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# Rafter Design — Baldwin Fiberglass Pergolas ## Overview The rafter is the most visible structural member in a pergola. Viewed from below, the rafters define the overhead rhythm of the structure — their spacing, their profile, and above all their tail shape determine whether a pergola reads as refined or ordinary. At Baldwin Pergolas, every rafter is a 2×8 pultruded FRP tube, CNC-machined to precise notch locations and a chosen decorative tail profile, produced on an automated notching line accurate to 0.001 inch. The rafter tail — the exposed decorative end that projects beyond the outer beam — is the signature design element of a Baldwin pergola. Five profiles are available, each with a distinct architectural character. The choice of rafter tail does more to define the personality of a finished pergola than almost any other single decision. ## Key Concepts - Standard rafter section is a 2" × 8" pultruded FRP tube — same profile as the beams - Decorative tail profile appears on the outer exposed end only; the house end or inner end is square-cut - Five standard tail profiles: Windsor, Baldwin, Kensington, Cove, Huntington - Rafters are CNC-notched on their bottom face at each beam location — notches are sized to the beam width - Notch locations are driven by a stepper motor from computer input, accurate to 0.001" - Purlins — 2" × 3" FRP tubes — span between rafters perpendicular to the rafter run - Extended rafters beyond 21 feet in depth use a CNC-machined fiberglass joiner plate system --- ## Rafter Section and Orientation Baldwin rafters are 2-inch wide by 8-inch tall pultruded FRP rectangular tube sections, standing upright on their 2-inch face. This orientation — the 8-inch dimension vertical — maximizes bending stiffness in the direction of load. The same material and geometry as the beams means consistent visual profile throughout the overhead structure: beams and rafters share the same crisp, clean 2-inch face width when viewed from any angle. The hollow tube section serves a structural and functional dual purpose. Structurally, it provides excellent bending stiffness for the spans involved. Functionally, the hollow interior is a wire chase — electrical wiring from the distribution box runs through the beams and transitions into the rafters through watertight fittings, routing power to fan blocks, overhead outlets, and lighting points completely out of sight. --- ## The Automated Notching Line Every Baldwin rafter is notched on its bottom face at each beam crossing location. These notches allow the rafter to seat over the beam, creating a positive mechanical bearing that transfers load cleanly and locks the rafter in position laterally. ### How It Works Notch locations for every project are calculated from the design layout and fed digitally to the notching bench. A stepper motor drives the rafter along the bench, advancing it precisely to each notch location in sequence. The cutter is fixed; the r
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