MASTER CRAFTSMAN EDUCATION & DEVELOPMENT PROGRAM EVERNEW PANORAMA COMPOSITE RAILING SYSTEM

Transcription

1 MASTER CRAFTSMAN EDUCATION & DEVELOPMENT PROGRAM EVERNEW PANORAMA COMPOSITE RAILING SYSTEM

2 Become a CertainTeed The Panorama Composite Railing Education and Development Workbook is a key element in CertainTeed s Master Craftsman education and training program. We hope that you will use it to master the information critical to installing our railing products. The more you know about CertainTeed railing, the better able you ll be to recommend solutions and estimate jobs for your customers. After you have reviewed this workbook, you will be prepared to take the Master Craftsman Test, which will earn you valuable rewards. These rewards and more importantly, the leg up you ll have on the competition are not available to everyone, just to those who have successfully passed the test. When you pass, you will: R eceive a personalized Certificate of Completion that you can use to promote your professional services B e listed as a Master Craftsman on our website; the listing will include your name, company name, phone number, address, and a link to your website if you have one

3 Table of Contents Glossary EverNew Panorama Composite Railing Its History and Benefits What Is Composite Railing? Homeowners Prefer Composites Benefits of Panorama Composite Railing Panorama Is Easy to Use Company History One Man s Dream Building Products Today Manufacturing Raw Materials Manufacturing Process Quality Control Jobsite Safety and Workmanship Tools Ladders Personal Protective Equipment Housekeeping Professionalism Sales Support Sales Tools Follow-up Tools Taking the Master Craftsman Test The Master Craftsman Test Panorama Composite Railing Will Work For You Lower Installed Cost Higher Profit Margins More Referrals Panorama Composite Railing Installation Overview Storage & Handling Exposure to Weather Cutting & Drilling Cleaning Building Code Requirement Installation Overview Installation Instructions for Panorama Composite Railing Install Post Support Kits Install Post Sleeves Assemble Railing Sections Install Railing Sections Install Top Rails Install Post Caps Installation Instructions for Stair Railing Install Stair Railing Sections Install Stair Top Rails Installation Instructions for Mitered/ Angled Deck and Porch Railing

4 Glossary ACQ Alkaline copper quaternary. Chemical preservative for wood that replaces CCA. Actual dimensions The exact measurements of a piece of lumber. Baluster (spindle) The numerous vertical pieces that provide a fence-like structure by filling the spaces between rail posts; one of a series of vertical supports used between posts of a railing. Board Any piece of lumber more than 1" wide and less than 2" wide in thickness. Building codes (1) Municipal rules regulating safe building practices and procedures; the codes encompass structural, electrical, plumbing and mechanical remodeling and new construction. (2) Regulations detailing accepted materials and methods of building, such as the size of the deck, setback distances, railing and stair construction, footing depths, fastening methods, lumber grades for certain deck components and fence or screen height around the deck. Usually adopted by city, county, or state building departments; most counties have local building codes. CCA Chromated copper arsenate. This chemical preservative is being phased out in favor of ACQ. Check Lengthwise separation of wood that usually extends across annual growth rings and commonly results from stresses arising in wood during drying. Composite An item manufactured out of wood and plastics to form a profile with better durability and performance properties than wood. Culling The process of selecting the best pieces of wood or lumber for a project; particularly used to remove warped and checked boards. Cup Type of warp; the distortion or deviation of a board flat-wise from a straight line across the width of the board. Cupping occurs when shrinkage is unequal between two faces of a board, such as the top and bottom of a decking board. The tendency of a board to cup varies with its density, moisture content when surfaced, width, thickness, and grain orientation. Decking Floor boards of a deck; the actual deck surface; 5/4x6, 2x6, and 2x4 planks are commonly used for decking and are attached to the joists. Decking boards Planks nailed or otherwise attached to joists, used for the deck surface. Decking lumber is available in a number of different species of wood and brands of wood composite and in a variety of dimensions. Extractives Substances in wood that are not an integral part of the cellular structure and can be removed by solution in hot or cold water, ether, benzene, or other solvents that do not react chemically with the wood components. Fastener Generic term for nails, screws, bolts, and metal hardware used to connect deck members. HDG (hot-dipped galvanized) Twist nail, casing nail, common nail, decking screw, etc., with thick zinc coating and rough surface. Hot-dipped Fasteners single- or double-dipped in molten zinc (usually 0.85 oz./ft2), which provides the best corrosion protection for wood used in damp conditions. Joists (1) Structural members, usually 2-by lumber, commonly placed perpendicularly across beams to support decking boards. (2) Lateral support boards that are attached to (or lay on top of) beams. (3) Horizontal framing members that support decking, usually set perpendicular to the house face. Live load The amount of weight a deck is designed to support; most deck designs call for a live load of 100 lbs./ft2. Maintenance Regular cleaning and inspection of deck; may include light sanding to remove raised grain, washing to remove mildew, and reapplication of a water-repellent preservative or semi-transparent stain on a wood deck. Mildew Black fungus that grows on the surface of wood, causing a wood deck to darken. 2

