Installation and Technical Manual Dura Pergola€¦ · Whilst each style and design of Dura outdoor...

Installation and Technical Manual

Dura Pergola

Dura Pergola, Dura Veranda and Dura Cabana From shade to structure, pergolas are a great way to add beauty and function to any outdoor space. Composite timber pergolas have a unique formula that provides an attractive long lasting material that is strong, durable and weathers extremely well. Striking yet with a traditional appearance, Dura Pergolas require little maintenance and will not rot or splinter. The material is UV stabilised to withstand harsh climates and is eco-friendly with an 87% recycled material content. Dura Pergolas are easy to install, but for the very best results we would always recommend that a professional contractor is appointed, preferably with previous experience erecting pergolas. If you require any further information or support, please visit www.duracomposites.com or call us on +44 (0)1255 423601 where one of our knowledgeable staff will be happy to help.

08 Fall

Installation and Technical Manual – Dura Pergola September 2016

Dura Pergola, Dura Cabana and Dura Veranda: Which Product Do I Need?

Pergolas, Cabanas and Verandas from Dura Composites are attractive outdoor structures made from composite timber, an immensely versatile material which combines the traditional appearance of timber with the durability and resilience of an engineered composite. Dura Pergolas, Cabanas and Verandas require no painting and staining, will not rot and are therefore designed to offer a low life cycle cost thanks to their low maintenance requirements and long life expectancy. Whilst each style and design of Dura outdoor structure has its own unique advantages, the best fit for your outdoor space will depend on your preferences, your available space and your budget. Dura Pergolas Dura Pergolas are freestanding structures with an open roof that is supported by columns or posts. A pergola may be used to cover a walkway or to provide a place to sit and socialise outdoors as well as year round protection from the sun. Dura Pergolas are available in a wide variety of sizes, to suit every style of property.

Dura Cabanas Dura Cabanas are permanent free standing shade structures with one open side placed on a practical raised decking area. Cabanas offer additional privacy and provide a tranquil retreat from the outside world. Dura Cabanas deliver a real impact and are ideally suited to beachfront or poolside environments. Dura Verandas Dura Verandas are shade structures which are attached to the home, whether at the front back, or side. Verandas are ideal places for spending some time in the fresh air without having to venture far from the house. A veranda installed along one or more sides of your home can lower temperatures inside the building and lessen your reliance on air conditioners and fans, saving you electricity and reducing your carbon footprint.

2


Dura Pergola – Freestanding Examples

Example Sample Design/Colours End Cap

Unsupported Span

Slat Spacing

(mm) FSC Availability

Four Post WPC Pergola

Yes 3 metres or

less

260

Optional

Four Post WPC Pergola

with GRP reinforcement

Yes

Between 3 metres and 5.4 metres

260

Optional

Six Post WPC Pergola

Yes Up to 6 metres

260

Optional

Six Post WPC Pergola with

GRP reinforcement

Yes

Between 5.4 and 10.8 metres

260

Optional

3

Teak and Charcoal

Teak and Charcoal

Teak and Charcoal

Teak and Charcoal


Dura Veranda – Examples

Example Sample Design/Colours End Cap

Unsupported Span

Slat Spacing

(mm)

FSC Availability

Two Post WPC Dura Veranda

Can be specified with either longitudinal or

cross slats

(longitudinal version illustrated)

Yes 3 metres or

less

260

Optional

Two Post WPC Dura Veranda



cross slats


Yes

Between 3 metres and 5.4 metres

260

Optional

Three Post WPC Dura Veranda


cross slats


Yes Up to 6 metres

260

Optional

Three Post WPC Dura Veranda



cross slats


Yes

Between 5.4 and 10.8 metres

260

Optional

Teak and Charcoal

Teak and Charcoal

Teak and Charcoal

Teak and Charcoal

4


Contents 1. Product Selector 2. Preparation and Materials 3. Installation

4. Maintenance and Cleaning Guide 5. Technical Specifications

3

3

5


1. Product Selector

Composite timber Dura Pergolas have a unique formula that provides the very best of both worlds, a long lasting material that is strong, durable and weathers extremely well. Composite timber Dura Pergolas are striking yet have traditional appearance, require little maintenance and will not splinter. The material is UV stabilised and above all eco-friendly with 87% recycled material content. The following components can be used to create your Dura Pergola, Veranda or Cabana:

