours 6 hours 6 hours 7 hours 8 hours 8 hours 9 hours Make sure you have assistance nearby to lift and secure parts in place Wear light duty work gloves while assembling pergola If you have questions ...

Page 4: ...rim ring A H I C B 4x4 wood post Top square post sleeve Post cover Foot bracket D Round trim ring F Top trim ring Vinyl column Parts Pergola Size A B C D E F G H I 8x8 4 4 4 4 4 4 4 4 4 8x12 4 4 4 4 4 4 4 4 4 10x14 4 4 4 4 4 4 4 4 4 10x16 6 6 6 6 6 6 6 6 6 12x16 6 6 6 6 6 6 6 6 6 14x14 4 4 4 4 4 4 4 4 4 14x20 6 6 6 6 6 6 6 6 6 ...

Page 5: ... P Rafter trim Q Shade trim S Shade splice T Shade R Parts Pergola Size J K L M N O P Q R S T 8x8 4 0 8 8 6 0 0 12 8 16 0 8x12 8 4 8 8 9 0 0 18 16 16 8 10x14 8 4 8 8 18 9 9 18 20 20 10 10x16 8 4 8 8 22 11 11 22 20 20 10 12x16 8 4 8 8 22 11 11 22 24 24 12 14x14 8 4 8 8 18 9 9 18 28 28 14 14x20 12 8 8 8 26 13 13 26 42 28 28 ...

Page 6: ... Y Concrete screws 1 2 x 4 Concrete screws bolts Washers Z AA EE X U FF Hardware Pergola Size U V W X Y Z AA EE FF 8x8 1 1 18 128 72 17 8 16 25 8x12 1 1 18 204 96 17 8 16 37 10x14 1 1 18 208 124 17 8 16 37 10x16 1 1 26 244 152 25 12 16 45 12x16 1 1 26 248 176 25 12 16 45 14x14 1 1 18 216 164 17 8 16 37 14x20 1 1 26 320 242 25 12 16 53 Note These pieces shown at actual size ...

Page 7: ...e the scope of the project 3 Before any digging check with local utilities to determine location of buried cables pipes etc 4 A four inch thick concrete slab or concrete piers are recommended as the foundation If a wood platform is chosen as the foundation use exterior grade wood Note Do not erect pergola on paver bricks Foundation must be a solid surface If you plan to erect the pergola on an exi...

Page 8: ...osts 4x4 Post wrapped w vinyl column Shades or 12 apart 2x6 Rafters or 16 apart Post D Post C Post A Elevation A Elevation B Post A C orientation Post B D orientation Post B 2x8 Beams Top size in feet Rafter length including ends in inches Beam length including ends in inches of posts of double beams Depth A in inches Width B in inches Diagonal C in inches 8x8 106 114 4 2 74 74 104 65 8x12 106 158...

Page 9: ...hers Beam trim Shade trim 2x6 Rafters w wood fillers 2x8 Beams w wood fillers Rafter trim Hollow shades Shade splice 1 wood filler inside beams 2x6 Rafters w wood fillers Shades secured w 2 5 screws Rafter clips secured w 1 screws Rafters secured to beams w rafter clips Beams 1 filler secured to post w 4 structural screws ...

Page 10: ...ses an additional 14 screws that are included 3 C A Slide the high wind bracket C onto the bottom of the post A making sure that it is snug against the bottom 2 C A If you have chosen to purchase the high wind brackets C remove the screws in the existing brackets B Set brackets aside and save all screws for later x10 1 B A Optional High Wind Bracket Pre assembly ...

Page 11: ...ot bracket B over mark and trace holes in bracket 2a Standard bracket B A 1 2 For high wind areas position post A and high wind bracket C over mark and trace holes in bracket 1 2b Optional high wind bracket 2 C A Support Post Installation Using the chart on page 8 determine post layout X X X X X X 35 ...

Page 12: ...align the tops of the posts This will ensure that when the beams are attached they will fit properly against the posts Note The bottom of the posts may not be perfectly parallel This is common and will not be visible once the vinyl columns are in place Position wood post over holes and plumb using a four foot level If needed use supplied washers to plumb posts Note The vinyl column covers bracket ...

Page 13: ...curely x4 6c Optional high wind bracket AA Repeat Steps 2 6 for remaining posts 7 Use concrete screws bolts AA to secure brackets Tighten securely DO NOT proceed with post covers until all wood posts are plumb and mounted securely As an option additional 1 2 x 4 concrete screws bolts AA can be installed 6a x4 Z x2 6b Optional bolts AA ...

Page 14: ...im ring F down column until it rests on the raised ledge Slide vinyl column D over wood post Fit lower portion of vinyl column over wood spacers until cover rests securely on concrete surface 10 E 11 F Unpack post trim boxes and position trim close to each post in the order shown 9 E G F H 8 D Post Trim Installation ...

Page 15: ...leeve H over wood post Repeat Steps 10 13 for remaining posts 14 Slide top trim ring G over column making sure the rounded part is facing down and the square part is facing up This is how the top post trim should look 13 H 12 G ...

Page 16: ...posite end of the beam Repeat for opposite post 16 CC DD 1 2 2 This is how the temporary beam holder should look when it is positioned to hold the beam during beam installation Insert wood block CC making sure the two holes in the wood block are facing upward Insert a wood peg DD in each hole Repeat for opposite post 15 BB ...