5 Nominal dimensions (1) The identifying dimensions of a piece of lumber; nominal dimensions are larger than the actual dimensions. (2) The label given to a standard piece of lumber. For example, a 2x4 is the name for a roughcut piece of about 2" x 4". On center (o.c.) (1) A point of reference for measuring; 16" on center means 16 inches from the center of one framing member to the center of the next. (2) A method of measuring distance between two structural members, such as joists. Post (column) (1) Vertical member, usually 4" x 4" or 6" x 6", that supports either the deck or railing. Posts support the deck beams and transfer the weight of the deck to the concrete footings. Posts extending above the level of the deck can also serve as railing supports. (2) The upright support lumber members that are attached to piers and footings. (3) The vertical structural element that rests on the footing and supports the beam. Post anchor (1) Metal fastener designed to keep the post from wandering and to inhibit rot by holding the post a bit above the concrete. (2) A metal piece attached to or imbedded in the footing that attaches the post to the footing and keeps the post from being exposed to moisture in the ground. Post cap Small piece of wood, plastic, or wood-plastic composite material attached to the top of the post to protect the post from the weather. Available in a variety of styles. Posthole digger Clamshell-type tool used to dig holes for posts. Power auger Tool that is powered by a gasoline engine and used for drilling into the ground; often used in larger projects to dig postholes. Preservative Chemical used to protect wood against decay. See ACQ and CCA. Pressure-treating Preservatives are forced into softwood under pressure to make the wood repel rot and decay and withstand fungal and insect attack; pressure-treated wood is known as green wood because of the residual color of the chemical; usually made from Southern Yellow Pine (SYP) or Lodgepole pine. Rail post A vertical structural support for the railing. Rail posts are thicker than balusters and are attached with bolts to the joists and beams. Recommended span The distance a piece of lumber can safely traverse without being supported underneath. Ring-shank nail A nail with grooves and ridges around the shank to prevent the nail from popping out of the wood as the wood contracts and expands because of changes in moisture and temperatures; also called an annular grooved nail. Riser (kick plate) Vertical boards placed between stringers on stairs to support stair treads; the vertical distance the step rises from one step to the next; also, the board that creates the rise; the vertical piece between two stair steps, located between each tread. Span The distance between supports, usually the ledger board to the beam. Spiral-shank nail A nail with helical grooves and ridges around the shank to prevent the nail from popping out of the wood as the wood contracts and expands because of changes in moisture and temperature; this nail looks as if it has been twisted along its axis. Tread On stairs, the horizontal boards supported by the stringers; a term used with stair construction that refers to the horizontal walking surface or step. Treated lumber Lumber that has been pressure-treated with an approved preservative under appropriate standards of the American Wood Preservers Association (AWPA) or American Society for Testing and Materials (ASTM). Weathering Photochemical degradation of the wood surface caused by the combined effects of sunlight (UV radiation), water, and abrasion by wind-blown sand or other particulates. Color changes occur in wood as it weathers, leading to a driftwood-gray weathered finish. Although weathering is often desirable in some applications (shakes, shingles, and siding), some protection is necessary to avoid checking, cracking and splintering. Rail A horizontal member that is placed between posts and used for support and as a barrier. Railing Portion of deck constructed for enclosure; includes rail post, cap rail, head rail and balusters. 3

6 1. EverNew Panorama Composite Railing Its History and Benefits Do you really need to add another railing material to your already wide product offering? Absolutely! Panorama composite railing offers the look of wood with exceptional weatherability. It provides the solid feel of wood railing with the strength of a durable composite that replicates the look of wood. 1.1 What Is Composite Railing? In general, the term composite lumber refers to any blend of plastic and wood or plastic and other natural fibers extruded into railing products. 1.2 Homeowners Prefer Composites Though relatively new, composite lumber is quickly becoming the preferred alternative to wood railing for four main reasons: 1. Composite lumber is low maintenance. Homeowners don t want to sand and stain or paint wood railing. Thus, they continue to choose modern, low-maintenance building products over more traditional materials. 2. Homeowners are questioning the safety of pressuretreated lumber. Their children play on treated deck and railing systems, and parents worry about the toxicity of CCA (chromated copper arsenate) used to treat wood. Also, there is concern about the chemicals, sealants, and stains used to maintain wood building products. 3. Homeowners are making purchase decisions that reflect their concerns about the environment and the ecological cost of harvesting trees for wood railing. The recycled content of our innovative, composite railing products is a feature that attracts these environmentally aware consumers. 4. Decreasing supply and increased transportation costs have dramatically increased the prices for premium natural lumber like cedar and redwood. Prices for quality exotic hardwoods like mahogany and ipé have also increased substantially in recent years. As a result of this increased preference for low-aintenance, durable railing, the market for composite and plastic lumber is predicted to grow an average of 12 percent every year through This is an opportunity you don t want to miss! 1.3 Benefits of Panorama Composite Railing Panorama combines the look of wood with the durability of a composite, while wood railing requires ongoing maintenance. Periodically, wood railings must be sanded and stained, and split or warped rails should be replaced. But Panorama composite railing doesn t rot, twist, split, or crack. Cleaning with a mild detergent and water will keep Panorama composite railing looking good for years. And you ll never be called back to replace split or warped rails. 1.4 Panorama Is Easy to Use If you can install wood railing, you can install Panorama. There are no special tools or installation techniques required. You and your customers will be delighted with your beautiful railing, and you ll enjoy fewer callbacks and more positive referrals. Remodelers love Panorama because it s easy to use and because it: is dimensionally stable installs like wood uses standard woodworking tools and fasteners cuts, fastens, and sands easily does not need to be painted or stained Best of all, installing Panorama railing is profitable. Composite railing is a high-end home improvement, so profit margins can be higher. And, unlike wood, you won t be competing with the do-it-yourselfer or neighborhood handyman. The more you use Panorama railing, the more you re going to like what it can do for your business. 4

7 2. Company History Quality Made Certain Satisfaction Guaranteed. More than just a slogan, it s our name. And since 1904, when the General Roofing Manufacturing Company began producing asphalt roofing materials, quality products and satisfied customers have been the hallmark of CertainTeed Corporation. 2.1 One Man s Dream First established in 1904 by George M. Brown, the General Roofing and Manufacturing Company was created to produce a fire-resistant and less expensive alternative to wood shingles. In 1917, the company changed its name to CertainTeed to reflect its expanding product line and Brown s business philosophy. In 1923, it began manufacturing gypsum wallboard for new home construction. During World War II, CertainTeed lent its extensive management and production expertise to the war effort, but in 1946 began investigating the potential of a new product fiber glass insulation. Within 10 years, CertainTeed was supplying roofing materials, gypsum, and fiber glass insulation to the booming construction industry and had established itself as a leader in the country s effort to supply affordable housing to former GIs and their families.in 1965, CertainTeed took its first step into PVC. Its later acquisition of Plains Plastic made CertainTeed a major manufacturer of plastic pipe. In 1969, the company began offering solid vinyl (PVC) siding to builders and contractors. The development of decking and railing began in 1996 with the acquisition of Bufftech vinyl fence and the development of EverNew vinyl decking and railing. In 2006, CertainTeed added Panorama composite railing to its EverNew product portfolio. Today, CertainTeed is North America's leading brand of exterior and interior building products, including roofing, siding, fence, decking, railing, trim, insulation, gypsum and ceilings. 2.2 CertainTeed Today CertainTeed is part of the worldwide Saint-Gobain organization. Saint-Gobain is a global manufacturer and distributor of flat glass, building products and highperformance materials. With more than 1,000 subsidiaries in 67 countries, it is the world s largest building materials company and a leading distributor of building products. Founded in 1665 and headquartered in Paris, France, Saint-Gobain had worldwide sales of $43.3 billion in 2016 and employs 170,000 people worldwide. CertainTeed is part of the Construction Products division of Saint-Gobain. This division enjoys a leading position in the United States home construction market. All across the U.S. and Canada, CertainTeed also offers a full line of outdoor living product solutions for individual homes including roofing shingles, vinyl siding, PVC trim, fence, decking, railing and housewrap. CertainTeed also offers top-of-theline interior products, including insulation, gypsum and ceilings. All of these products are renowned for their ease of use, nearly maintenance-free materials, weather resistance and smart appearance. The Outdoor Living division, which supplies Panorama composite railing, is just one of a number of operating groups that make up CertainTeed Corporation. CertainTeed roofing and vinyl building products are consistently rated at the top for quality and performance by consumer and trade publications alike. From its humble beginnings in East St. Louis, through two World Wars and the Great Depression, CertainTeed has become one of the nation s largest and most respected manufacturers of building products. Today, CertainTeed celebrates more than 100 years of leading the building industry with creative advancements, insightful solutions, and unparalleled dedication to service. 5