PROFILE DIMENSIONS (mm)

Colour

WEIGHT (KG per linear metre unless stated)

Item Width Length Height

Vertical Column Support (200x200)

200 3000 200 Charcoal,

Teak 17.43

Main Transverse Beam (300x100)

100 4500 300 Charcoal,

Teak 11.03

Upper Roof Slat (160x60)

60 4500 160 Charcoal,

Teak 4.59

End Cap Type 160

60 n/a 160 Charcoal,

Teak 2.61

TOTAL

End Cap Type 300

100 n/a 300 Charcoal,

Teak 8.61

TOTAL

6


Base Bracket (Domestic Applications)

300 300 103

Metal Finish as standard. Powder coated colours by special order

N/A

Base Bracket (Commercial Applications)

180 180 600 Charcoal, Teak

N/A

Flat End Cap 300x100


N/A

Flat End Cap 160x60


N/A

300x100 Top and Bottom Section Insert

(83.5x59 and 64x37) Sold as Pair

(A) 64 (B) 83.5

1200 (A) 37 (B) 59

Charcoal, Teak

(a) 4.63 TOTAL (b) 4.02 TOTAL

300x100 Middle Section Insert

(74x83.5) Sold as Pair

74 1200 83.5 Charcoal, Teak

10.26 TOTAL

160x60 End Cap Insert (46x32) Sold Individually


2.51 TOTAL

A:

B:


Pergolas: A Typical Example Using Dura Composites Profiles

Front View

Side View

8

7


Verandas: A Typical Example Using Dura Composites Profiles Front View

Side View

9


2. Site Preparation and Materials

Dura Pergolas are renowned for their simplicity and ease of installation. However, to ensure long-term performance and to preserve your warranty, installations MUST be carried out by experienced professionals. Dura Composites also recommends that all commercially applied pergola or veranda designs be approved by a licensed architect or engineer before any installation takes place in case of safety issues.

Safety First Keep children away from the work area until the job has been completed and tools have

been stored safely.

Refer to the operator’s manuals for safety guides for all power tools being used.

When handling Dura Pergola timber composites, always wear gloves with additional eye protection and work in a well ventilated area.

Do not burn composite timber off cuts. Dispose of them safely as refuse.

Wear eye protection when pressure washing or scrubbing.

Please ensure that your proposed design meets any relevant local building codes and regulations before you begin the installation.

10


Tools Required

Assembly Day Tips

Complete site preparation and foundation construction before unpacking parts and beginning assembly.

DO NOT attempt to assemble on a day with strong winds.

Allow materials to acclimatise to site temperature for approximately 24 hours before beginning installation.

Set aside appropriate amount of time to completely assemble your pergola.

Make sure you have assistance nearby to lift and secure parts into place.

Wear light duty work gloves while assembling pergola.

Tape Measure

Square

Level

Mallet

Chalk Line

Ladder

Jigsaw Socket Set Router

Hammer Drill

Circular Saw Drill Driver

11


Site Preparation To prepare your site for a Dura Pergola, Veranda or Cabana, you should follow these steps:

1. Before beginning your foundation and erecting the pergola, you should ensure that your proposed design meets any relevant local building codes or planning regulations that may apply.

2. Please ensure that you consult your local representative to determine whether your foundations are suitable for the scope of the project.

3. Before commencing any digging you should check with your local utility provider to determine whether there are any buried cables or pipes that may affect your Pergola installation.

4. If installing a Veranda, please ensure there are no live wires or cabling on the wall before you

fix your horizontal support beam.

5. The recommended foundation for a Dura Pergola is a four inch thick concrete slab or suitable concrete piers. Foundation surfaces must be solid and flat.

