INSTALLATION INSTRUCTIONS FOR BALCO, INC. TWO COMPONENT STAIR NOSINGS

Transcription

1 2626 South Sheridan PO Box Wichita, Kansas Phone: (316) Fax: (316) INSTALLATION INSTRUCTIONS FOR BALCO, INC. TWO COMPONENT STAIR NOSINGS 2015, Balco, Inc. 11/20/15 Document Control No. SNI1004

2 INSTALLATION INSTRUCTIONS FOR BALCO, INC. TWO COMPONENT STAIR NOSINGS Document Control No. SNI1004 The following installation instructions are very important. Read them carefully, and be sure you understand them completely before you begin any work. STORAGE & HANDLING Store this product in the horizontal position in a clean, dry location. This is a finished product. Store this product in a protected area. This product may be provided with a protective tape covering. Do not store stair nosings in direct sunlight. Do not remove the protective tape covering until the stair nosings are installed. Remove the protective tape from the stair nosings immediately after their installation. TWO COMPONENT STAIR NOSINGS PARTS LIST 1 DST-330 DXH-330 XH-330 A. Stair Nosing Assembly 1. Base Member DXHS3B DXHT3B DXHS3B 2. Tread Plate DST3A DXJT3A XJT3A B. Anchor 1 : 1. Standard: a. Cap Screw #1 #1 #1 b/ Jamb Nut HJN14 HJN14 HJN14 2. Barbed STA STA STA 3. Continous STA STA STA 4. Double Barbed STNA STNA STNA 5. Strap STA STA STA 6. Wing a. Wing STNWA STNWA STNWA b. Cap Screw #1 #1 #1 c. Jamb Nut HJN14 HJN14 HJN14 7. Scuring Clip 33T 33T N/A 2 8. Securing Screw N/A N/A N/A 1 Anchor options for the stair nosings are listed here. Only one type of the listed types of anchors is provided. 2 Not Applicable TOOLS REQUIRED This is a list of tools recommended for use in the installation of these stair nosings. Tools are not provided by Balco, Inc. A. Electric Dtill B. Level C. Phillips Head Bits for screw-secured systems D. Pry Bar (or other prying tool) 2

3 Figure 1 INSTALLATION These installation instructions are for use in the installation of two component stair nosings types: DST-330 and DXH-330 (Drive-Fit); and XH-330 (Screw-Secured). These systems are designed to be cast into place in concrete stairs. Inspect all base members prior to installation to ensure that they have a flat, non-distorted surface into which to insert the tread plates. The stair nosings shall be installed as follows: STEP 1. Review Balco, Inc. approved shop drawings for types and locations. STEP 2. Prepare the riser forms for the stairs in accordance with standard industry practice and all applicable requirements. Ensure that the riser forms are straight and true. Straight and true riser forms will help ensure proper installation of the stair nosings. NOTE: PROTECTIVE BOARD IS PLACED INTO THE STAIR NOSING BASE MEMBERS AT THE FACTORY, SEE FIGURE!. DO NOT REMOVE THE PROTECTIVE BOARD FROM THE BASE MEMBERS UNTIL THE FINAL STAGES OF PROJECT COMPLETION, WHEN THE TREAD PLATES ARE INSTALLED. FOR SAFETY, ENSURE THAT THE PROTECTIVE BOARD REMAINS INTACT, SOLID AND WELL ANCHORED IN THE BASE MEMBER. IF THE BOARD BECOMES DAMAGED DURING CONSTRUCTION. REPLACE IT IMMEDIATELY WITH PLYWOOD AND SECURELY ANCHOR THE REPLACEMENT TO THE BASE MEMBER. STEP 3. STEP 4. \STEP 5. If continuous anchors are not used, determine the number of anchors necessary for each stair nosing. This can be done by measuring the length of a representative stair nosing base member and providing an anchor at a nominal 3" from each end of the stair nosing base member with additional anchors spaced 12" o.c. between these end anchors. If continuous anchors are used, proceed directly to Step 8. Select a stair nosing base member and the number of anchors required to install it, as determined in Step 3. Inserted the anchors into the raceway in the bottom of the stair nosing base member. For standard anchors (part no. 1 with HJN14), slide the jamb nuts into the raceway. For wing anchors (part 3