8 3. Manufacturing 3.1 Raw Materials The quality you ve come to expect from CertainTeed is built in at the factory. From the time raw materials are received at our plant until the finished product is shipped to our customers, we control, adjust, inspect, and test throughout the manufacturing process. As part of ongoing quality assurance, we work with our suppliers to develop and test for tight specifications. The result is composite lumber you can count on for superb appearance, durability, and ease of installation every time. 3.2 Manufacturing Process Technical excellence, processing expertise, and an unwavering commitment to quality characterize the equipment, processes, and personnel at our manufacturing plant. Since the 1960s, CertainTeed has been developing innovative products and processes to improve the look and durability of our products. At the same time, tried and true manufacturing methods are tested and re-tested to ensure that you consistently receive the highest quality product. 3.3 Quality Control Panorama composite railing undergoes ongoing quality control checks as it is being extruded and after it is manufactured. More importantly for you, the specifications and quality control testing for Panorama composite railing products have been reviewed and approved by Intertek. 6

9 4. Panorama Composite Railing Will Work for You Why, in the highly competitive remodeling market, should you recommend Panorama composite railing? The answer is obvious: Performance! Performance that turns the higher initial cost of Panorama railing into long-term savings and distinct advantages for your customers and your business. 4.1 Lower Installed Cost Homeowners will choose Panorama composite railing over traditional wood products because composite lumber lasts longer and costs less to maintain. On average, railings made of pressure-treated wood must be replaced every 10 years. In contrast, Panorama composite railing is warranted against defects for 25 years! And homeowners will never have to sand, stain, or replace Panorama composite railing. In the end, Panorama lasts longer and costs less than typical wood railings. 4.2 Higher Profit Margins For you, recommending Panorama composite railing makes good business sense. First, Panorama composite railing is recognized as a premium building product. You won t be competing on price with the low-end weekend remodelers, and you can position your business as the modern, professional alternative to remodelers offering only wood railing. Second, in markets where severe weather extreme heat and cold, salt air, high humidity significantly reduce the life of wood products, homebuilders and owners are looking for a long-lasting, low-maintenance alternative to wood. Panorama composite railing looks like wood, but offers outstanding performance. Finally, Panorama composite railing lets you spend less time on installation. Profits will improve because you won t: Spend time culling warped, split, or knotty rails Invest time or money in painting or staining Be called back to replace checked, cracked, or warped rails. When you re finished, you re finished. You can confidently move on to the next job. 4.3 More Referrals Panorama composite railing is an attention getter, even after years of use. It resists mildew better than wood, so Panorama railing keeps its good looks for years. You can be assured of continued referrals, especially when homeowners experience the joys of a railing that: does not splinter stays cool to the touch requires only occasional cleaning with water or mild detergent will not rot or decay is impervious to termites and other wood-boring insects never needs painting or staining Can you sell a product that, on the surface, looks pricier than wood? Certainly once you demonstrate the lower installed cost, significantly less maintenance, and longer life of Panorama composite railing. 7

10 5. Panorama Composite Railing Classic painted wood style with true architectural details Top and bottom universal rails with a decorative top rail cap Concealed external rail-to-post connection for flat, stair, column and 45º applications Available in two heights and two lengths Available in three colors: white, almond and black Choice of two baluster styles: square composite and decorative steel Powder-coated, hot-dipped galvanized steel decorative balusters create a rustic yet customizable system approach for both flat and stair applications Suitable for one- and two-family dwellings/townhouses not more than three stories high Independent tested as designated in report CCRR-0115 (white and almond) Class A flame spread rating 25-year limited warranty with 2-year SureStart protection 8

11 6. Installation Overview 6.1 Storage & Handling Panorama composite railing components should be stored on a dry, flat surface. Do not store in an area where excessive heat build up can occur, such as on an asphalt surface covered by a tarp. Individual Panorama components may weigh more than wood so take this into account before lifting or moving Panorama composite railing. Panorama composite railing does not produce respirable dust when it is cut or fastened, but you should always wear eye protection and safety equipment when working with any wood product. For more information about the safety of Panorama composite railing, consult the Material Safety Data Sheet (MSDS). 6.2 Exposure to Weather 6.4 Cleaning Panorama composite railing resists most common household stains but it will become dirty like any product exposed to atmospheric conditions. Periodic washing with a soft bristle brush and clean water from a garden hose may be necessary to remove surface dirt which may accumulate on the surface. For best appearance, clean your Panorama composite railing at least once a year, unless local conditions require additional cleaning. 6.5 Building Code Requirement Panorama composite railing is designed for 1- and 2-family residential applications. Contact your local code authority for requirements in your area. Exposure to sunlight and water will not adversely affect the appearance of Panorama composite railing. Normal weathering should be expected. 6.3 Cutting & Drilling Working with Panorama composite railing is as easy as working with wood. Use conventional woodworking tools to cut, drill and rout Panorama composite railing. Carbidetip blades provide improved tool wear and results. A fine-tooth saw will help reduce chipping and provide a cleaner cut surface. Eye protection and protective clothing should always be worn for your safety. C A R B I D E Tools Required Tools - Miter Saw - Power Drill and Bits - No. 2 Square Head Driver - 1/4" Drive Socket, extension, and 7/16" Socket - Level - Square - Tape Measure - Pencil - Safety Glasses (and equipment as identified by tool manufacturers) Optional Tools - Jigsaw/Coping Saw - Utility Knife - File - Box-End Wrenches - Chalk Line - Silicone Caulk and Caulk Gun - Angle Finder - Extension Bit for Crush Block Panorama boxed kits are available in 6' and 8' lengths. Measurements are from post center to post center. Panorama 6' and 8' products are designed not to exceed 6' or 8' from center of post to center of post, respectively. Actual rail lengths are 67-1/2" (6') and 92-1/2" (8'). 9