6. If required, clear & level the site where your Dura Pergola will be positioned

7. Measure the area of ground where your Dura Pergola is to be situated, identify where the posts will be and mark their exact position. Check that any windows or doors will not be impeded by the pergola once it is assembled.

8. When preparing the site for installation:

The ground should slope away from the foundation area to provide suitable drainage.

The foundation surface must be flat and level.

Follow local building codes to ensure a proper vapour barrier is used.

12


Dura Composites Materials

End Caps Type 160 (Solid and Flat)

Upper Roof Slat (160x60)

End Caps Type 300 (Solid and Flat) Main Transverse Beam (300x100)

Vertical Column Support (200x200) Fixing detail showing nvelope bracket attached to Upper Roof Slat

13

160x60

300x100


Choosing Your Location

If required, clear & level the site where your Dura Pergola will be positioned

Measure the area of ground where your Dura Pergola is to be situated, identify where the posts will be and mark their exact position

Check that there are no underlying utilities (e.g. water/gas/drainage or sewerage pipes or electricity cables) that could be damaged

Check that any windows or doors will not be impeded by the pergola once it is assembled

14


3. Installation Column Support Installation for Commercial Use The install of the 200x200 Column Support in a commercial setting is achieved by using a manufactured steel base plate that has a height of 500mm (as picture below).

15

Plan View of post bracket


Column Support Installation for Domestic Use The Base Plate in a domestic setting is a thick stainless steel plate, cut and folded into the correct position, which the Support Column is fixed to. The Base Plate is fixed to the substrate using M12 90mm or longer anchor bolts.

15

Plan View of post bracket

16


Installation Steps

1. Free Standing Pergola Installation Preparation of trim inserts (where applicable)

300x100 Main Transverse Beam

Insert A goes inside Insert B before

they are inserted together into Top

and Bottom of the the Main

Transverse Beam.

The two middle sections are inserted

into the centre of the Main

Transverse Beam.

160x60 Upper Roof Slat

All Inserts are the same size as the

holes and are inserted where/when

required.

1:

2:

17


Setting out your Vertical Column Supports

Choose from either domestic post

(Figure A1) or commercial post

(Figure B1) bracket options

depending on the desired location of

your intended application.

Both commercial and domestic post

options rely on Rawl-Plug or

equivalent anchor fixings through the

lower bracket flange direct into a pre

cast concrete pile or substrate.

Locate your column bracket into the

correct position using a tape rule or

temporary jig.

Tip: By measuring diagonally across opposing corners you will ensure that your support columns are always square to one another.

Fix all brackets in place ready to add

your support columns over or into

your ground bracket depending on

whether your Pergola is for domestic

(Figure A2) or commercial (Figure

B2) use.

A1:

A2:

B1:

B2:

TIP:

16

18


Cutting your Vertical Column Support posts

Cut the post to desired length

Cut slots into the top of each post so that

the Main Transverse Beam (Figure A)

(and side beams if required as shown in

Figure B) can fit snugly within the slots.

Once all posts are cut to length fit them

over or into your pre-fixed ground

brackets and screw into place. Figure C

shows the commercial post option for

reference.

Installation & preparation of the Main Transverse Beams (300mm x 100mm)

Figure A: Cut your Main Transverse Beams to

the desired length, ensuring they are all equal

Figure B: On a workbench or trestles (for ease

of assembly) place both opposing Main

Transverse Beams alongside each other. With a

set square, measure and pencil mark on top of

both beams where the overhead slats will be

located.

Figure C: Fit your nvelope brackets to the top of

both support beams ready to receive your Upper

Roof Slats later in the assembly process.

Figure D: Lift all Main Transverse Beams into

place and lock into the top of all Dura Pergola

Vertical Column Support posts.

A: B: C:

A. B.

C. D.

19


Installation of Upper Roof Slats

Figure A: One by one lift and insert each

overhead slat into place and screw into position

Installation of Solid Flat End Caps

Once all beams and slats are securely in

place you can fit the end caps using

either method statement illustrated.

METHOD ONE:

METHOD TWO:

A.

