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RioOutdoors 4S-PO Installation Instructions Manual

4x4 surface mount partial octagon pergola kit
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WARNING: If the information in these instructions is not followed exactly, weakening or failure of the erected
structure may result causing property damage, personal injury, or loss of life.
All brackets designed and sold by RioOutdoors.com are to be used for building pergolas only and are not to be used for
other structure construction purposes.
•
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-channels eliminate need for lifting equipment. Super-easy assembly work.
•
Self-aligning design squares up structure automatically.
Estimated Assembly Time is less than 2 hours.
•
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P a g e
Installation Instructions
4x4 Surface Mount Partial Octagon Pergola Kit
Pergola Kits
Figure 1: Items included in the kit, (
Items not included in this kit: wood, tools, some hardware.
4S-PO
).
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Summary of Contents for RioOutdoors 4S-PO

  • Page 1 WARNING: If the information in these instructions is not followed exactly, weakening or failure of the erected structure may result causing property damage, personal injury, or loss of life. All brackets designed and sold by RioOutdoors.com are to be used for building pergolas only and are not to be used for other structure construction purposes.

  • Page 2: Table Of Contents

    A properly sized pilot hole must be drilled before you attempt to drive lag screws into any pergola lumber member. See Table, below. Driving lag screws into lumber, without first drilling a pilot hole, can prevent the lag screw from driving fully into the wood or can lead to crack formation while driving the lag screw in, or later, as the wood dries naturally.

  • Page 3: Safety And Warning Information

    GENERAL INFORMATION 1.1 SAFETY AND WARNING INFORMATION 1.1.1 Building Permit & Inspection Requirements We recommend that you consult with your local building permit office and obtain advice and any required building permits and inspection approvals from the local building inspection department or the local authority over building codes. 1.1.2 Other Cautions CAUTION: Adhere to all s afety r equire ments.

  • Page 4: Tools Required

    1.2 TOOLS REQUIRED Listed below, are common tools required for pergola projects. These tools are not included in this kit. Your pergola project may not require all tools. Select and acquire the tools for your project from the “Required for” column in this table. Description Tool Purpose Required for...

  • Page 5: Contents Of Kit

    The contents of this kit are shown in the table, below. Before you begin your project, take an inventory of all items that you received from us. If any items are missing, contact us directly via email at info@RioOutdoors.com. Include your name and shipping address and your order number, if available.

  • Page 6: List Of Materials That You Will Supply Recommended

    1.4 LIST OF MATERIALS THAT YOU WILL SUPPLY, OR ARE RECOMMENDED This is the list of required materials which are not included in this kit. You will acquire these items locally for your project. Use this table to help you calculate your total project budget. Total Item Item...

  • Page 7: General Lumber Requirements Information

    1.5 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 octagonal shape for your pergola.

  • Page 8: Surface Mount System

    1.6 SURFACE MOUNT SYSTEM 1.6.1 What is a Surface Mount system? Surface Mount means that the vertical posts for a pergola are secured to the top of a concrete footings, concrete pad, or deck cross-brace beams using Floor Anchor Brackets. You may bolt the floor anchor brackets directly on top of a concrete pad or on top of a footing.
  • Page 9 1.6.2 Call 811 811 is the national call-before-you-dig phone number. Anyone who plans to dig should call 811 or go to their state 811 center's website before digging to request that the approximate location of buried utilities be marked with paint or flags so that you don't unintentionally dig into an underground utility line.

  • Page 10: Overall Pergola Size

    1.7 OVERALL PERGOLA SIZE We have designed the octagon corner elbow brackets to provide automatic alignment of the header 4x4s. By making certain all outer perimeter “Header Lengths” are of the same length, following the instructions properly, and securing the 4x4s to the elbow brackets as instructed, you will achieve a perfect octagonal pergola.

  • Page 11: Side Elevation Diagram

    1.8 SIDE ELEVATION DIAGRAM Based on the height of the post used, the diagram below provides the side elevation profile for this pergola system. POST HEIGHT DIM A (in.) (in.) 92 1/2 104 1/2 116 1/2 128 1/2 140 1/2 The Post Height, above, equals the outer height of the pergola.