12 6.6 Installation Overview Step 1: Install Post Sleeves Be sure posts are plumb. Cut post sleeve to length. Slide the post sleeve over the post to rest on the deck surface. Slide post trim ring (1a) over the post sleeve to also rest on the deck surface. Step 2: Assemble Railing Section Measure the distance between post sleeves. Lay universal rails side-by-side, aligning pre-drilled holes, not the rail ends. Calculate the center of the universal rails and assign the center either directly to a pre-drilled baluster hole or the space centered between two baluster holes. Measure and cut rails from the calculated center. Attach the balusters to the top and bottom universal rails (2a). Then attach the crush block to bottom universal rail (2b). Place and secure rail brackets. Step 3: Install Railing Section Drive lag bolts into posts leaving approximately 1/2" gap from lag bolt head to post sleeve surface. Place railing assembly over bottom lag bolts. Mark the position for the top lag bolts using the top rail bracket s position as a guide. Use a 1/4" drive socket with an extension to tighten lag bolts to the posts. Step 4: Install Top Rail Measure the distance between post sleeves. Cut the top rail to length. Secure from underneath with supplied whitehead screws. Step 5: Install Post Caps Slide inverted post trim ring over top of the post sleeve. Place post cap over top of the post sleeve. Screw through side holes of the post cap to secure. Snap inverted post trim ring onto secured post cap a Rail Brackets 1 Closed rail bracket; for use in top rails only Open rail bracket; for use in bottom rails or flat sections 1a Panorama boxed kits are available in 6' and 8' lengths. Measurements are from post center to post center. Panorama 6' and 8' products are designed not to exceed 6' or 8' from center of post to center of post, respectively. Actual rail lengths are 67-1/2" (6') and 92-1/2" (8'). 2a 2b 10

13 7. Installation Instructions for Panorama Composite Railing 7.1 Install Post Support Kits Use the Post Sleeve Mount to install post sleeves directly onto the deck or porch surface. Post sleeve mounts are available for concrete or wood/composite surfaces. When installing a post sleeve mount on a concrete surface, the support system is anchored into the concrete. When installed on a wood or composite deck, the support system is installed after the deck surface has been attached. Follow these guidelines to complete the post installation. Post Surface Mount with Wood Insert for Concrete (Figure 7.1) 1.1.a. Determine the desired location(s) and finished height of the post sleeve from the deck surface. 1.2.a. Trim the post sleeve to the desired length. 7.1 For concrete surface installations Includes 4" x 4" wood insert for easy sleeve-over applications Post Sleeve 1.3.a. Ensure the treated 4" x 4" (generally 3.5" x 3.5" actual) wood post is structurally sound and code compliant. 1.4.a. Trim the length of the 4" x 4" wood post. The wood post length is typically 1" shorter than the post sleeve length. 1.5.a. The base of the mount should be positioned a minimum of 3" on center from the edge of the concrete pad. Use the base of the mount as a template and mark the four corner holes for the concrete anchors (included in kit). Concrete 4" x 4" Wood Post Post Mount 1/4" x 3" Concrete Anchors 1.6.a. Drill the marked holes using a 1/4" masonry drill bit. Drill the holes into the concrete base to a depth of at least 1/2" deeper than the length of the 1/4" x 3" anchors. Blow the hole clean of dust and debris. 1.6a 1.7.a. Locate the mount by aligning the mount corner holes over the drilled holes. 1.8.a. Insert the trimmed end of the 4" x 4" wood post into the mount. Ensure that the post is plumb and true. 1.9.a. If necessary, place a shim under the mount to make the post plumb and true. Attach wood post to the base a. Insert the four concrete anchors into the corner holes of the mount. Begin tightening the anchor by rotating clockwise and applying pressure in toward the base. This will engage the first few threads as the anchor begins to advance. Continue to tighten until the head of the anchor is firmly seated against the post mount. Repeat for the remaining anchors. 1.10a 1.11.a. Slide the post sleeve over the 4" x 4" treated wood post until it contacts the base of the mount. 11

14 Post Surface Mount with Wood Insert for Wood 1.2b 1.1.b. Determine the desired location(s) and finished height of the post sleeve from the deck surface. Decking 1.2.b. The thickness of the wood/composite deck and reinforcement boards underneath the deck should be a minimum of 4" (two treated and structurally sound 2" x 8" lumber under the deck board). 2x8 2x8 1.3.b. Fasten the reinforcement boards with 3" stainless steel fasteners as shown. 1.4.b. Trim the post sleeve to the desired length. 1.5.b. Ensure the treated 4" x 4" (generally 3.5" x 3.5" actual) wood post is structurally sound and code compliant. 1.3b 2" x 8" Reinforcement Boards 3" Stainless Steel Fasteners 1.6.b. Trim the length of the 4" x 4" wood post. The wood post length is typically 1" shorter than the post sleeve length. 1.7.b. Use the base of the mount as a template and mark the four corner holes on the deck surface. Mark inside square of bracket on deck surface. Joists 1.8.b. Drill four 3/8" holes at the marked locations, drilling through the deck board and the reinforcement boards. Drill a 3/8" drainage hole in square through deck board and reinforcement boards for drainage. 1.13b Post Sleeve 1.9.b. Locate the mount by aligning the mount corner holes over the drilled holes b. Insert the trimmed end of the 4" x 4" wood post into the mount. Ensure that the post is plumb and true. Attach wood post to the base b. If necessary, place a shim under the mount to make the post plumb and true b. Insert the 5/16" x 5" galvanized hex bolts into the mount holes and the drilled holes. (Galvanized bolts, nuts and washers not included.) 4" x 4" Wood Post Post Mount Deck Board 5/16" x 5" Galvanized Bolt 1.13.b. Fasten the four bolts underneath the reinforcement boards with the 5/16" Fender washer (included in kit) and 5/16" galvanized hex nuts b. Slide the post sleeve over the 4" x 4" treated wood post until it contacts the base of the mount. 5/16" Galvanized Nut 5/16" Fender Washer 12