1. Push inserts into top and bottom hollows until flush.

2. Use suitable adhesive to fix End Cap.

3. Sand in directions shown to finish.

17

20


Continued from previous page. Installation of End Cap Type 300 and Type 160 are illustrated opposite.

1. Use suitable adhesive.

2. Slide End Cap into position.

3. Sand in direction shown.

21


How to join Main Transverse Beams

On occasion you may

be required to join Main

Transverse Beam

lengths together. For

this purpose we have

jointer trim insert

profiles that can be

inserted into the hollow

profile and remain

concealed once the two

lengths are pushed

together.

Please note that we do

NOT recommend

extension of the 160mm

Upper Roof Slats as

this profile is less sturdy

and therefore not

suitable for extension.

1. Slide Trim Inserts half way (200mm) into top and bottom hollow of one joint.

2. Slide other side of joint into place.

3. Slide one side of joint to meet other joint (centre of inserts as below Cross Section).

22


1. Veranda Installation (a Pergola structure attached to a building) Setting out your Vertical Column Supports

Choose from either domestic post (Figure

A1) or commercial post (Figure B1)

options depending on the desired location

of your intended application.

Both domestic and commercial post

options rely on Rawl-Plug or equivalent

anchor fixings through the lower bracket

flange direct into a pre cast concrete pile

or substrate.

Locate your column bracket into the

correct position using a tape rule or

temporary jig.

Fix all brackets in place ready to add your

support columns over or into your ground

bracket sleeve depending on whether

your Veranda is for domestic (Figure A2)

or commercial (Figure B2) use.

A1:

A2:

B1:

B2:

23


Cutting your Vertical Column Support posts

Cut the post to desired length

Cut slots into the top of each post so that

the Main Transverse Beam (Figure A)

(and side beams if required as shown in

Figure B) can fit snugly within the slots.

Once all posts are cut to length fit them

over or into your pre-fixed ground

brackets and screw into place. Figure C

shows the commercial post option for

reference.

Installation & preparation of the Main Transverse Beams (300mm x 100mm) Option A: Slats mounted along Veranda ( transverse to wall - 90°)

Figure A: Cut both wall mounted & front facing

Main Transverse Beams to desired length,

ensuring they are equal. (If using additional side

view beams, also cut these to desired length and

put to one side ready for install later in the

assembly process).

Figure B: On a workbench or waist high trestles

(for ease of assembly) place both the wall & front

facing support beams alongside each other. With

a set square, measure and pencil mark on top of

both beams where the Upper Roof Slats will be

located.

Figure C: Fit your nvelope brackets to the top of

both support beams ready to receive your Upper

Roof Slats later in the assembly process.

Figure D: Lift front facing Main Transverse

Beam into place and lock into top of all pergola

support posts.

A. B.

C. D.

A. B. C.

24

Slats mounted transverse to wall 90°


Support and fit wall-mounted Main

Transverse Beam to wall using the

following method statement:

Step 1.

Step 2.

Step 4.

25

Step 3.


Installation & preparation of the Main Transverse Beams (300mm x 100mm) Option B/ Slats mounted across the Veranda (parallel to wall) Figure A: Cut both wall mounted & front

facing Main Transverse Beams to desired

length and put to one side ready for install

later in the assembly. Cut both side view

transverse beams to desired length, ensuring

they are equal

Figure B: On a workbench or waist high

trestles (for ease of assembly) place both

side support beams alongside each other.

With a set square, measure and pencil mark

on top of both beams where the overhead

slats will be located.

Figure C: Fit your nvelope brackets to the top

of both side support beams ready to receive

your overhead slats later in the assembly

process.

Figure D: Lift front facing and side view Main

Transverse Beams into place and lock into

top of all support posts.

Figure E: Support and fit wall mounted Main

Transverse Beam to the vertical surface

using method statement as illustrated on next

page.

A. B.

C. D.

E.

26

Slats mounted parallel to wall


Installation of Upper Roof Slats

One by one lift and insert each upper

roof slat into place and screw into

position

Step 1. Step 3.

Step 2.

Step 4.

A.

27

Step 3.


