Fypon BAL5X24RL Instructions / Assembly
Contents
1. 12 Balustrade System AN INSTALLATION INSTRUCTIONS D YPON Page 1 of 2 It s How You Finish Check applicable building codes since this procedure may require alterations to meet applicable building code regulations Fypon does not under any circumstances warrant the installation of its products Materials Needed e Ladder e Circular or Hand Saw e Tape Measure e 1 1 8 Drill Bit e Hacksaw or Reciprocating Saw e 1 2 Drill Bit e Exterior Spackling e 5 32 Drill Bit e Pencil e 7 32 Drill Bit e Safety Glasses e Power Drill e Sandpaper e Plumb Bob e Corrosion Resistant Fasteners e Hydraulic Jack e Paint Brush e Phillips Head Driver e Latex Paint e Combination Square e Polyurethane Compatible Adhesive e Zinc based Primer Spray Paint Stee use only e 3 4 Open End Wrench or Adjustable Wrench 1 Initial Layout A Temporarily position newel post bottom sections and mark layout lines on floor surface B Measure the distance between each of the newel post bottom sections and cut respective lengths of railing to be installed While measuring and cutting bottom rails cut matching top rails to be installed in a later step 2 Anchoring Steel Base Plates A Center steel base plates inside layout lines from Step 1A above and anchor each steel base plate to an adequate mounting surface These will anchor the newel posts 3 Installing Bear Claw Brackets A Install 5 16 18 clip nuts on bear claw brackets Position bear claw brackets2. el post top section Align newel post top section onto newel post center section E Fasten the 5 16 18 x 5 hex head cap screws into the bear claw brackets in the top rail and tighten to 75 in lbs torque F Install a 3 8 flat washer a 3 8 lock washer and a 3 8 16 hex nut onto the threaded rod assembly Tighten the entire assembly to 100 in lbs torque G Apply caulk to seam in channels of newel post assembly to prevent moisture infiltration H Apply a 1 4 bead of adhesive to newel post top section and then install newel post top 1 Mouldings such as MLD601 MLD602 MLD610 and MLD611 may be applied to newel post center section as a decorative treatment 8 Wall Installation Optional When working with wall installations fasten the rails to the wall first then assemble away from wall sections Note The fasteners for mounting bear claw brackets to the wall are not included in the rail installation kit A Determine position of baluster bottom rail and mark layout on wall Locate position of center of bear claw brackets on wall Mount bear claw brackets securely to wall fasteners for this are not included in hardware pack B Apply a 1 4 bead of adhesive on the end of baluster bottom rail and position over bear claw brackets and flush with the wall Drill a 7 32 pilot hole from the top of the baluster bottom rail into center of each bear claw bracket Secure with 1 4 20 x 2 flat head self tapping screws provided with bal
3. ewel Posts for Balusters A Install and tighten the two 3 8 16 x 39 threaded rods into the steel base plate assemblies B Install the two steel corner brackets inside the newel post top section using the 10 x 3 4 flat head self tapping screws provided Align diagonally to match threaded rods C Temporarily position balusters on each end of bottom rail Temporarily position top rail and the remaining newel post components to determine height of the newel post If the newel post is too high trim newel to desired height D Trim if required remaining newel post sections to the same height E As in Step 4B lay out and drill the 1 2 holes into each newel post top section where they will contact the top rail Continued on next page Fypon Ltd 1750 Indian Wood Circle Maumee Ohio 43537 1 800 446 3040 www fypon com 12 Balustrade System continued Page 2 of 2 7 Final Assembly A Position the newel post bottom section with the floor layout lines marked in Step 1A Apply a 1 4 bead of adhesive to the channel in newel post bottom section and align newel post center section onto newel post bottom section B Working with one rail section at a time apply a 1 4 bead of adhesive on both ends of each baluster C Position a baluster into each pre drilled hole in the baluster bottom rail assembly Align and cap off with pre drilled top rail assembly D Apply a 1 4 bead of adhesive to baluster top rail ends and to the channel in new
4. flush with the bottom of the rail and predrill 5 32 holes B Fasten bear claw brackets using 12 x 3 4 pan head screws provided Position the screws as close as possible to the front of elongated slots in the bear claw brackets Repeat this step for corresponding top rails 4 Mounting the Bottom Rail A Temporarily thread a 5 16 18 x 5 hex head cap screw into center of the bear claw bracket and record the indicated center line measurements B Transfer the measurements onto the newel post bottom section and drill 1 2 holes in the newel post bottom section The position of these holes will determine the height that the bottom rail will be raised above the mounting surface Note For installations where bottom rail is raised off of mounting surface blocking is recommended with a rail support block RSB4X4X6 every 4 or less C Apply a 1 4 bead of polyurethane compatible adhesive on each end of the bottom rail D Position the bottom rail between the newel post bottom sections and align the 5 16 18 x 5 hex head cap screws with the bear claw brackets Check that the bottom rail is level Tighten 5 16 18 x 5 hex head cap screws to 75 in Ibs torque Repeat Step 4 around the entire balustrade layout E With the bottom rail in place lay out and mark center lines for the balusters Note Check applicable building codes concerning regulations on distance between balusters Drill 1 1 8 holes to 3 deep to accept balusters 6 Preparing N
5. rior exterior grade PVC compatible adhesives sealants and fillers when installing Fypon products Consult the manufacturer s recommendations for your particular climate and the substrate you are installing to If painting is desired a 100 acrylic latex paint with a Light Reflectance Value LRV of 55 or higher must be used Applying paint with an LRV of 54 or lower will void the warranty 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 moulding 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 Fypon Ltd 1750 Indian Wood Circle Maumee Ohio 43537 1 800 446 3040 www fypon com
6. uster rail installation kit C Position and install balusters using the steps described previously in these guidelines Use above procedures to attach top rail General Installation Notes Any adhesives sealants fillers or paint used must be compatible with the material that is being installed see manufacturer s recommendations in the Finishing and Adhesives section below Always use corrosion resistant mechanical nails or screws along with manufacturer s recommended adhesive product when installing all Fypon products This combination provides a secure long lasting bond Countersink all fasteners about s and fill with product compatible filler Exterior installations should be finished using a manufacturer s recommended caulk to prevent water infiltration behind siding windows and doors Some exterior 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 Finishing and Adhesives Polyurethane PUR Fypon polyurethane products are factory primed Depending on product location always use interior exterior grade PUR compatible adhesives sealants and fillers when installing Fypon products Consult the manufacturer s recommendations for your particular climate and the substrate you are installing to Cellular PVC Depending on product location always use inte
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