15 7.2 Install Post Sleeves Sleeve Mount (Over existing 4 x 4 Posts) Plumb 4" x 4" posts. (Post centers cannot exceed 96".) 2.2 Cut post and Post Sleeve to required length inches minimum for 36" rail height - 46 inches minimum for 42" rail height 2.3 Slide Post Sleeve down over the post to the deck surface. 2.4 Slide Post Trim Ring over the Post Sleeve to the deck surface. 2.4 If structural post is slightly twisted or warped, shim stock can be used between the post and inside of Post Sleeve so that the Post Sleeve is oriented properly. Otherwise, replace wood post. 7.3 Assemble Railing Sections There are two types of balusters available for the Panorama composite railing System: Square and Steel. Though most of the installation steps are the same for both, there are a couple of steps unique to Steel Balusters. These steps are designated by adding the letters S (for Steel) to the numbered steps below. 3.1 Measure the distance between the Post Sleeves at the top and bottom. These two measurements may be slightly different. It s important that the posts are plumb. 3.2 Establish the center of the Universal Rails by applying the measurement between the Post Sleeves. You may choose to base the center of the Universal Rail on a pre-drilled hole OR exactly between two pre-drilled holes. This decision will affect the spacing between the Post Sleeve and adjacent Baluster on each side of the Railing Assembly. Arrange the rail so you do not end at a post with a portion of a Square Baluster or Steel Baluster Shoe. 3.3 To ensure that the Balusters will be installed plumb, place the two Universal Rails side-by-side on a flat surface, baluster stops both on the inside, aligning them according to the pre-drilled Baluster holes, NOT the ends. Now, measure and cut each Universal Rail carefully to minimize gaps. Measure from the established center (Figure 3.2) of the Universal Rails, trimming the proper amounts from each end to achieve rail lengths. 3.3S Insert one black Baluster Shoe completely into each end of every Steel Baluster S (top view) 13

16 3.4 Lay out the components of the railing section on a flat work surface, roughly in the final, assembled position. Make sure the baluster stops are on the same side of the Railing Assembly. Direct a 2-1/2" Baluster Screw or a 3" Baluster Screw for Steel Balusters into the channel of a Universal Rail, through the pre-drilled hole and into the center pilot hole in the end of a Baluster (Square) or into the pilot hole of the Black Baluster Shoe (Steel), which were already inserted in the Steel Baluster. Make sure Baluster or Black Baluster Shoe is installed square and does not overlap the baluster stop on the Universal Rail. Repeat for the remaining Balusters S NOTE: Set clutch on drill to avoid overtightening screws. TIP: For the opposite Universal Rail, direct a 2-1/2" Baluster Screw (or 3" Baluster Screw for Steel Balusters) into the channel of the Universal Rail, through the pre-drilled hole and into the center pilot hole in the end of a Baluster or into the pilot hole of the Black Baluster Shoe (Steel). Start the screw into the Baluster or Shoe but do not tighten. This will provide space between the Universal Rail and the Baluster end or Baluster Shoe to allow you to locate the remaining pilot holes in the Baluster or Black Baluster Shoe. Repeat for the remaining Balusters. When all Balusters have been started, return to each Baluster and tighten. TIP 3.5 Using (2) #10 x 3/4" screws, secure each Rail Bracket into the channels of the Universal Rails by aligning the Rail Brackets flush or slightly recessed inside each end cut. Make sure not to let the Rail Bracket face extend beyond the Universal Rail end cut. Secure the Rail Bracket through the two screw holes at each end of the Rail Bracket, leaving the center screw hole empty. 3.6 Fit the beveled end of the Crush Block up into the channel of the bottom Universal Rail on the Railing Assembly, centered between the two cut ends. Using (2) #10 x 3/4" screws, secure the Crush Block from underneath, up into the channel of the bottom Universal Rail. 3.5 Baluster Stop Baluster Stop 3.6 (side view) 14

17 7.4 Install Railing Sections 4.1 It is critical that posts are plumb. Double check posts to ensure proper fit of completed Railing Assemblies. 4.1 At 4-3/8" above the deck surface and centered on the Post Sleeve, drill a 1/8" pilot hole through the Post Sleeve and into the post. Then drill a 3/8" clearance hole through the Post Sleeve ONLY for the bottom Lag Bolts. Do not drill holes for the top Lag Bolts. 4.2 Thread bottom Lag Bolt into Post Sleeve, leaving approximately 1/2" of the Lag Bolt shaft exposed. Repeat for opposite post. 4.3 Place Railing Assembly over bottom Lag Bolts with Universal Rail baluster stop on the outward side of rail, making sure the Rail Brackets seat properly over the Lag Bolt heads /2 4-3/8 4.4 Center and plumb the top of the Railing Assembly to the Post Sleeve. Mark the position for the top Lag Bolts on the Post Sleeve using the top Rail Bracket s position as a guide Rotate the top of the Railing Assembly out of the way. Drill a 1/8" pilot hole through the sleeve and into the post. Then drill a 3/8" clearance hole through the Post Sleeve ONLY for the top Lag Bolt. Repeat for opposite post (other side of Railing Assembly). 4.6 Rotate the top of the Railing Assembly back into the proper position and thread the top Lag Bolts through the Rail Brackets and into the holes in the Post Sleeves. With the Lag Bolt heads now located in the channels of the Universal Rails, a 1/4" drive socket with 3 inches or greater extension and a 7/16" socket is needed to sufficiently tighten the Lag Bolts. Repeat for opposite post. 4.7 Return to bottom Lag Bolts and tighten. 4.4 (view down length of top Universal Rail toward post) 4.5 (view down length of top Universal Rail toward post) 4.6 (view down length of top Universal Rail toward post) 15

