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RioOutdoors 6F-WPH Installation Instructions Manual

6x6, floating deck, wall attached, open top, partial hexagon pergola kit
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6x6, Floating Deck, Wall Attached, Open Top, Partial Hexagon Pergola Kit
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.
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-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 (not including deck).
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P a g e
Installation Instructions
6F-WPH
Pergola Kits
Figure 1: Items included in the kit, (
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Summary of Contents for RioOutdoors 6F-WPH

  • 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

    ......3 AFETY AND WARNING INFORMATION 1.12 P ARTIAL EXAGON PERGOLA ASSEMBLY WORK OUTLINE 1.2 T ........... 4 OOLS REQUIRED 1.3 C # 6F-WPH ........5 ONTENTS OF 1.4 O ....5 1.13 A #4HL PTIONAL ECK SUPPORT RACKETS SSEMBLING...

  • 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 safety requirements.

  • 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

    If you wish to build a wooden deck as the floor for your floating pergola, you may wish to use our deck beam support brackets, SKU #24BS. This bracket can support 2x4 or 2x6 beams. You can order the required number of brackets at RioOutdoors.com.

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

    1.5 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

    1.6 GENERAL LUMBER REQUIREMENTS INFORMATION We have designed the corner elbow brackets to provide automatic alignment of the header 6x6s. By making certain all header 6x6s are of the same length and not warped, following the instructions properly, and securing the 6x6s to the elbow brackets as instructed, you will achieve a perfect hexagonal shape for your pergola.

  • Page 8: Floating System

    To create a deck, you must add support beams every 24”, or less, to support the deck boards. You may toenail the support beams in place or choose an easier and more precise mounting method using our Beam Support Brackets (SKU# 24BS, available at RioOutdoors.com). P a g e...
  • Page 9 1.7.2 Floor Leveling and Preparation. Plan to assemble this wall attached floating pergola against a wall where you can excavate and create a level platform, at least, the overall outer dimensions of the pergola. If soil type is sandy, soft, or wet, you must consider adding concrete blocks or pier blocks under the posts of the pergola to prevent the pergola from sinking into soil.

  • Page 10: Overall Pergola Size

    1.8 OVERALL PERGOLA SIZE We have designed the corner elbow brackets to provide automatic alignment of the floor floating 6x6s and the header 6x6s. By making certain all outer perimeter “Header Lengths” are of the same length, following the instructions properly, and securing the 6x6s to the elbow brackets as instructed, you will achieve a perfect hexagonal floating deck base for your pergola.

  • Page 11: Side Elevation Diagram

    1.9 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.) 90 1/2 102 1/2 114 1/2 126 1/2 138 1/2 The Post Height, above, equals the outer height of the pergola.

  • Page 12: Posts Preparation

    1.10 POSTS PREPARATION A total of five (5) posts of equal length are required to build this structure. Make certain that all post members are as straight as possible and they are of equal lengths. The lumber you acquired from the store shelf can vary in lengths. Measure all post lengths, first.
  • Page 13 1.11.2 Preparing lumber member “A.” Follow the steps, below. Cut and prepare four (4) identical lumber members to be used as item 1.11.3 Preparing lumber member “B” Follow the steps, below. Cut and prepare four (4) identical lumber members to be used as item 1.11.4 Preparing lumber member “C”...

  • Page 14: Brackets

    1.12 PARTIAL HEXAGON PERGOLA ASSEMBLY WORK OUTLINE 1.12.1 Brackets Application Depiction The image, below, show where all brackets are applied. 14 | P a g e...
  • Page 15 1.12.2 Assembly Summary 1. Lay out the five floor 6x6 members in a rough partial hexagon shape, as shown below, close to the wall you intend to attach this pergola. 2. Starting with corner#1, add a 2-Way Hex Elbow on top of the two 6x6s. 3.
  • Page 16 7. Move the floating structure to the desired location and butt against the wall. 8. Check top of all floating 6x6s for level. Adjust and make level, as necessary. 9. Insert a vertical post inside all five post receiver tubes. Slide post all the way down. If you feel any resistance, tap the top of the post lightly with a hammer.
  • Page 17 13. Add and secure a 1-way elbow to post tops #4 and #5. See section 1.13. 14. Lift and place a header member in the open U-channels between two posts. Repeat adding all headers. 15. Secure the headers to the U-channels. See Section1.14 and Section 1.15. 17 | P a g e...
  • Page 18 16. Secure the two posts, which are adjacent to the wall, using the wall anchor brackets (#1WAB), see Section 1.19. 18 | P a g e...

