Pergola Assembly Instructions. About our Pergolas

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1 Pergola Assembly Instructions About our Pergolas The wood that we use for our pergolas is cut, trimmed, treated and finished ready for you to assemble straight away. The softwood is also tannalised and has a 10 year guarantee. The wood that we use comes from sustainable sources and is approved by the Forest Stewardship Committee (FSC). You have a choice of two different woods: 1) Hardwood Air-dried oak is very long lasting and weathers to a natural classic appearance that compliments your existing home and garden beautifully. This is a brilliant material to use where a strong architectural look is required and will give you years of life and pleasure. 2) Softwood All our softwood undergoes a pressure - treated, tannalising process allowing us to offer a 10 year guarantee plus the option of two different colour finishes. Please bear in mind that if you do grow climbing plants or vines to cover the pergola a lot of the wood will not be exposed during the spring and summer months due to the foliage. The natural green finish is typical of what you will find in your local garden centre and the deeper, darker brown finish looks particularly striking when paired with newer built properties. The softwood can be specified in either rough sawn or sawn & chamfered depending on the look you want to achieve. 3) Wood sizes a) Posts these come in 4 x 4 x 8 (4 inch by 4 inch by 8 foot) sections. The 4 width giving maximum structural support whilst not being too unwieldy and also allowing you a maximum of 8ft headroom which is ample for most people s requirements. They have been designed to withstand most of the harsher elements of our British weather and are strong enough to carry a full coverage of climbing plants, snow and ice. One end of these posts will be notched to allow the fitting of the main beam. b) Cross Rafters supplied in 5 x 1.5 x 9 (5 inch by 1.5 inch by 9 foot) sections. The 5 depth to these rafters prevents sagging and again gives support not only to the structure but the climbing plants as well. Please be aware that although the length of these rafters is 9ft, the actual depth of your pergola will only be 8ft. This is because we finish one end of the rafter with a decorative design that overhangs the main outer support beam giving a typical pergola feature that completes the picture. The cross rafters should be spaced at 27 inch intervals ensuring sufficient support for climbing plants to cover the roof of your pergola. c) Ledger Board this is the main inner support beam that is attached to the wall and, from which, you fix the unfinished end of the rafters to by using the hanging joists. Again, these are supplied in 5 x 1.5 x 9 (5 inch by 1.5 inch by 9 foot) sections. If you order our basic 9ft x 9ft module, the single ledger board will have decorated ends to match the ones on the cross rafters. When ordering our 9ft x 16ft module only one end of each ledger board will have a decorated end allowing the 2 unfinished ends to butt up to each other giving a

2 seemingly continuous line. The 9ft x 23ft module will obviously have 2 x 9ft ledger boards (decorated as above) and the shorter central one will have no decorated ends, again allowing you to butt these against each other for the same continuous look. d) Main Outer Support Beam exactly the same dimensions as the Ledger Board and ties together the posts and cross rafters completing the structure. Depending on the module required the Main Beam follows exactly the same principle as the Ledger Board in terms of decorative ends and quantity. e) Strengthening Support Struts cut at a 45 degree angle at either end and measuring 5 x 1.5 x 18 max (5 inch by 1.5 inch by 18 inch) these braces when screwed to the post and main outer beam finish off the pergola by giving it the necessary rigidity. Part Descriptions: 1) Posts a) 8 foot b) 4 inch x 4 inch c) Notched and pre-drilled for the main fixing coach bolts 2) Rafters a) 9 foot b) 5 inch x 1.5 inch c) One decorated end 3) Ledger Board a) 9 foot b) 5 inch x 1.5 inch c) Depending on size of module ordered, the ledger boards will either have both ends decorated for the 9ft x 9ft module. One end decorated for the 9ft x 16ft module and an extra blank ledger acting as the middle extension for the 9ft x 23ft module. 4) Main Beam a) 9 foot b) 5 inch x 1.5 inch c) Pre-drilled for the corner posts to accept the main fixing coach bolts d) Decorative ends and extra blank extension beams follow exactly the same principle as for the Ledger Board above.

