How do I assemble a Pole Pergola using your Redwood Poles?
Sunday, March 22nd, 2009Do you give any detailed directions on pergola assembly? Such as where chainsaw cuts are needed, how to attach the different poles, how to set the pole on top of a cement base, and any type of sealant?
A Pole Pergola is relatively simple to build. You will need a bit of muscle to put it together, but it’s healthy fun work. I would buy at least one extra pole in each size to make sure you have everything beforehand. When we build them locally, we have always cut at least one to the wrong size or placed a notch in the wrong place. And, we almost always make at least minor design changes as the structure starts to take shape. What you don’t want happening is having to email us a month from now to ship you ONE more post cross country.
We have installed about a dozen pole pergolas in California over the past couple years for customers that didn’t want to tackle it. We build them using just a few tools: a small chainsaw to resize and notch the posts, a drill to pre-drill the holes where the lag bolts will be screwed in, a ratchet for the lag bolts, a couple ladders, and a level to make sure everything is straight.
If you follow a few simple steps, you can have a beautiful Redwood Pole Pergola that will last for years!
Here are a few pointers we’ve picked up that will save you time and make the structures last a couple decades at least:
If the pergola is going on undeveloped ground, dig holes a couple feet deep (or below your local frost-line). You can use sonotubing about 8 inches wide or just dig a hole about 10” wide or so and add metal and rebar. Place a metal anchor (like a Simpson Tie brand anchor available at any hardware store in dozens of sizes) about two inches above ground level to dry into the concrete pour. A day after the concrete pour you can attach your posts to these metal anchors with lag bolts.
Make sure your corners are squared before pouring concrete. To square your corners, make sure the diagonals across to each corner are identical in length (or at least to a ¼” difference).
To maximize the life of these beautiful rustic pole pergolas, make sure to elevate the posts a couple inches off the ground (by pouring the concrete that way). This will keep the posts from absorbing constant moisture from the ground and you’ll significantly increase their life. Another thing to do is to seal up all the pole ends thoroughly. Use oil-based paint in a color that is closest to the natural wood color so it will blend in and barely be noticeable. Add 2 or 3 coats to all the ends to seal them up as much as possible. Take extra time to do this to the ones that will be facing down at ground level.
You’ll also need at least one helper with a good back to help hoist the poles in place and basic chainsaw operation and safety knowledge (yes, gloves and a helmet are excellent ideas!). When you are putting up the first pieces, you may need a second helper for a few minutes to hold things in place.
Now the real fun begins. Notch into the bark and a bit into the wood where the poles will meet to “lock” them together and to make the lag bolt go from wood to wood and not from bark to bark. Each spot where a pole meets another pole should be notched this way. Then drill through and attach a lag bolt. We usually use 8-inch log galvanized lag bolts. 3/8” thick is usually enough. As you lay out the poles, notice they all have taper of approximately 1 inch in diameter per 6 to 8 ft. This is the natural shape of the young trees. To compensate for this place the fat ends of the poles in alternating directions—one fat end followed by one thin end followed by one fat (per side), etc.
Other than that, be safe and have fun with it. A tiny chainsaw is more than sufficient to do the work. No need for a $500 saw—a $100 chainsaw will do the job fine.
