PROJECT BUILD THE PERGOLA
Gather your supplies
Wall plate 140 x 45mm H3 treated pine
Posts 90 x 90 H4 treated pine
Beam 190 x 45mm H3 treated pine
ers and blocking 140 x 45mm H3 treated pine
Fascia 230 x 18mm primed treated pine
Gu er 100mm quad gu er, stop ends, brackets, downpipe outlet and 100 x 50mm downpipe
Roofing Colorbond Steel Trimdek roof sheets and custom-fabricated barge cappings and flashings in Monument
Ceiling Lining Hardiegroove fibre cement sheets
You’ll also need Post-hole digger; spirit level; 125 and 100mm ba en screws for treated pine; timber for bracing; clamps; circular saw; stringline; sliding bevel; builders square; concrete mix; crowbar; combination square; framing nail gun and nails; chalkline; metal strapping; tensioning clips; timber connector nails; Multi-grip connectors; sarking; foil clips; galvanised flat head nails; pop rivets; pop rivet gun; clear silicone; tinsnips; wide vice grips; 50mm roofing screws; hired panel lier; fibre cement screws; angle grinder fi ed with a diamond cu ing blade; dust mask; acrylic gap filler; exterior wood pu y; sandpaper; exterior paint; painting gear
For you to note
Check with your local council on pergola size and position regulations, before you start building.
STEP 1 Determine positions of posts along the front of the pergola. Li pavers and dig 800mm deep holes at post positions using a post-hole digger.
STEP 2 Cut wall plate to go along extent of your pergola. Determine height of wall plate, which here allows the roofing to fit under the fascia on the house. Hold against the wall, make level and screw into the wall studs using 125mm ba en screws. Use two screws per stud. Use masonry anchors for brick walls.
STEP 3 Sit uncut posts into holes at each end of pergola, make plumb and temporarily brace. Mark level of top of beam on post, which will also be top of post. Allow at least 50mm of fall on the roof for every metre it spans.
STEP 4 Remove post and use a circular saw to cut posts to length then cut a 140mm long and 45mm deep rebate in the top of the posts. Reposition posts in holes so rebates face inwards, make plumb and brace again.
STEP 5 Sit beam in rebates on posts, leaving it long in case you need to adjust position of the ra ers along it. Make sure it is level, adjusting the length of the posts if necessary. Clamp to hold.
STEP 6 To get the angle to cut on the ends of the ra ers, run a stringline between the top of the beam and the wall plate. Set a sliding bevel to the angle where the stringline meets the beam and plate then transfer this to the ra er. Cut to length.
STEP 7 Li ra er in position at end of pergola, buing the ends into the wall plate and the beam. Screw in position to hold using 100mm baen screws. Check your pergola is square by using builders square in the corner where the ra er meets the beam. If building a pergola that is open on 3 sides, measure diagonals to check they are the same. Adjust position of posts and ra er on beam as required.
STEP 8 To make sure beam is straight, run a stringline along the top corner from end to end. Cut and fit a ra er into the centre of the pergola so the beam meets the stringline.
STEP 9 Run a stringline between the boom of the end posts then cut and fit intermediate posts along the beam so they meet the stringline. Make sure they are plumb then screw all posts into the beam.
STEP 10 Concrete posts in position using a crowbar to make sure the concrete is thoroughly mixed. Leave to set.
STEP 11 Along faces of beam and wall plate, mark out positions of ra ers using a combination square. Space ra ers about 600mm apart. Also position ra ers so that the edges of the sheets that will line the underside of the pergola will sit on the centre of a ra er, installing extra ra ers if required. Nail to hold and then screw to beam and wall plate using baen screws.
STEP 12 Along underside of ra ers, use a chalkline to mark position of blocking that fits between the ra ers. Position blocking so an edge of the ceiling lining will sit along the centre of the blocking. Cut blocking and nail in position so it is in a straight line. Before fiing last blocking piece, run a stringline along the end ra er to ensure it is straight, cuing the blocking to suit.
STEP 13 Run metal strapping diagonally across the top of ra ers to brace the structure. Nail at each end then use tensioning clips to make it tight. Nail through strapping into ra ers using timber connector nails.
STEP 14 At junction between ra ers and the wall plate and beam, aach Multi-grip connectors, nailing into both members with connector nails.
STEP 15 Roll out sarking across top of ra ers. Start at boom of roof, allowing the sarking to overhang the outside of the posts by about 70mm. Hold sarking in place using foil clips. Work your way up the roof, overlapping the sarking as you go.
STEP 16 Cut fascia to fit along front and side of pergola. Cut on a 45-degree angle at the corners to form a mitred join and to width so it will overhang the boom of the beam by 20mm. Where the fascia spans between the posts, nail blocks to the beam to provide something solid to nail the fascia to. STEP 17 Along fascia use a chalkline to mark out for the boom of the guer brackets. Make the guer fall a minimum of 2mm for every metre of length, although a lile more is beer. Nail brackets to fascia with flat heads nails, spacing them about a metre apart.
STEP 18 Fix stop ends to guer using pop rivets. Drill holes for rivets through the guer into the stop ends then insert rivets and
tighten using a pop rivet gun. Smear silicone around the inside of the gu er to seal the join.
STEP 19 Cut hole for the downpipe outlet in the bo om of the gu er near the downhill end. Sit the outlet upside down on the inside of the gu er and trace the inside of the
outlet on it. Drill a large hole to allow access for your tinsnips, then cut out. Sit outlet inside then pop rivet and silicone as you did for the stop end.
STEP 20 Sit gu er inside brackets on fascia. Bend spigots on top of the brackets down over the gu er to hold it in place. STEP 21 Using wide vice grips, bend up the back end of the trays in the roofing to stop water overflowing the top edge of the roofing. STEP 22 Li roofing onto pergola so it overhangs into gu er by 50mm and is square to pergola. Screw through ribs of roofing into beam and rows of blocking between the raers using roofing screws.
STEP 23 Measure up roof for barge capping to cover the join where the roofing meets the side of the pergola and also flashings that will cover the join where the roofing meets the house to prevent water entry there. Have these elements fabricated by your roofing supplier. Screw through capping and flashing into ribs of roofing and silicone where these elements meet to prevent water entry.
STEP 24 Have your electrician run cables for the lighting and any other electrical elements.
STEP 25 Using a hired panel lier, li ceiling sheets into position on underside of raers. Screw sheets in place using fibre cement screws. To cut sheets to fit, use an angle grinder fi ed with a diamond cu ing blade or a circular saw with a fibre cement cu ing blade. Make sure you wear a dust mask while doing this.
STEP 26 Fill gaps around your pergola with an acrylic gap filler. Fill nail holes using an exterior wood pu y and sand smooth. Apply 2 coats of exterior paint to pergola and ceiling, allowing it to dry aer each coat.
STEP 27 Get your electrician back to install light fi ings.