  • Page 12: Octagon Pergola Assembly Work Outline

    1.9 OCTAGON PERGOLA ASSEMBLY WORK OUTLINE 1.9.1 Brackets Application Depiction 12 | P a g e...
  • Page 13 1.9.2 Headers Preparation The diagram, below, provides detailed information about all lumber headers required to build this structure. Prepare the specified lumber members by following the table and diagrams in this section. See section 1.7 Overall Pergola Size to determine the overall size and applicable lengths for items A and B.
  • Page 14 1.9.4 Preparing lumber member “A.” Follow the steps, below. Cut and prepare three (3) identical lumber members to be used as item 1.9.5 Preparing lumber member “B” Follow the steps, below. Cut and prepare two (2) identical lumber members to be used as item 14 | P a g e...
  • Page 15 1.9.6 Make Post Assemblies Create four post assemblies by adding post-bottom #4FA floor anchor brackets and post top #4OL octagon elbows to four posts of equal lengths. See section 1.10.1 and 1.10.2 Create two post assemblies by adding post-bottom anchor brackets and post top 1-way elbow bracket.
  • Page 16 1.9.7 Erect the Structure Stand two posts, Post #1, and Post #2 (both with Octagon Elbow Brackets) in designated locations and hold them securely in place by placing two sandbags on two sides of the #4FA floor anchor brackets. The distance between posts should be measured at the two outer corners. This distance must be close to the length of the headers you will be installing.
  • Page 17 After verifying that the distance between the two corner points, above, is close to the header length, place a header “A” loosely between the two posts in the U-channels of the octagon elbow brackets. Adjust position of posts until the header fits snugly between the post top #4OL octagon brackets. The miter cut edge of header “A”...
  • Page 18 Stand a third post, Post #3 with an Octagon Elbow Bracket, in its designated location and place two sandbags on two sides of #4FA floor anchor bracket. Measure and adjust the distance between the second post and the third post. See step 3, above. Place header loosely between post #2 and post #3 in the U-channels of the octagon elbow brackets.
  • Page 19 11. Next stand Post #5 (with a #4C1L Elbow). Rotate the header receiver U-channel in the #4C1L elbow towards the open U- channel on the top of Post #3. 12. Measure for header distance between the 1-way elbow’s face and the corner in the #4OL octagon elbow bracket. Adjust as necessary.
  • Page 20 15. Verify that the structure is as you desire it, all posts are plumb, and that all headers are in their proper positions. 16. Make certain that all pergola posts are plumb and located in the proper positions and check for level on top of all headers. If level is not proper, you may be required to place some shims under the #4FA floor anchor brackets.
  • Page 21 21. Your pergola project is now complete. Consider adding some additional decorative elements like the lattice fence and upper horizontal divider lumber. Also consider our solid roof brackets kit which makes it extremely easy to add an all-weather solid roof structure. The structure you have built is compatible with our partial octagon solid roof kit.

  • Page 22: Creating The Post Assemblies

    1.10 CREATING THE POST ASSEMBLIES 1.10.1 Adding #4FA Floor Anchor Bracket Lay a post on the ground. Lift one end of the post up and slide a #4FA floor anchor bracket, all the way over the post end. 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.
  • Page 23 Locate four 5/16” diameter holes, two holes in each opposing face of the floor anchor’s square tube. 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. 23 | P a g e...
  • Page 24 Using a ratchet driver and a 7/16” socket, drive one ¼” x 1-1/4” Lag Screw through all four pilot holes you drilled. Tighten all lag screws. Repeat steps 1-6 and add a #4FA floor anchor bracket to all remaining posts. 24 | P a g e...
  • Page 25 1.10.2 Adding post top #4OL Octagon Elbow Bracket It is now time to add the post top #4OL octagon elbow brackets. Before you begin, note which faces of the #4FA floor anchor bracket’s tube face inside the pergola. When adding the Octagon elbow bracket to the post top, make certain that the same faces of the #4FA floor anchor bracket’s tube point inside the pergola.
  • Page 26 Perform these steps with the post laying down on the ground in the orientation shown, below. Slide a 2-way octagon elbow bracket’s tube over the 4x4 post top after aligning the header receiver u-channels in the proper directions. Push 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.
  • Page 27 Identify the four 5/16” holes which are on the sides of the gussets in the elbow bracket. 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.
  • Page 28 1.10.3 Post Top #4C1L Bracket Installation Slide a #4C1L bracket’s tube on the 4x4 post tops #5 & 6 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.
  • Page 29 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. Drive one ¼ 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.

  • Page 30: Ecuring The Headers

    1.11 SECURING THE HEADERS 1.11.1 Header “A” Installation Lift and place one “A” 4x4 header 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”...
  • Page 31 3. Before driving lag screws, review the position of the header ends on both ends of the header. Make certain that it is conforming to the image, below. The mitered ends of the headers should touch the bracket’s corner square tube face or be close to touching the tube face.
  • Page 32 1.11.2 Header “B” Installation Lift and place one header “B” between post top #3 & #5 and one header “B” between post top #4 & #6. The miter cut ends of header “B” are to be positioned against post #3 and post #4. At both ends of header “B,”...
  • Page 33 Drill 3/32” X 1-1/4” deep pilot holes at the center of 5/16” holes at both ends of the header and on both sides. Locate pilot holes at the center of each 5/16” hole. Perform this step for both “B” headers. Drive one ¼...

  • Page 34: Floor Anchor Brackets

    1.12 SECURING THE #4FA FLOOR ANCHOR BRACKETS 1.12.1 Concrete Footing, Concrete Pad, or Concrete Block Anchoring 1. Apply tape to the drill bit to mark the 2” depth required for the 2-3/4” Vibration Resistant Hammer-On Stud Anchor you will be using to anchor the bracket to the concrete footing or pad. 2.
  • Page 35 4. Hammer in one concrete anchor (1/2” X 2-3/4”) into each hole you drilled through the hole in the Floor Anchor floor bracket. 5. Tighten down the nut using a crescent wrench. 6. Repeat steps 2-3 for all Floor Anchor Brackets. 1.12.2 Anchoring on existing deck Consult your local building permits office.
  • Page 36 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 37: Warranty Policy Statement

    Warranty protects against defect in manufacture only, unless herein specified otherwise. Any part(s) found to be defective during the warranty period as outlined above will be repaired or replaced at RioOutdoors.com’s option provided that the defective part is returned, if requested by RioOutdoors.com. Alternatively, RioOutdoors.com may at its own discretion fully discharge all its obligations under the warranty by refunding the verified purchase price of the product to the original purchaser.

  • Page 38: Imitations Of Liability

    Parts where the RioOutdoors.com logo has been altered, deleted, removed, or made illegible will void this warranty. Minor movement, expansion and contraction of the steel parts is normal and is not covered under the terms of this warranty.

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