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Pergola kits USA PREMIUM VINYL PAVILION Assembly Manual

Traditional (hip) roof stick-built
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PREMIUM VINYL TRADITIONAL (HIP)
ROOF PAVILION STICK-BUILT
ASSEMBLY MANUAL
Shown above is a 16' x 24' Hip Roof Pavilion
Thank you for your purchase of a new Hip Roof Pavilion. Depending on the size of your
Pavilion, installation can usually be completed in 1 to 2 days. These instructions are meant to
serve as a guide for people with a base knowledge of general handyman skills. This assembly
requires a minimum of four people to complete.

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Summary of Contents for Pergola kits USA PREMIUM VINYL PAVILION

  • Page 1 PREMIUM VINYL TRADITIONAL (HIP) ROOF PAVILION STICK-BUILT ASSEMBLY MANUAL Shown above is a 16' x 24' Hip Roof Pavilion Thank you for your purchase of a new Hip Roof Pavilion. Depending on the size of your Pavilion, installation can usually be completed in 1 to 2 days. These instructions are meant to serve as a guide for people with a base knowledge of general handyman skills.

  • Page 2: Before You Begin

    Before You Begin Please always check with your local building codes, they will vary from state to state. The base for the Pavilion must be solid and level. If installing on a concrete slab or on concrete footers, they should be level where the posts will rest. If they are not, it may be necessary to cut the bottom of the posts so that the bottoms are all level.
  • Page 3 Notes: An air-nailer or stapler can be used for rubber or asphalt shingles. (Air nails and staples not included in the kit.) There will be a parts list sent with the Pavilion. All hardware is included in each Pavilion kit. The specific hardware will vary depending on the Pavilion.
  • Page 4 Once the template is in posi- tion, square the template. Do this by measuring diagonally from one corner to its oppo- site corner, then measure diagonally between the other t w o c o r n e r s . T h e s e t w o dimensions MUST be the same.
  • Page 5 Collect post components to be placed on posts (Bottom post trim, top sleeve trim, top square trim , and post sleeve). NOTE: If you ordered an electrical package, there will be a 6X6 post with a notch in one side. Put the sleeve with the receptable on that post as you complete step Assemble post vinyl kit.
  • Page 6 Attach short end headers with three 3 1/2” screws (in the pre- drilled holes) into the end of the other two beams. Repeat on opposite side with the last remaining beam. Locate twenty-four 8" GRK screws in the hardware box (if you have a standard 4 post struc- ture).
  • Page 7 When all posts have two L brackets on, use a drill with 1/2" masonry bit to drill down about 1/2" farther than length 1/2” of wedge anchor. Before inserting the bolt, make sure dust is removed from hole. Then screw the nut and washer on about 1/8”...
  • Page 8 Install the four 2X12 top plates. The top plates should mount close to flush with the inside post. Make sure that the over- hang is the same on both sides. Use two 3 1/2" screws to fasten the plates to the posts. Do not cut these without calling.
  • Page 9 Set finished sections up onto plate. Screw the two sections togeth- er at the top with two 2 1/2” screws between every rafter. Keep ends even. Fasten two 2x4 temporary props at either end of ridge pole to hold in place. Anchor each rafter to the plate on the marked “X”s using three 3 1/2”...
  • Page 10 Fasten the marked “short side” rafter to the ridge pole using one 2 1/2” screw, keep- ing flush with top of ridge pole. Assemble top of hip rafter to ridge pole using two 2 1/2” screws. Secure the bottom of each hip rafter with six 3 1/2”...
  • Page 11 Jack rafters will only fit prop- erly on left or right side based on upper bevel angle. Fasten correct jack rafter into the hip rafter with two 2 1/2” screws staying 1/4-1/2” in on the edge of the plate. Measure from the top of the jack rafter to the side of the side rafter.
  • Page 12 Install the first piece of roof Install the first piece of roof decking making sure not to decking making sure not to extend past plate edge. extend past plate edge. Board may need to be cut to Board may need to be cut to length.
  • Page 13 Next, drive 2 1/2” screws every 16” along the entire length of the fascia board. Follow these same steps with the other short-sided fascia board. Moving to the short side, hold fascia in place, butting the top of the fascia board against a square following the pitch of the decking.
  • Page 14 Once you have all the braces installed, put the 2x4 block back in place, fasten with two 2 1/2” screws at the top and two 2 1/2“ screws at the bottom. Install the bottom brace covers using three 2 3/4” Cortex screws.
  • Page 15 Install the outside center trim by fastening it to the top of the center post with six 2 3/4” Cortex screws into pre-drilled holes on the face of the outside center trim. Use Cortex Use Cortex counter-sink bit counter-sink bit Install the inside center trim by fastening it to the top of the center post with six 2 3/4”...