Installation of Solid Flat End Caps

Once all beams and slats are securely

in place you can fit the end caps using

either method statement illustrated.

METHOD ONE:

1. Push inserts into top and bottom hollows until flush.



26


METHOD TWO:

1. Use suitable adhesive.


29



How to join Main Transverse Beams

On occasion you may

be required to join

Main Transverse

Beam lengths

together. For this

purpose we have

jointer trim insert

profiles that can be

inserted into the

hollow profile and

remain concealed

once the two lengths

are pushed together.

Please note that we

do NOT recommend

extension of the

160mm Upper Roof

Slats as this profile is

less sturdy and

therefore not suitable

for extension.

1. Slide Trim Inserts half way (200mm) into top and bottom hollow of one joint.

2. Slide other side of joint into place.

3. Slide one side of joint to meet other joint (centre of inserts as below Cross Section).

30


4. Maintenance and Cleaning Guide Dura Pergola Care and Cleaning Information Dura Pergolas require no oiling, sanding or staining throughout their lifetime, however you may need to clean your pergola occasionally to keep it looking at its best. Here are the solutions to common cleaning issues.

General General Dirt and Debris Spray with a hose to remove surface debris. Use warm soapy water and a soft bristled brush to clear dirt and/or debris from grooves/contours. Pressure wash to remove more stubborn stains. Oil/Grease/Food/Drink Remove and mop as soon as possible—spray with a hose and use warm soapy water and a soft bristled brush. Pressure wash for more stubborn stains. Any surface stain that has been absorbed can be also easily removed with light, progressive sanding using coarse grit (22-60 grit) sandpaper. Do not sand more than 0.5mm into the surface. Tannins from Spillages/Water Spots Tannins will naturally be released from long lying material/vegetation etc. This should be sprayed with a hose and brushed off using a soft bristled brush and soapy water. Pressure wash for more stubborn stains. Any surface stain that has been absorbed can be removed through light sanding with a coarse sandpaper (22-60 grit). Do not sand over 0.5mm into the surface. Marking For Cutting Always use a non-permanent marker such as baby powder/dust-off marking chalk or plumb line wherever possible. Rust Stains and Engrained Dirt Cleaning products containing Oxalic or Phosphoric acid can be used. Do not bleach, as this will lighten the product. With any cleaning product, test it on a small inconspicuous area first, following manufacturer’s instructions. Ice & Snow Use a plastic shovel or broom to remove snow. Use rock salt or calcium chloride to melt frozen precipitation/ice.

31


Cleaning Techniques Once you have completed the install of your Dura Pergola, we advise that the finished product is either washed down thoroughly with a yard broom or pressure washed to ensure that a good clean surface is ready for you to enjoy. Basic Cleaning Spray with hose to remove surface debris. Use warm soapy water and a soft bristled brush to clear dirt and/or debris from grooves/contours. Pressure Washing Pressure washers up to 1500psi may be used to maintain cleanliness of your Dura Pergola. In order to prevent any damage, always keep the pressure washer nozzle at least 15cm (6 inches) from the surface, and avoid concentrated spraying on one area for more than 3 seconds. Use of a pressure washer in this manner will not shorten the life of the material. Sanding Sanding should be used only when basic cleaning or pressure washing fail to remove stubborn stains. Sanding should only be used for very stubborn scuffs and/or marks. Always use coarse grade Emery paper (22-60 grit). Sanding should be carried out lightly and progressively harder if necessary to a maximum of 0.5mm surface depth. Most marks blend naturally after 12 weeks weathering.

Product Disposal For both domestic and commercial use you should safely dispose of any offcuts as per local laws. Do not burn. Treat as construction waste. If unsure always consult your local governing body/ council.

