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# The Baldwin Distribution Box — Structural Junction and Electrical Hub ## Overview At the top of every Baldwin Pergolas column sits a component that does three jobs simultaneously: it anchors the column to its footing via a single threaded rod, it receives both structural beams with twelve fasteners through keystones and crush blocks, and it serves as the electrical distribution point for the entire pergola. Baldwin calls this the distribution box — or D-box — and it is one of the most carefully engineered details in the system. ## Key Concepts - The D-box is a 5×5" FRP extrusion, 8.75" tall, 1/4" wall thickness - A 3/8" steel cap plate and one threaded rod nut anchors the column, the structure, and the D-box lid simultaneously - Both beams connect through keystones with internal crush blocks — 6 screws per beam, 12 total per column - All wiring routes from the footing through the hollow column into the D-box, then distributes to every electrical point in the pergola - Watertight fittings at beam tops maintain code compliance where wire exits structural members - All connections are factory color-coded and labeled for clean field installation --- ## Physical Description | Dimension | Value | |---|---| | Width × depth | 5" × 5" | | Wall thickness | 1/4" (0.250") | | Height | 8.75" | | Cap plate | 3/8" steel plate | | Beam height (for reference) | 8.00" | The 8.75" D-box stands 3/4" taller than the 8" beams. This clearance allows the cap plate to sit above beam tops, providing geometry for the fastener connections and ensuring positive bearing of beams against the box faces. --- ## Structural Connection — One Nut, Three Functions ### The Threaded Rod Anchor A threaded rod runs from the concrete footing, up through the hollow FRP column, and terminates at the 3/8" steel cap plate. One nut simultaneously: 1. **Holds the column down** — clamping the column base to the footing anchor plate 2. **Holds the pergola structure down** — the tensioned rod ties the entire column assembly to the foundation 3. **Holds the D-box lid down** — the cap plate is the structural lid of the distribution box ### Beam-to-D-Box Connection Both beams connect to the D-box through keystones and crush blocks: - **Keystones** — precision-machined FRP fittings that interlock with the beam end and transfer load into the D-box wall - **Crush blocks** — installed inside the hollow FRP beam at the connection point, preventing tube wall crushing under screw clamping force - **6 screws per beam** — through keystone, through beam wall, through crush block, into D-box wall - **12 screws total** per column This connection is deliberately overbuilt. The fastener count and geometry provide significant lateral stiffness at the beam-to-column joint — resistance to racking forces from wind that a simpler connection would not provide. > At the top of each column, a structural box receives both beams with 12 fasteners through keystones and crush blo
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