Installation Guide

www.fypon.com Phone [phone] • 419.445.0116 U.S. and Canada Fax [phone] • 419.445.4440 U.S. and Canada
INSTALLATION GUIDE
35
5", 6" and 7" Balustrade Systems
INSTALLATION INSTRUCTIONS
1. INITIAL LAYOUT
Mark layout lines on floor surface where all PORCH POSTS and NEWEL POSTS
will be located. Allow dimensions for the layout of both NEWEL POSTS and
PORCH POSTS.
Note: This layout is important in order to get accurate measurements for the actual length of each TOP and BOTTOM RAIL.
2. BUILD UP AND ASSEMBLE RAIL SECTIONS
To speed up field installations, build up and assemble the BALUSTRADE RAIL
SECTIONS in a shop setting when possible. Follow up with easy installation between
the supporting posts out on the job site.
A) Using accurate field measurements (taken in Step 1) cut the matching TOP and
BOTTOM RAILS to length for each respective section.
B) Lay out and mark center lines on RAILS. Mark BALUSTER positions then drill holes
to accept BALUSTERS. The diameter of the drilled holes will vary according to the
BALUSTRADE size. Tip: A drill press with standard woodworking drill bits works well
for drilling these holes.
C) Apply a 1/4" bead of urethane base construction adhesive on each end of
BALUSTER. Then insert BALUSTER into the drilled TOP and BOTTOM RAIL.
D) Lay the RAIL ASSEMBLY on a flat surface. Use strap clamps as needed to draw RAIL
ASSEMBLY together. Clamp tightly and allow the adhesive to set up. (This usually takes
a minimum of 12 hours.) As the RAIL ASSEMBLY is drying, before it sets up, make sure it
is square and that the BALUSTERS are square to the RAIL SECTION. Clean off any
excess adhesive with a putty knife before the adhesive sets. Do not handle the newly
assembled RAIL SECTIONS until the adhesive has cured completely. If painting is desired,
a good time to paint the RAIL SECTIONS would be now, before field assembly begins.
3. INSTALL PORCH POSTS
A) The PORCH POST is a load bearing support post. It can be trimmed to various heights
in the top or bottom flat post areas without affecting the integrity of the POST. However,
the PORCH POST has a steel pipe molded into the center which must be cut with a
hack saw or Sawzall
®
reciprocating saw with metal cutting blades.
B) Slide TRIM COLLARS along POST.
C) Install the 2" wide x 1 1/2" x 2" angle brackets as shown in Fig. 3C. Drill 1/8" x 2 1/2" pilot
hole for #14 x 2 1/2" stainless steel flat head screws. (Masonry fasteners not included.)
Then slide TRIM COLLARS over the brackets. Secure with adhesive and trim nails.
A) Determine the required height of the PORCH POST by carefully measuring the distance
from the floor to the bottom of the porch overhang or other structure being supported.
B) Fypon PORCH POST are trimmed for height at the bottom. Transfer the measurement
from Step One, above, marking all the way around the base of the POST. Carefully cut the
polymer shell of the POST using a circular saw or hand saw, being careful to not cut into
the steel reinforcement. Then cut through the steel reinforcement using a hack saw or
power reciprocating saw with a steel cutting blade.
USING CORROSION-RESISTANT FASTENERS AND PL PREMIUM ADHESIVE
Always use corrosion-resistant mechanical fasteners (nails or screws) and PL Premium Adhesive when installing Fypon products. This combination provides a secure, long lasting
bond. Countersink all fasteners about 1/8 inch and fill with exterior grade white spackle. If desired, sand any minor imperfections and topcoat with a quality exterior latex or oil
base paint. Fypon exterior millwork installations should be finished using a quality, exterior grade silicone caulk to prevent water infiltration behind siding, windows and doors.
Some exterior millwork installations, in particular new construction (before siding is applied) may require a J-channel and/or flashing to prevent water infiltration. Installers must
determine which installation technique is best for the specific situation.
IMPORTANT:
Please read these installation guidelines thoroughly before beginning installation. Please note that these guidelines are provided only to assist with the installation of Fypon mouldings
and millwork products. Modified procedures may be required in order to meet specific situations, unique applications and local building codes. The manufacturer does not under any
circumstances warrant the installation of its products. Be sure to wear appropriate protective clothing, gloves and safety glasses when working with any tools. Installer should check
for and relocate all electrical wiring within the proposed installation area, as needed (be sure to disconnect all electric power before working with any electrical wiring and follow all
applicable local electrical codes and safety procedures).
STEP 1
STEP 2B
STEP 2C
STEP 2D
STEP 3A
STEP 3B
STEP 3C
INSTALLATION INSTRUCTIONS CONTINUED ON FOLLOWING PAGE.
FOR PP6X96 ONLY
FOR PP8X96 ONLY