3 5) Strengthening Struts a) 18 inch length b) 5 inch x 1.5 inch c) Both ends cut at 45 degree angle and pre-drilled 6) Hanging joists a) To fit Rectangular wood 5 inch x 1.5 inch b) 5 rafters per 9 foot section = 5 hanging joists 7) Post Fixings a) Spiked for use straight to earth b) Bolted for use on patio/paving c) Concrete In for use with unfavourable soil conditions 8) Fixings a) Coach Bolts/Nuts 1 set per corner post b) Screws (masonry and wood) plus wall plugs c) Steel angle braces to attach rafters to main beam d) Joist hangers to attach to the Ledger Board providing support for the rafters e) Special 3-Way fixing bracket for extra posts allows attachment of post and 2 main beams together f) Spacers to allow 10mm space between ledger board and wall

4 How to build and assemble your Pergola There are 4 different options to choose from when ordering your Pergola. Our basic 9ft x 9ft standard building block system is designed to be extendable in a simple and easy way, proving that you do not need to be a construction engineer to install one! The following sizes are available: 1) Option 1: Standard - 9ft x 9ft (max outside dimensions) 2) Option 2: Standard - 9ft x 18ft 3) Option 3: Standard - 9ft x 27ft All our pergolas have a standard width of 9ft but with the option of 9ft incremental increases in length. We decided to keep to the 9ft width as our pergolas are designed as a lean-to system and this width allows a quick and easy installation in most locations giving enough room in which to entertain, live in and customize to your own specification whilst keeping the costs down. To assemble any of the longer pergolas simply repeat the assembly instructions for each of the modular 9ft x 9ft building blocks it couldn t be easier! 4) Option 4: Customise the length to your own requirements If you require a different length of pergola from the ones detailed above the easiest thing to do is to purchase extra individual parts from our Accessories page and add to either Option 1, 2 or 3 above and adjust the length yourself by cutting down the ledger board and main beam and adding the number of rafters required. Care must be taken to ensure that the gap between the posts is no more than the 84.5 inches that we specify. This is our maximum recommended span width for this size of wood and type of usage. Most of the measurements detailed in these assembly drawings are in old fashioned feet & inches however, to keep up to speed, please find below a simple metric conversion table allowing you to work in whichever system you find easier: To Convert: Into: Multiply By: Inches Millimetres 25.4 Millimetres Inches Inches Centimetres 2.54 Centimetres Inches Feet Metres Metres Feet 3.281

5 Please see below a Parts Explosion drawing that shows all the constituent items that are needed in order to successfully build your pergola together with a brief description of each part. Once you have chosen the length of pergola you require, just tick the option you require on our ordering page and leave the rest to us. All of the necessary components will be automatically calculated and added to your order making it easier for you to concentrate on just the assembly. Parts List: Module 1 9ft x 9ft 1 x Ledger board (decorated both ends) 1 x main beam (decorated both ends) 2 x Posts 4 x Rafters 4 x Strengthening struts 7 x Wall plugs 7 x Masonry screws 35 x Washer spacers 4 x Mini joist hangers 64 x Wood screws 8 x Metal angle brackets 2 x Coach bolts 2 x coach nuts Fig 1 Parts explosion drawing and description 2 x Metal Fixing posts supports (choice of 3 different options if using the bolt-down system bolts will be provided) Module 2 9ft x 16ft 2 x Ledger boards (decorated one end only) 2 x Main beams (decorated one end only) 3 x Posts

6 7 x Rafters 7 x Strengthening struts 14 x wall plugs 14 x masonry screws 70 x Washer spacers 7 x Mini joist hangers 102 x Wood screws 14 x Metal angle braces 3 x Coach bolts 3 x Coach nuts 1 x T connector 3 x Metal Fixing post supports (choice of 3 different options if using the bolt-down system bolts will be provided Module 3 9ft x 23ft 3 x Ledger boards (2 x decorated end & 1 x straight ended middle extension board) 3 x main beams (2 x decorated end & 1 x straight ended middle extension beam) 4 x Posts 10 x Rafters 10 x Strengthening struts 20 x Wall plugs 20 x masonry screws 100 x washer spacers 10 x Mini joist hangers 160 x Wood screws 20 x Metal angle brackets 4 x Coach bolts 4 x Coach nuts 2 x T connector