Page 17: ...ller piece is exposed 2 19 1 Re attach one side of the logo plate 6 18 K Keep logo plate with screws 1 17 2 J K Unwrap beam sleeve J with the Suncast logo Unscrew logo and remove Set logo plate and gold screws aside to be reattached later Beam Assembly ...

Page 18: ...sfer the measurement to the other end of the logo plate Insert and tighten remaining screw Unpack 1 wood beam inserts L Slide wood beam insert into hollow ends of beam sleeve J Wood beam insert should be flush with end or recessed 1 4 20 1 2 J Slip opposite beam sleeve J over wood beam insert Lift logo plate while sliding beam sleeve underneath The seam should be snug where two sleeves meet ...

Page 19: ...tion Repeat Steps 17 26 for remaining beams 27 5 1 1 2 26 U Measure and mark holes 5 and 1 1 2 from bottom of beam Predrill holes making sure that the hole that is 1 1 2 from the edge is towards the bottom of the beam 24 6 X Fasten a 1 screw X on the top edge of beam 6 from the end of the beam Note Top edge of beam is determined by the logo plate orientation ...

Page 20: ... U 31 W Make sure that the beam is resting on top of the vinyl column and pressed securely against the 4 square posts Secure with two 4 pan head screws W through the beam and into the post Repeat on opposite end of beam 28 J Position two 8 step ladders next to two posts Double check the orientation of the temporary beam holders and make sure they are positioned to support the beams Ensure the Sunc...

Page 21: ... DD and slide out wood blocks CC to remove temporary beam holders BB Reinstall them as needed on remaining posts 32 J Position next assembled beam J on opposite side of post Make sure the pre drilled holes are facing outward and towards the bottom The installed beam should look like this ...

Page 22: ...four 2 1 2 pan head screws Y secure trim to beams Repeat for other post Attach a rafter clip FF exactly 1 1 4 from the end of beam with two 1 screws X Rafter Clip Installation 35 I I H Apply cement to the flange of post cover I Promptly slip post cover over the top of the top square post sleeve H Repeat for remaining posts Note It may be necessary to loosen the top of the beams to allow the cover ...

Page 23: ...acing Using a tape measure and pencil mark the location of rafter clips Pergola Size Rafter Spacing on center Number of Rafters 8x8 16 3 4 6 8x12 16 9 10x14 19 9 10x16 17 3 8 11 12x16 17 3 8 11 14x14 19 9 14x20 19 1 4 13 Attach a rafter clip FF directly over the top of the beam splice in the center of each beam with two 1 screws X 2 39 FF X 1 1 ...

Page 24: ... rafter collar O onto 7 wood rafter insert P so that half of it rests on the rafter sleeve N 1 1 2 44 X N 42 43 N P Slide the 7 wood rafter insert P out of the rafter sleeve N until it protrudes 42 Rafter Assembly Repeat steps 37 41 to install remaining beams and rafter clips 42 ...

Page 25: ...rocess all of the posts beams and rafter clips should be permanently installed All of the rafters should be assembled and ready to be installed Repeat steps 43 46 to assemble remaining rafters 47 Installing the Rafters 46 X N P 1 1 2 Slide rafter sleeve N over 7 wood rafter insert P until the two vinyl sleeves are touching Insert a 1 screw X next to the collar ...

Page 26: ...ecure rafter to the rafter clips 52 X x4 Using four 1 screws X secure rafter to the rafter clips on opposite end of beam 51 X x4 Center the rafter on the beams by measuring from each end of the rafter to the outside edge of the beam Both of the measurements on each side of the beam should be equal 50 ...

Page 27: ... been centered and positioned Adjust the rafters as needed make sure all rafters line up perfectly straight before securing to rafter clips Before moving on measure the beams at the seam to make sure the spacing between the beams is 4 If needed temporarily insert a 4 spacer while attaching remaining rafters Repeat steps 49 52 to center rafter and secure rafter to rafter clips 54 ...

Page 28: ...he two shades come together is directly centered over the middle rafter 59 1 1 2 1 1 2 60 R R Slide another shade R over shade splice T until it butts against exisiting shade Insert a 1 screw X about 1 from end of the shade 2 58 T R R X 1 Slide the shade splice T halfway into shade R Insert a 1 screw X about 1 from end of the shade 57 T R X 2 1 Assembling the Shades Installing the Shades ...

Page 29: ...hade for remaining shades Prior to fastening the shades sight the rafters and straighten shades as needed 62 Y After positioning the shades begin at the corner and fasten shades using 2 1 2 pan head screws Y Ensure screws go through the top of the shade and into the rafter Secure remaining shades to rafters 63 ...

Page 30: ...ly cement to inside ring of beam trim M Promptly tap beam trim into place so that trim is snug and level Repeat for remaining beams Multi purpose cement is provided to install decorative trim Installing Decorative Trim Apply cement to inside ring of shade trim S Promptly tap shade trim into place so that trim is snug and level Repeat for remaining shades 66 S S ...

Page 31: ...square and parallel to the beam Secure trim with two 1 screws X on opposite sides of the posts Repeat for remaining posts After beam rafter and shade trim have been installed the pergola should look like this Congratulations Your pergola is now ready to enjoy ...

Page 32: ...HE REPAIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT OR PART AND THE MANUFACTURER SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM ANY DEFECT IN MATERIAL OR WORKMANSHIP OR FROM THE BREACH OF ANY EXPRESS OR IMPLIED WARRANTY Some states do not allow the exclusion or limitation of incidental or consequential damages or a limitation of how long an implied warr...

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