18 7.5 Install Top Rails 5.1 Measure the distance between Post Sleeves. Cut the Top Rail to length. The Top Rail s bottom channel fits over the top edges of the top Universal Rail. 5.2 (view down length of top Universal Rail toward post) 5.2 Drill a 3/16" clearance hole down through middle (empty) hole in top Rail Bracket, completely through top Universal Rail. Repeat for opposite top Rail Bracket. 5.3 Roughly divide the Railing Assembly into three equal sections by counting Balusters or Baluster spaces. Drill 3/16" clearance holes between the Balusters at these points. 5.4 Place Top Rail over top Universal Rail and drive the 2-1/2" Top Rail Screws (with color matched heads) up through the four clearance holes in the bottom of the top Universal Rail, into the Top Rail to secure. Be sure not to overtighten the screws. 7.6 Install Post Caps Invert Post Trim Ring and slide over the top of the Post Sleeve. Position Post Cap over the top of the Post Sleeve and secure with (2) #10 x 3/4" screws through tabs. Slide inverted Post Trim Ring up and snap together with secured Post Cap. OR 6.2 Snap together a Cap and inverted Post Trim Ring to create a complete Post Cap Apply a small bead of construction adhesive to the inside lower lip of the Post Cap and slide it over the top of the Post Sleeve Construction adhesive 16

19 7.7 Installation Instructions For Stair Railing 7.1 Assemble Stair Railing Sections 7.1 Make sure Post Sleeves are installed and plumb. Evaluate the rise and run of the stairs to determine the proper stair angle. Be as accurate evaluating the stair angle as possible every cut you make from this point forward will depend upon this angle. Rise Angle Run Measure and cut 7.2 Measure the distance between the Post Sleeves at the top and bottom. These two measurements may be slightly different. 7.3 Cut each Universal Rail to the proper length and angle, making sure that the baluster stop will be on the same side (yard side) of the finished Railing Assembly. 7.3 (side view) Angle 7.4 Determine number of Balusters needed on Stair Railing Assembly to maintain approximately the same Baluster spacing as the deck railing. (Deck railing Baluster spacing is 5" on center for Standard Balusters, and 4-3/8" on center for Steel Balusters.) Multiply number of Balusters needed by two to determine number of Black Baluster Shoes required for Steel Balusters. (Refer to Stair Railing Tables below.) Angle 7.4 5" O.C. (at 90 ) Rail Length Stair Angle Angled Baluster Spacing Composite Balusters Steel Balusters STAIR RAILING TABLE RISE % RUN STAIR ANGLE BALUSTER SPACING O.C /16" /8" /2" /16" /16" /4" /8" /16" " /16" /8" STAIR RAILING TABLE RISE % RUN STAIR ANGLE BALUSTER SPACING O.C /32" /32" /32" /8" /32" /16" /32" /16" /32" /32" /16" 17

20 7.4S Cut each Stair Baluster Shoe at the proper angle. To safely cut the Stair Baluster Shoes, insert a Stair Baluster Shoe into each end of the supplied 8" steel tube (included in the Stair Baluster Shoe package to prevent hands from getting close to the saw blade). Rotate the Stair Baluster Shoe so that the raised dot is in the upward position (the raised dot is a bisecting point for the saw blade to cut through). Proceed to cut the Stair Baluster Shoe at the determined angle. TIP: If using a chop saw with a rotating table, clamp a piece of lumber to the back fence of the saw. This will close the gap on each side of the blade. Set the saw to the correct angle and make a cut through the lumber. Lay the steel tube holder with the two Stair Baluster Shoes on the saw table and make the first cut, bisecting the raised dot. Use the cut Stair Baluster Shoe to mark another Stair Baluster Shoe across the raised dot, then insert it into the steel tube holder. Set up a wood block on the lumber fence that will act as a stop and position the marked line of the uncut Stair Baluster Shoe. Cut the Stair Baluster Shoe. Repeat this procedure until all Stair Baluster Shoes are cut. 7.5 Measure and mark for the Baluster screw holes on the Universal Rails. Use the Stair Railing Table to determine angled Baluster spacing for layout (see table on page 17). Drill 3/16" holes at the proper angle. Use the Baluster-scrap drill jig (see tip below) to assist in aligning the drill to the proper angle. For Steel Balusters, use the Stair Baluster Shoe cut to the stair angle to assist in aligning the drill to the proper angle. TIP: If you have an extra scrap Baluster, cut a small piece of that Baluster to be used as a drill jig for drilling the Baluster screw holes through the Universal Rails. 7.6 Determine required Baluster length to maintain rail height at stair nose. Cut Balusters to length with angled cuts, top and bottom. Make sure all Balusters are the same length. 7.6S Insert one Black Stair Baluster Shoe (Steel) into each end of every Baluster, making sure the Baluster Shoes are positioned properly before inserting them completely. Now insert them completely into the Balusters. TIP: For the opposite Universal Rail, direct a 2-1/2" Baluster Screw into the channel of the Universal Rail, through the pre-drilled hole and into the center pilot hole in the end of a Baluster. Start the screw into the Baluster but do not tighten. This will provide space between the Universal Rail and the Baluster end to allow you to locate the remaining Balusters pilot holes. Repeat for the remaining Balusters. When all Balusters have been started, return to each Baluster and tighten. 7.7 Lay out the components of the stair railing section on a flat work surface, roughly in the final, assembled position. Make sure the baluster stops are on the same side of the Railing Assembly. Direct a 2-1/2" Baluster Screw (3" Baluster Screw for Steel Balusters) into the channel of a Universal Rail, through the pre-drilled hole and into the center pilot hole in the end of a Baluster, or the center pilot hole of the Stair Baluster Shoe for Steel Balusters. Make sure the Baluster or Stair Baluster Shoe is installed square, at the proper angle, and does not overlap the baluster stop on the Universal Rail. Repeat for the remaining Balusters. 7.4S S Rail Length Stair Angle Angle 4-3/8" O.C. (at 90 ) Angled Baluster Spacing Baluster scrap drill jig Angle 18