7 4 x Metal Fixing post supports (choice of 3 different options if using bolt-down system bolts will be provided) Once you have received your delivery, please carefully check that all items have been included against the packing list supplied and, once done, you re ready to start to assemble your own pergola. Please follow these simple steps as a guideline to ensure that the assembly of your pergola is as trouble free as possible: *NB By using wood as the main material in the construction of a pergola, its very nature means you may find that it expands or contracts slightly depending on conditions. For example, if you experience difficulty in inserting a 4 inch x 4 inch post into the Fixing Post support - it may be because the wood has expanded a little. If this is the case, just take some coarse sandpaper and sand the bottom outside faces and edges that will be inserted into the support. Not too much though and it s worth checking about every 30 seconds of sanding as to whether it will fit snuggly into the metal support. If not, continue to gently sand and check often! Step 1 Measuring the Site in Preparation & Positioning of the Posts Fig 1A Once you have prepared and measured the site it is a good idea to stake out the area (Fig 1A) and mark clearly where your posts will be situated as Figs 2 & 3 below demonstrate Fig 2 Fig 3 Positioning of the Posts: Using a tape measure or a piece of string, mark a spot exactly 100 inches from the wall making sure that you use a builders square to ensure that the line is at right angles (90 degrees) to the wall. This will be the position for the first Fixing Post. Once you have found the spot, either bang into the ground the spiked Fixing Post or mark the spot carefully if you need to dig a hole for the concretein Fixing Post. If you are using the bolt-down Fixing Post onto a patio or hard surface, simply put a cross using some chalk, marking the centre of where the Fixing Post will be positioned.

8 To mark the position of the second Fixing Post take your piece of string or tape and mark out 87.5 inches from the centre of the first Fixing Post, parallel to the wall, again using your builders square to ensure that the two Fixing Posts are aligned. To make sure that the footprint is completely straight use the builders square to check that all corners are 90 degrees. Depending upon the length of the pergola, and where it will be positioned on the wall of your house, you will see from Fig 4 below how the footprint of the pergola will look. Fig 4 Step 2 Securing the posts to the ground. There are 3 different methods for you to choose from: a) Original Spiked Fixing Posts pic 1 + description b) Bolt-Down Fixing Posts pic 2 + description c) Concrete-In Fixing Posts pic 3 + description We have chosen these methods of securing as the Fixing Posts are easy to install and keep the bottom of the posts out of the ground, reducing the risk of rotting. The method that you choose depends on your local conditions and where your pergola is to be sited. If you have good, solid earth - choose the first option. If you want your pergola positioned over a patio, concrete or on existing decking choose the second option as the Fixing Post is secured either by using a hammer drill and masonry bit to drill through the hard surface and then bolted down using the special masonry bolts or, if fixing to an existing wooden deck, by using the traditional wood screws. In both cases the bolts and screws will be provided. If your soil is of a poor constituency you should go for the final option. If this is the case, you will need to dig a hole and buy a bag of quick setting concrete (sourced from any builder s merchant or garden centre) and follow the simple instructions for a safe and secure fix. When ordering, you will be prompted as to which method you require in order to secure the posts to the ground. See Figs 5, 6 & 7 below for information on how to use the 3 different methods: Fig 5 Fig 6 Fig 7 Post supports Installation instructions: 1) Original Spiked version

9 These have been designed to allow you to install your posts securely in the ground in no time and without the hassle of digging holes or buying concrete. Simply, place the tip of the spike over the point in the ground where you want your post position to be and using the Driving-In tool take your sledgehammer and gently drive the support into the ground, making sure to check the vertical alignment with a spirit level as you do so, until the box section of the support is level with the ground. 2) Bolt Down Support As this version of post support is flush fitting, it is ideally used for situations where your pergola is to be sited on an existing patio, concrete or decking. Using the base as a template, mark the holes on the surface, drill and then secure using the bolts provided ensuring that they are tightly screwed in. 3) Concrete In Support These supports are best used in areas where the ground conditions prevent the use of the original Spiked post support. So, for example, if your ground is particularly stony or prone to very wet earth it is best to opt for this version. You will need to visit your local builder s merchant or garden centre and purchase a bag of quick drying concrete. Once done, dig out a hole (where you want to place the post) approximately 18 ins x 18 ins x 18ins in size, and place enough of the prepared quick drying concrete to fill the hole. Next, insert your post support into the centre of the hole and check that it is vertical aligned. Once, the concrete has set (usually an hour but check the manufacturer s instructions) the post can be placed in the support. All 3 of the above versions above can be painted to match the finish of the timber you have specified and will ensure years of maintenance free, secure anchorage. If, for whatever reason, you have cause to change the timber post, you can simply loosen the holding bolts, take it out and replace with another without having to re-dig, drill or concrete in any new post supports. To ensure that the posts are completely straight, it is a good idea to use a post level as it is vital to the whole structure that the posts are in line and vertical. Please make sure that the notched side of the post faces inwards as you will be attaching the main beam to this side in Step 4 Step 3 Attaching the Ledger Board to the House Fig 8 If you attach anything to the brick or stone of an outside wall water can become trapped and soak into the surface which can lead to a brown stain running down the wall where the attachment has been fixed. If this occurs, the stain is particularly difficult to remove and looks a bit of an eyesore. Therefore, it is important to follow the method below to prevent this staining from happening. By using the spacers provided, it creates a gap between the Ledger Board and the wall itself which allows air to flow and helps the surfaces to fully dry out after rainy days. Fig 9