32


5. Technical Specifications 1. Definition

Range of Pergola, Veranda and Cabana shading and landscaping products produced from Wood Polymer Composite (WPC) which is manufactured by an extrusion process using a mix of recycled plastics and hardwood wastes with various bespoke additives. 1.1 Applications

WPC is an immensely versatile material which combines the traditional appearance of natural timber with the durability and resilience of an engineered composite. Given it can be produced in a virtually unlimited range of colours and huge range of profile sections, the engineer can create a product or component suitable for many landscaping and shading applications. 1.2 Benefits

Natural appearance, long life, light weight, low maintenance, no warping, no rotting, no trip hazards, corrosion/electrical resistance, low tooling/installation cost, long service life, no splintering, UV stable. WPC products compete very favourably on a life cycle cost basis versus traditional materials due to their limited maintenance needs and long life span. 2. Raw Materials

WPC is manufactured using a composition comprising high density polyethylene, hardwood waste plus a number of specialist additives such as coupling agents, inhibitors and stabilisers. The exact composition used for Dura Composites products is confidential. It is this highly developed, precise composition that enables the composite to deliver such strength and durability. 3. Product

Pergolas, Cabanas and Verandas from Dura Composites are attractive outdoor structures made from composite timber, an immensely versatile material which combines the traditional appearance of timber with the durability and resilience of an engineered composite. Dura Pergolas, Cabanas and Verandas require no painting and staining, will not rot and are therefore designed to offer a low life cycle cost thanks to their low maintenance requirements and long life expectancy. Whilst each style and design of Dura outdoor structure has its own unique advantages, the best fit for your outdoor space will depend on your preferences, your available space and your budget.

33


3.1 Manufacturing Tolerances

Width +1mm -1mm Thickness +1mm -1mm Length +3mm -3mm 3.3 Colours Dura Pergola products are available in Teak and Charcoal colours as standard, to suit most project needs. It is possible to produce Dura Pergola in bespoke colours subject to minimum volumes and extended lead times. Please ask for details. 3.4 Fire Certificate Standard composition reaches Class Dfl-S1 – EN13501 Standards Optional Fire Retardant Composition reaches Class Bfl-S1 – EN13501 Standards

4. Safety Data Sheet

This section provides data for protection against substances hazardous to health.

4.1 Material Identification and Use Chemical Name: Wood Polymer Composite Common Name: WPC, Composite Timber Product Identification: Dura Pergola

Uses: Residential/Commercial areas requiring shading structures

4.2 Composition High Density polyethylene, Hardwood waste materials from industry, coupling agents, UV stabilisers, mould inhibitors. Components are extruded through die, heated and cured.

4.3 Hazard Identification None by contact. Dust produced by cutting or grinding can penetrate pores and skin causing itching. Avoid breathing dust, skin contact or dust inhalation when cutting. People with a condition that could be aggravated by dust should avoid cutting or grinding. First Aid procedure: Skin – shower with water and soap. Eyes – flush with sterile eye wash solution.

34


4.4 Product Appearance

Solid or hollow profile sections cut to specified lengths. Wood odour. Not soluble in water. Standard colours Teak/Charcoal.

4.5 Fire Fighting Measures Standard extinguishing equipment, water, foam, A, B or C fire extinguishers. Produces black smoke while burning, carbon particles. Use air respirator.

4.6 Waste Disposal Product is not considered a hazardous waste. Abide by local laws and procedures.

4.7 Handling/Cutting Wear masks and goggles when cutting or grinding. Cover exposed parts of the body. Wear gloves when moving or lifting. Use standard wood working equipment & tolls for cutting. Avoid direct fire source.

5. Product Warranty 10 year limited warranty, further details available on request.


Notes:





Head Office Dura Composites Ltd Dura House, Telford Road, Clacton-on-Sea Essex CO15 4LP United Kingdom Tel: +44 (0)1255 423601 Fax: +44 (0)1255 435426 www.duracomposites.com [email protected] For further information, please do not hesitate to call us. Please note that every effort has been made to ensure that the information in this publication is correct at the time of publishing. Dura Composites Ltd. assumes no responsibility or liability for typographical errors or omissions or for any misinterpretation of the information within this publication and reserves the right to change without notice.

Date post:	20-Aug-2020
Category:	Documents
Upload:	others
View:	2 times
Download:	0 times

Installation and Technical Manual Dura Pergola€¦ · Whilst each style and design of Dura outdoor...

Documents