21 7.8 Using (2) #10 x 3/4" screws, secure each Rail Bracket into the channels of the Universal Rails by aligning the Rail Brackets just inside each end cut. Make sure that no part of the Rail Bracket extends beyond the Universal Rail end cut. Do not bend the Rail Brackets. Secure the Rail Bracket through the two screw holes at each end of the Rail Bracket, leaving the center screw hole empty. 7.8 Install Stair Railing Sections 8.1 Position Stair Railing Assembly between Post Sleeves to determine bottom Lag Bolt positions. Railing Assembly s bottom rail should be positioned so that the distance to tread or gap meets your local code requirement (typically, a 6" sphere cannot pass through the space created between the riser, stair tread and bottom of stair railing) (side view) Closed rail bracket; for use in top rails only Angled distance between Post Sleeves 8.2 Centered on the Post Sleeve at the proper height, drill a 1/8" pilot hole through the Post Sleeve and into the post, then drill a 3/8" clearance hole through the Post Sleeve only at the proper angle (in-line with the bottom Universal Rail) for both bottom Lag Bolts. Do not drill holes for the top Lag Bolts. 8.3 Thread bottom Lag Bolt into the post at the proper angle, leaving approximately 1/2" of the Lag Bolt shaft exposed. Repeat for opposite post. (side view) 8.4 Place Stair Railing Assembly over bottom Lag Bolts with Universal Rail baluster stops facing yard side, making sure the Rail Brackets seat properly over the Lag Bolt heads Center and plumb the top of the Stair Railing Assembly to the Post Sleeve. Mark the position for the top Lag Bolts on the Post Sleeve using the top Rail Bracket s position as a guide. 8.6 Lift the top of the Stair Railing Assembly out of the way. Drill a 1/8" pilot hole through the sleeve and into the post at the proper angle. Then drill a 3/8" clearance hole through the Post Sleeve only for the top Lag Bolt at the proper angle. Repeat for opposite post. 8.5 View down length of top Universal Rail toward post 8.7 Place the top of the Stair Railing Assembly back into the proper position and thread the top Lag Bolts through the Rail Brackets and into the holes in the Post Sleeves. With the Lag Bolt heads now located in the channels of the Universal Rails, a 1/4" drive socket with an extension and a 7/16" socket is needed to sufficiently tighten the Lag Bolts. Repeat for opposite post. 8.8 Return to bottom Lag Bolts and tighten the baluster stop on the Universal Rail. Repeat for the remaining Balusters. 19

22 7.9 Install Stair Top Rails 9.1 Measure the distance between Post Sleeves. Cut the Top Rail to length and proper angle. The Top Rail s bottom channel fits over the top edges of the top Universal Rail. 9.2 To secure the Top Rail to the Stair Railing Assembly, the Top Rail Screws must be driven through the bottom of the Universal Rail and into the Top Rail at a 90 degree angle, NOT parallel with the Balusters. Two of the four Top Rail Screws should secure the Top Rail nearest each post, with the other two screws spaced equally over the span of the rail, dividing the Top Rail into three equal sections. Clearance holes should be located where there is room between Balusters to maneuver a tool. Drill 3/16" clearance holes down through the top Universal Rail, between the Balusters, in the four calculated positions. 9.2 (side view) 9.3 Place the Top Rail over the top Universal Rail. Make sure that the Top Rail s bottom channel fits over the top edges of the Universal Rail. Attach the four 2-1/2" Top Rail Screws (with color matched heads) through the pilot holes in the bottom of the Universal Rail and into the Top Rail to secure. Be sure not to overtighten the screws. 9.3 (side view) 9.4 Place Top Rail over top Universal Rail and drive the 2-1/2" Top Rail Screws (with color matched heads) up through the four clearance holes in the bottom of the top Universal Rail, into the Top Rail to secure. Be sure not to overdrive the screws. 9.5 Install Post Caps. Refer to page 16 for instructions Installation Instructions For Mitered/ Angled Deck and Porch Railing Refer to Section 1 for Railing Assembly and Railing Installation Instructions (top view) 10.1 For angled railing, determine the angle and type of cut needed to fit the Universal Rails and Top Rail to the Post Sleeve For angles less than or equal to 30 degrees, the Universal Rail and Top Rail can be cut to the required angle. Secure Rail Brackets and Railing Assembly to the post as shown. <30 angle 10.3 For angles more than 30 degrees, the Universal Rail can be cut to the required angle. The Top Rail will require a birds mouth cut to fit properly around the corner of the Post Sleeve as shown (top view) 10.4 For angles more than 45 degrees, both the Universal Rail and Top Rail will require a birds mouth cut to fit properly around the corner of the Post Sleeve. >30 angle (45 shown here) 20

23 8. Jobsite Safety and Workmanship The care and skill that you and your crew use on the jobsite can positively affect the outcome of the job as well as the reputation and profitability of your company. The National Association of Home Builders (NAHB) has assembled a set of suggestions for jobsite safety and care. This chapter highlights some of those recommendations. 8.1 Tools One of the most important things you can do to make the job go smoothly is to make sure that all tools are in good shape and everyone understands how to use them properly. Maintain all hand tools and equipment in a safe condition and check regularly for defects. Do not use broken or damaged tools. Use double insulated tools or ensure that all tools are grounded. Protect all temporary power with ground fault circuit interrupters (GFCI). Plug into GFCI-protected generators or use GFCI extension cords. Equip all power saws with blade guards and turn them off when they are not in use. Before you or your crew use pneumatic or power-actuated tools, make sure everyone has been trained and checked out on their use. Wear proper eye protection, especially when using power tools. Never leave cartridges for pneumatic or power-activated tools unattended. Keep equipment in a safe place and store according to the manufacturer s instructions. 8.2 Ladders Ladders should be well maintained and used only as they were intended. Regularly inspect all manufactured and job-made ladders to verify that they are in good condition and free of defects. Before you climb on a ladder, make sure it is stable and level. Secure ladders near the top or at the bottom to keep them from slipping and causing falls. Extend ladders 3 feet above the landing to provide a handhold for balance when getting on or off the ladder from other surfaces. Locate and identify overhead electrical lines. Make sure ladders and scaffolds never come within 10 feet of electrical power lines. Use ladders only for what they were made not as platforms, runways, or scaffold planks. 8.3 Personal Protective Equipment The Occupational Safety and Health Administration (OSHA) requires that workers wear applicable personal protective equipment. Falling debris is a hazard on any jobsite. Wear a hard hat. When cutting or nailing Panorama composite railing, always wear safety glasses or face shields. Wear sturdy shoes or boots they keep toes from being crushed and help prevent protruding nails from penetrating shoes. 21