  • Page 16 Plug all countersinked Cortex screw holes with provided plugs, and using the provid- ed caulk, caulk all gaps in the trim components. Congratu- lations! You are now ready to install your roofing option. Installing Collar Ties Your pavilion kit may include collar ties. Collar ties prevent the middle of the main beams from bowing outwards due to the downward pressure of the roof due to gravity (i.e., the weight of the roof).
  • Page 17 Roofing Option 1: Installing A Metal Roof Fasten horizontal "Roof Lath" pieces with two 2" roofing nails at each rafter. Place the first piece of lath directly on top of the lowest decking board. Space each lath board roughly 20-24" apart with the longest piece placed at the bottom and the shortest piece at the top.
  • Page 18 Lay out the roof tin. Install the tin, starting at the center and moving to each end. Ensure the first piece is installed squarely. Keep the bottom of the tin flush with the drip edge. Fasten with 1” screws. The first piece will have 3 screws at every lath.
  • Page 19 Fasten hip capping with 1 1/2" screws on the tall ridges. Fasten ridge cap with 1 1/2” screw every 24” on both sides. Roofing Option 2: Installing An Asphalt Roof NOTE: Before you begin the steps below, install roof paper starting at the bottom. Be sure to overlap 2" as you work upward.
  • Page 20 To install 1st row of shingles, turn shingle upside down with black tar line at bottom edge facing up and attach to roof using four 5/8” roofing nails. Place nails approximately 3” from bottom. Use four 5/8” roofing nails and attach to roof through shingle at the center line marked on the shingle.
  • Page 21 Trim corner shingles using a shingle scissor or utility knife. When using a knife cut on the bottom side. CUT SHINGLES AT CORNER Also instructions shingle package. Work across then up. Continue to the top. To cap the ridge, start the first capper centered on the ridge down past the corner.
  • Page 22 Place second capper into place. Fasten using two 5/8” roof nails per capper. Fasten nail through the black tar strip. Leave approximately 5 1/2” 1/2” exposed to the weather. Continue up the ridge using the same previous steps. Install cappers in a nice straight row for a neat appear- ance from a ground view.
  • Page 23 CUT CAPPERS AT PEAK Trim the top. Start at both ends of ridge and work toward the center of the ridge. Last piece will need cut in half and will bring the corners together. Trim the bottom edges using a shingle scissor or a utility knife.
  • Page 24 Ceiling Option 1: Installing An Interior Vinyl Ceiling Install T Channel centered on ridge pole, using 3/4” nails, nailing every 16”. Begin at ends and work inward. Note: If you have a square pavilion, skip this step. Install T Channel on hip rafters.
  • Page 25 Complete Step 3 on all hip rafters. Install first piece of vinyl ceil- ing. If piece is longer than provided space, mark appro- priate angle and cut accord- ingly. Be sure to measure twice before cutting reduce gaps. Nail 3/4” nails at each rafter.
  • Page 26 Using the largest piece start at the bottom and work upward. Note: The first piece will have and an angled side and a tongue side. Fasten the board with 1 1/2” screws at each rafter. Note: Be sure that the tongue of the board is facing upward, so the next board can connect to the...
  • Page 27 Next, install the four 1”x3” hip rafter trim pieces. Fasten with three 2 1/2” screws. Place one screw at the bottom, one in the middle, and one at the top. VIEW FROM INSIDE VIEW FROM INSIDE PAVILION LOOKING UP PAVILION LOOKING UP You are now ready to install the 1”x3”...
  • Page 28 Heavy Duty Anchors for High Wind After placing post bases on from step 9, slide HD high wind bracket onto the bottom post. Screw 3/8”x3” hex lags into the pre-drilled holes on opposite sides of the bracket. Repeat on all posts. Continue on with regular instructions, starting at step 10.
  • Page 29 Continue on with regular instructions at page 7, step 19. Square Pavilion Roof Construction Build scaffolding in the center of the square stick built pavil- ion. Locate compression Ring and place on the top of the scaf- folding for later.
  • Page 30 Locate the four rafters, marked “Center” and place one on each side of the pavilion for later. Hold the compression ring at the needed height. Place a center rafter with the side marked “Center” against the compres- sion ring. Be sure to line the center of the rafter up with the marked line and the pre-drilled holes of the compression ring.
  • Page 31 Fasten rafters centered on the marked line, located on the plate. Screw five 3 1/2" screws, two horizontally on each side and one on the top side of the rafter. Be sure to fasten each opposite side first. Do not work clockwise. Locate four hip rafters, which are two boards screwed together.
  • Page 32 Fasten eight 3 1/2" screws into the hip rafter and plate. Three horizontally on each side and one per board on the top. Identify your jack rafters. The jack rafters will have a bevel cut on the upper end. Jack rafters will only fit prop- erly on left or right side based on upper bevel angle.
  • Page 33 Fasten two ‘A23 Simpson’ brackets with 1 1/2” screws on either side of each corner hip rafter and one ‘A23 Simp- son’ bracket at each side rafter and jack rafter. Install the first piece of roof decking making sure not to extend past plate...
  • Page 34 You are now ready to return to page 12, step 38.
  • Page 35 Notes:...
  • Page 36 Notes:...