  • Page 19: Assembling Floor Corner #4Hl

    1.13 ASSEMBLING FLOOR CORNER #4HL HEX ELBOW BRACKETS Before starting assembly work, measure the length of each perimeter 4x4 to verify that they are of equal length and make certain each member is straight (has no bow nor is warped). On the ground, mark the location of one corner post. Start assembly at this post location and continue assembling floor members and corner elbow brackets around the perimeter.
  • Page 20 5. 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”...
  • Page 21 7. Use a ratchet driver and a 7/16” socket to drive one ¼” X 1-1/4” lag screw through the pilot holes you drilled. Total of four lag screws are required. One in each lower hole on the sides of the U-channels. 8.

  • Page 22: Adding Floor #4C2L Brackets

    1.14 ADDING FLOOR #4C2L BRACKETS 1. At corner #5, slide one #4C2L elbow over two adjacent 4x4s so the U-channels in the 2-way elbow bracket are inverted and over the 4x4s. 2. Place two shims under each 4x4 near the 2-way elbow. 3.
  • Page 23 5. 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”...
  • Page 24 8. Drive one ¼” X 1-1/4” lag screw through four pilot holes you drilled in the outer faces. 9. Repeate step 8 for the holes in the inner corner faces of the U-channels. 10. Repeat Steps 2 to 9 at corner #6 and add the second 2-way 90 degree elbow bracket. 11.

  • Page 25: Posts Installation

    1.15 POSTS INSTALLATION 1. Slide a 6x6 post inside the open vertical tube in all corners’ elbow brackets. If post resists sliding easily, tap top of post lightly with a hammer. Post must slide all the way down to the bottom of the square tube. 2.
  • Page 26 3. Drive one 1/4x1-1/4” lag screw through each pilot hole you drilled and tighten down using a ratchet and 7/16” socket. 4. Repeat steps 2 to 3 at all corners. Check top of floor 6x6s for level one more time and adjust as necessary to maintain level. 26 | P a g e...

  • Page 27: Rackets Installation

    1.16 POST TOP #4HL ELBOW BRACKETS INSTALLATION 1. Slide a #4HL elbow bracket’s tube over the 4x4 post top after aligning the header receiver u-channels in the proper directions. 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 28 3. Identify the four 5/16” holes which are on the sides of the gussets in the #4HL elbow bracket. 4. 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 29: Post Top #4C1L Bracket Installation

    1.17 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 30 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 31: Post Top #4Hl Elbowb

    1.18 HEADERS INSTALLATION 1. Lift and place one 6x6 header into the U-channels of adjacent post top brackets. 2. Slide header all the towards the corner square tube until the miter cut edge of the header makes contact with the square tube face.
  • Page 32 3. Locate the two 5/16” holes on each vertical face of the U-channels holding the 6x6 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 33: Wall-End Headers Installation

    1.19 WALL-END HEADERS INSTALLATION 1. Lift and place a header between the wall-end post top 1-way elbow and the adjacent post top elbow bracket. 2. Identify the four 5/16” holes which are on the sides of the U-channel in the elbow brackets. 3.
  • Page 34 4. Drive one ¼ 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 opposite end of the header. 6.

  • Page 35: Securing Vertical Posts To The Wall

    1.20 SECURING VERTICAL POSTS TO THE WALL Vertically locate the wall anchor brackets, one above the bottom elbow bracket and one below the top elbow bracket. Vertical location of the wall anchor bracket is flexible. Use the supplied ¼” X 1-1/4” lag screws to secure the wall anchor brackets to the side of the vertical posts.

  • Page 36: Nstalling Deck Board Support Beams

    1.21 INSTALLING DECK BOARD SUPPORT BEAMS 1. Decide on which direction you would like the deck boards to run. Deck support beams run in a perpendicular direction to the deck boards. Support beams should be spaced, approximately, every 24” or less to support the deck boards. Using a pencil or marker, mark the center locations of each beam on the inside face of the floating 6x6s to which you will attach the beams.

  • Page 37: Nstalling Deck Boards

    6. Secure the support beams to brackets using #6 x 1” SS wood screws. Two screws on each side of the Beam Support Bracket are required. 1.22 INSTALLING DECK BOARDS 1. Plan and lay down your deck boards starting in the center of the pergola. Work outward from the center in both directions. Use the thick end of a wood shim as a spacer to leave an 1/8”-1/4”...
  • Page 38 2. When you approach the vertical post corners, create notches in the deck boards ends to fit around the corner post bracket and the gussets. The gussets are 1/8” thick. Make a cut the width of a carbide tipped circular saw blade to create a clearance slot for the corner gussets.
  • Page 39 See image, below, for some decorative suggestions. You can also view other decorative ideas at RioOutdoors.com. Let us know how the construction 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.

  • Page 40: 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 41: 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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