24 8.4 Housekeeping Most railing applications involve working around the family and the neighborhood. For this reason, it is particularly important that the area be kept clean and free of unnecessary debris. Keep all walkways and stairways clear of trash and debris. Use and store tools and supplies away from walkways and doors. Scrap lumber, fasteners, boxes, and other discarded material are tripping hazards. Throw them in a dumpster or other trash receptacle. Exercise care around shrubs and flower beds. Some minor damage to the landscaping is unavoidable, but be prepared to replace shrubs that are accidentally crushed or broken. 8.5 Professionalism Remodelers rarely have the luxury of working alone. Your jobsite is often in the heart of a busy neighborhood, where your customers, their families, and their neighbors can watch you work. For this reason, it is particularly important that you and your crew look and act professionally. Wear appropriate clothing. Avoid work clothes that are excessively worn and tee-shirts with inappropriate graphics. Watch your language the fact that you don t see anyone but your co-workers is no guarantee that others can t hear you. Pick up cigarette butts, drink containers, and other trash that accumulates during the day. Keep the homeowner informed of your progress. Show up on time. If you run into unexpected delays or are unavoidably called from the jobsite, let the homeowner know when you will return to complete the job. Follow up. A simple phone call or visit with the homeowner when the job is complete is an opportunity to answer minor questions and avoid unnecessary call backs. 22

25 9. Sales Support CertainTeed supplies more than composite lumber. We also create and supply marketing support: sales tools that help you generate leads, present Panorama composite railing, and make the sale. But we don t stop there. We complete the sales cycle with tools that ensure a satisfied customer through proper installation and follow-up materials that leave a lasting, good impression. 9.1 Sales Tools These sales tools can help you generate leads: Product Samples: Panorama composite railing samples are available to help you demonstrate the beauty and versatility of the product. Product Brochures: Full-color product brochures contain beautiful photography as well as descriptions that emphasize the features and benefits of Panorama composite railing. Countertop Displays: Show the great looks of Panorama composite railing. 9.2 Follow-up Tools CertainTeed s support doesn t end with the sale. Installation Instructions: All-inclusive railing and decking installation instructions are available. Ask for publication FRD411. Warranty: Once the railing is installed, you can make customers feel secure and help ensure referrals by providing them with CertainTeed s warranty. You ll have confident, grateful customers the kind who call you for more work and recommend you to their friends. Education Programs: If you need further help planning your marketing efforts, CertainTeed has ongoing education programs like this Building Solutions program that can help. There s product and installation education and information that can have a big impact on the growth of your business. The Building Solutions series can show you how to maximize profit from the sales you make, as well as how to keep making sales to your growing customer base. 23

26 10. Taking the Master Craftsman Test The more you know about CertainTeed s Panorama Railing, the better you will be able to recommend railing solutions and estimate jobs for your customers. More importantly, the product knowledge and installation techniques you learn in the Master Craftsman Workbook will help you differentiate yourself from your competition. To successfully complete this course and receive your Panorama Railing credential, you must answer 24 of the 25 questions correctly. You can take the test online at Your test will be graded instantly, and you will have the results within minutes. When you successfully pass the course, you ll be given the option to print a Certificate of Completion right online. Take the test online: 24

27 The Master Craftsman Test 1. Composite railing is preferable to wood because a) homeowners question the safety of pressuretreated lumber b) lumber prices are steadily increasing c) composite railing is virtually maintenance free d) all of the above 2. Panorama s weatherable exterior is a) wood b) vinyl c) fiberglass d) paint 3. Panorama composite railing is protected by a a) 10-year limited warranty b) 15-year limited warranty c) 25-year limited warranty d) labor warranty only 4. Which of the following statements about Panorama composite railing is not true a) it installs like wood b) it is dimensionally stable c) it requires special tools and fasteners to install d) it does not need to be painted or stained 5. CertainTeed has been manufacturing high-quality building products for more than a) 25 years b) 50 years c) 75 years d) 100 years 6. Which of the following materials is used in Panorama composite railing a) recycled natural fibers b) recycled tires c) pressure-treated lumber d) fiberglass 7. The Panorama warranty offers two years of labor coverage with SureStart a) true b) false 8. When compared to typical wood railings, in the long run Panorama composite railing a) lasts almost as long as wood and costs more to maintain b) lasts longer than wood and costs less to maintain c) doesn t last as long as wood but costs less to maintain d) lasts almost as long as wood with about the same maintenance costs 9. Panorama composite railing is offered with which type of balusters a) square composite balusters b) colonial vinyl balusters c) decorative steel balusters d) both a and c 10. Panorama composite railing is available in three colors a) true b) false 11. Panorama composite railing is designed for a) commercial applications b) installations over three stories c) 1- and 2-family residential applications d) all of the above 12. When installing Panorama post sleeves for flat railing sections, the post centers should be no more than how many inches apart a) 72 b) 84 c) 96 d) Which of the following components is not included in a flat railing boxed kit a) universal rail b) top rail c) crush block d) post cap 25

28 14. To create a complete post cap with Panorama, snap together the a) post cap and inverted post trim ring b) post cap and post sleeve c) post sleeve and inverted post trim ring d) none of the above 15. When installing railing sections, it doesn t matter if the posts are plumb a) true b) false 16. Typically, building codes require baluster spacing is less than a) 2 inches b) 4 inches c) 5 inches on center d) 6 inches on center 17. If the rise and run of the stairs is 45%, the proper stair angle is a) 22 b) 24 c) 26 d) When securing the top rail to the stair rail assembly on Panorama, the top rail screws must be driven through the bottom of the universal rail and into the top rail a) at a 45 angle b) at a 60 angle c) at a 90 angle d) parallel with the balusters 19. For mitered/angled railing installations with angles of more than 45, only the top rail requires a bird s mouth cut to fit properly around the post sleeve a) true b) false 20. If you need to field cut steel balusters, to protect the ends against rust and corrosion you should apply a) zinc spray b) WD40 c) linseed oil d) vegetable oil 21. Assembly of Panorama flat railing sections with steel balusters is different from square composite baluster installation for the a) universal rails and balusters b) universal rails and top rails c) universal rails and post sleeves d) balusters only 22. Only 8 foot sections of Panorama require a crush block a) true b) false 23. When cutting Panorama composite railing, always wear a) gloves b) a hat c) safety glasses d) sneakers 24. Which of the following sales tools can help you generate leads a) product samples b) product brochures c) countertop displays d) all of the above 25. CertainTeed s Building Solutions program is designed to help you grow your business a) true b) false 26

29 ASK ABOUT OUR OTHER CERTAINTEED PRODUCTS AND SYSTEMS: CertainTeed Corporation 20 Moores Road Malvern, PA ROOFING SIDING TRIM DECKING RAILING FENCE GYPSUM CEILINGS INSULATION Professional: Consumer: /18 CertainTeed Corporation Code No. PN032