Installation Guide

TM
Fypon, Ltd. 1750 Indian Wood Circle Maumee, Ohio 43537 1.800.446.3040 www.fypon.com
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5” & 7” Balustrade Systems
INSTALLATION INSTRUCTIONS
Materials Needed
• Ladder
• TapeMeasure
• HacksaworReciprocatingSaw
• SteelCuttingBlade
• ExteriorSpackling
• Pencil
• SafetyGlasses
• Sandpaper
• CorrosionResistantFasteners
• PaintBrush
• LatexPaint
• PLPremiumAdhesiveorequivalent
1. Initial Layout
Marklayoutlinesonoor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 Balustrade Sections
A)UsingaccurateeldmeasurementstakeninStep1,cutthetopandbottomrailstolengthforeachrespectivesection.
B)Markcenterlinesonrails.MarkBalusterpositions,thendrillholestoacceptthebalusters. Note: Check applicable building codes concerning
regulations on distance between balusters.
 Tip: Adrillpresswithstandardwoodworkingdrillbitsworkswellfordrillingtheseholes.
C)Applya
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”beadofurethanebaseconstructionadhesiveoneachendofbaluster.Theninsertbalustersintothedrilledtopandbottomrail.
D)Laytherailassemblyonaat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.Beforegluesetsup,makesureassemblyissquareandthatthebalustersaresquareto
therailsection.Cleanoffanyexcessadhesivewithaputtyknife.Allowgluetodrycompletely.Paintingcanbedonebeforeeldassembly,
ifdesired.
3. Install Porch Posts
A.)Determinetherequiredheightofthepostbycarefullymeasuringthedistancefromtheoortothebottomoftheporchstructurebeing
supported.
B.)Thepostisaloadbearingsupport.Itcanbetrimmedtovariousheightswithoutaffectingtheintegrityofthepost.Ifsizingisneeded,the
posthasasteelpipemoldedintothecenterwhichmustbecutwithahacksaworreciprocatingsawwithmetalcuttingblade.Ifpostis
trimmedbesuretomaintainadequateatareaatbottomtomountrailsections.
C.)Pre-drillholesapproximately¾”upfromthebottomofthepostusinga13/64”drillbitandroughlycenteredonthepost.Drillthroughboth
thepolymershellandthesteelreinforcement.Nowusea½”drillbittoexpandtheholesthroughthepolymeronly(donotdrillthroughthe
steelreinforcement).Repeatthisprocessatthetopofthepost,pre-drillingholesapproximately¾”fromthetopandcentered.
D.)Paintallexposedsteelatboththetopandbottomofthepost,usingahighqualityzincbasedprimerspraypainttohelppreventcorrosion.
E.)Identifythecorrectlocationofthetopmountingplaterst,anduseaplumblinedroppedfromthecenterpointofthetopplatelocationto
accuratelyalignthecenterpointlocationforthebottompostmountingplate.
F.)Installthetopandbottommountingplatesusingcorrosionresistantmechanicalfasteners.Forinstallationintoconcreteorstonematerials,
appropriatemasonryand/orotherfastenersmustbeused.
G.)Lift(jack)theupperstructurejusthighenoughtoallowtheposttobesetintoplacebetweenthemountingbrackets.
H.)Usethe13/64”holesdrilledinthepostasguideholestodrill13/64”holesthroughthepostmountingplates.Attachtheposttothetop
andbottommountingplateswithcorrosionresistantscrews(fourscrewsprovided,twoforeachmountingbracket).
I.)Patchscrewholesusingpolyurethanecompatibleexteriorgradeller.
J.)Sandandpaintasdesired.
CircularorHandSaw
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"DrillBit
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"DrillBit
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"DrillBit
PowerDrill
PlumbBob
HydraulicJack
PhillipsHeadDriver
CombinationSquare
Zinc-basedPrimerSprayPaint(Steel use only)
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"OpenEndWrenchorAdjustableWrench
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.
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