10 Fig 9 shows the picture of the Ledger board and the suggested fixing holes and spacings that you should pre-drill. We recommend using a zig-zag pattern with an approximate 18 inch gap between fixings. This will provide a firm footing and will be more than enough to maintain the position and shape of the Ledger Board and prevent it warping over time. The Ledger Board fixings also offer a secure base for the rafter beams and are strong enough to carry the weight of any climbing plants that are grown up the structure. Start by drilling the pilot holes, which helps prevent the wood from splitting, with a 2mm wood bit followed by a 6mm drill bit to widen them for use with the outdoor screws and wall plugs provided. Fig 10 Once you have prepared your Ledger board the next step is to mark the wall ready for drilling so that the Ledger board can be attached. See Fig 10. You might find the task easier to ask for an extra pair of hands to help secure it firmly against the wall. Offer the Ledger Board up to the wall (use a spirit level here to ensure a completely horizontal fit) and taking a drill with a small pilot masonry bit, drill through the ledger board holes and into the wall to a depth of half an inch or so. Continue to do this with all of the holes that you have made in the Ledger Board. Once done, take the ledger board down and deepen the holes in the wall by a further 2 inches using the same small 2mm pilot masonry bit. Next, widen the holes using an 8mm masonry drill and clean out any dust that has gathered there and insert the wall plugs provided into the holes. If any of the plugs prove stubborn, take a small hammer and gently tap them into place so that they end up flush with the face of the wall. Fig 11 After you have drilled the holes in the wall, push the screws through the ledger board and spacers (see Fig 11) lining them up with the plugs in the wall and screw them in tight ensuring a firm attachment. If you have ordered a longer pergola than the standard unit, simply butt up another rafter (or plain ended rafter if longer than 18ft) which will act as the second ledger board, against the one already screwed into the wall and repeat the above process in Step 3. Step 4 Attaching the Main Beam(s) to the Posts The next job to tackle is attaching the main beam to the posts. Line up the pre-drilled holes on the posts and the main beams and thread the coach bolts and nuts provided through the holes and tightening. For best results, push the coach bolt through leaving the head visible on the outside of the post and the bulky nut on the inside (See Fig 12 & 13 below) Fig 12 Fig 13 If you have ordered one of the longer pergolas, you will need to join together 2, or more, main beams using the supplied 3 Way fixing plates as shown in Fig13A & Fig 13B below

11 Fig 13A Fig13B Attaching extra main beams to posts to increase the length of the pergola Step 5 Attaching the Cross Rafters to: a) The Ledger Board Fig 14 Ledger Board with hanging joists fitted (new) The first task is to attach the joist hangers to the Ledger board. See Fig 14. It is important that you follow the spacing between the hangers as this will ensure that the final structure is aligned perfectly. Fit the rafters in the hanging joists and screw tight. Fig 15. Using both your spirit level and builder s square, make sure that each rafter is square in relation to the ledger board before final fixing. As you have already attached the main beam, you can rest the other end of the rafter on top to give you support whilst tightening the joist hanger fixings. Fig15 Joist hanger side view b) The Main Beam Lay the rafter(s) on top of the main beam, ensuring that they are at right angles to the wall and fix to the main beam using the right-angle brackets and screws provided. This keeps the metalwork on the top side of the beam and out of plain sight. Fig16 Fig17 Fig18 Step 6 Attaching strengthening Struts to Main Beam & Posts These are provided not only for the strengthening of the whole structure but they also look good and help bring the whole project to an attractive conclusion. Please see Figs 19 & 20 below for fixing instructions of the strengthening strut from the main beam to the post (Fig19) and from the outside rafter to the post (Fig20) Fig19 Fig20 If you have specified a longer pergola, we have provided another 3 struts (per extra post) for attaching to the rafter, main beam and post for added strength and continuity. See Fig23

12 Fig 23 Attaching Strengthening Struts for extra posts Step 7 (optional) If you have chosen Option 4 and want a customised length designed to your own requirements, you will have to cut down a Ledger board and Main Beam to fit. In case of problems or if you have made a mistake, please find below Fig 24 which shows the dimensions required for you to cut and prepare your own decorated end to match the others. Fig 24 One final job left and that is to revisit all of the screws that you have put in to check that they are all tight. Whilst working on a project like this, some of the screws may not have been tightened as fully as possible and may have worked a little loose with all the movement generated by assembling the structure. That s it! Your Pergola is now up and ready for you to enjoy and accessorise as you see fit. You will find a selection, on our Accessories page, of top quality products that will not only complement your pergola but bring it to life as well - allowing you to make the most of our warmer, longer summers and increase the enjoyment of an active, outdoor lifestyle. Fig25 (new) Final drawing & Pic Of completed pergola Important Safety Statement Pergolas are decorative products and are not designed to be used as a structural system for carrying live loads such as humans or animals. They are not designed to support a hanging swing or hammock. These pergolas have been designed to tolerate their own weight, climbing plants, light decorative adornments (such as lanterns or low weight outdoor lighting systems) and moderate snow or ice conditions. Safety Building a substantial structure like a pergola is exciting and fulfilling and working outdoors with masses of space and blue skies can create a rather pleasant atmosphere. However, it is important to consider that while undertaking any such project, that you do not become too relaxed as a casual

13 attitude can be potentially dangerous so, keep your mind on the job, ask for help where needed and take a break every now and then! Please find below some helpful hints to keep your work space accident free: 1) Take your time to do the work carefully and methodically. If you are running behind schedule do not feel under pressure to rush as this can lead to accidents and a disappointing end result 2) Keep all electrical leads and connections from getting wet or damp. If it is damp or looks like rain do not use any electrical equipment 3) Unplug or disable all equipment when not in use. If you are leaving the site for any time at all, please remove the electrical equipment as these can attract attention particularly from children. 4) Cover all unfilled holes and, if they are to be left for any length of time, cordon off the area to keep people and animals out. 5) Ensure that all children and pets are kept well away from the site. They can be distracting and therefore a danger to you and themselves. 6) When wood is required to be cut, please remember to use a waist high work bench or saw horse. The wood must be firmly held in place by vice or clamp. This makes is not only easier to cut cleanly and accurately but helps prevent possible accidents from occurring 7) Check that all your tools are in proper working order and are in good condition 8) Do not try and do everything yourself. The main beam and ledger board, in particular, are heavy and awkwardly shaped to lift into position. It is much better to borrow another set of hands to help 9) Ensure that any ladders you use for the assembly are sturdy and safe for the job. Extension ladders must be firmly set into the ground at their base and should be on an angle of about 60 degrees 10) Keep the site tidy at all times and do not leave any tools, leads etc lying around as, again, these are potential hazards which could lead to accidents and injury 11) Purchase proper safety equipment and use it. Wear safety glasses all the time and ear protectors when using powered equipment. Disclaimer: Important: Perfect Pergolas Ltd has produced this basic information guide on how to assemble and construct your pergola. However, this information is provided for use on the understanding that Perfect

14 Pergolas Ltd is not liable for any loss or damage which is suffered or incurred (including but not limited to indirect or consequential loss) for any personal injury or damage to property suffered or sustained as a result of using the information contained in these guidelines. Perfect Pergolas Ltd advises you to contact a qualified tradesperson, such as an electrician or plumber, where expert services are required and to independently assess any safety precautions that will need to be followed prior to using the information provided by this guide.