4 Figure 2 Figure 3 Figure 4 Figure 5 no. STNWA), slide the head of the cap screw (part no. 1) into the raceway. For barbed, double barbed, or strap anchors (part no. STA or STNA), slide the anchor tab into the raceway (see Figures 2 through 5). STEP 6. Space the anchors in the raceway. Anchors are spaced a nominal 12" o.c. with an anchor at a nominal 3" from each end of the stair nosing. NOTE: ATTACH CAP SCREWS AND JAMB NUTS BY HAND. DO NOT OVERTIGHTEN THE CAP SCREWS. STEP 7. For standard anchors, attach the cap screw (part no. 1) to the jamb nut in the raceway. Attach the cap screw by hand. DO NOT OVERTIGHTEN THE CAP SCREW. For wing anchors, attach the wing and the jamb nut to the cap screw in the raceway. Ensure that the anchors are spaced a nominal 12" o.c. with an anchor at a nominal 3" from each end of the stair nosing (see Figure 6 and Figure 7). 4

5 Figure 6 Figure 7 Figure 8 Figure 9 STEP 8. STEP 9. If continuous anchors are to be used. Slide the tab of the continuous anchor into the stair nosing base member's raceway until the tab's end is flush with the raceway's end. Repeat Step 4 through Step 8, as applicable, until all the anchors are inserted into and in the proper position in all the stair nosing base members' raceways, see Figure 8 and Figure 9. NOTE: IF PAN STAIRS ARE USED, AS AN ALTERNATIVE INSTALLATION METHOD, THE STAIR NOSING BASE MEMBER MAY BE ATTACHED TO THE PAN (TEMPORARILY) AT THIS TIME. STEP 10. If the stair nosing is to be temporarily attached to the pan, select the self-drilling screws and the stair nosing base member. Place the base member into its installed position on the pan, and attach the stair nosing base member to the pan, see Figure 10. through Figure 13. STEP 11. Pour the concrete to form the stairs. 5

6 Figure 10 Figure 11 Figure 12 Figure 13 NOTE: THE USE OF VERY LARGE AGGREGATE OR CONCRETE WITH A VERY LOW SLUMP WILL MAKE INSTALLATION OF THE STAIR NOSINGS DIFFICULT. STEP 12. For stair nosings not temporarily attached to the pan, select one of the stair nosing base members, and, ensuring that the anchors are properly positioned, place the nosing base member, with attached anchors, into the fresh concrete. Ensure that the front edge of the nosing base member is flush with the riser form. Ensure that the receiver for the screw or the clip is at the back end of the installation, away from the riser form. STEP 13. Gently work the base member into the concrete until the back edge of the base member is level with the finished edge of the stair tread. Work the base member into the concrete until it is level, plumb, and at the proper elevation. Use a level to ensure that the base member is level. To provide a stable installation ensure that the stair nosing anchors are securely set in the concrete and that the concrete is surrounding them (see Figure 14 through 17). 6

7 Figure 14 Figure 15 Figure 16 Figure 17 NOTE: FOR STEEL PAN STAIRS, ENSURE THAT THE BASE MEMBER IS SET LEVEL, PLUMB, AND FLUSH ON THE TREAD AREA. THE BOTTOM FRONT OF THE BASE MEMBER MUST SET TIGHTLY ON THE STEEL PAN RETURN. STEP 14. STEP 15. Repeat the procedures given in Step 12 and Step 13 above until all the stair nosings are installed and properly positioned. After the concrete has taken its initial set, remove the riser forms, and finish the concrete riser flush to the stair nosing front or as otherwise specified. This is important to ensure that the riser has a clean finish. STEP 16. The tread plates must be installed after the concrete has cured and just prior to final inspection. Prepare the stair nosing for tread plate installation by removing the protective board from the base. This is accomplished using a prying tool, such as a pry bar, to pry the board out of the tread plate. 7

8 Figure 18 Figure 19 Figure 20 Figure 21 STEP 17. Insert the claw of the pry bar or other prying tool between the exposed portion of the aluminum extrusion and the protective board at the front of the tread. Extreme care must be taken to ensure that none of the exposed aluminum surfaces are marred. STEP 18. Ensure that the surfaces of the base member are free from dirt, grease, grit, grime, etc. Clean the surfaces of the base member as necessary. NOTE: GRIT, GRIME, DIRT, GREASE, ETC. LEFT ON THE BASE MEMBER SURFACES CAN AFFECT THE ENGAGEMENT OF THE BASE MEMBER AND THE TREAD PLATE. DIRTY BASE MEMBER SURFACES CAN MAKE INSTALLATION MORE DIFFICULT AS WELL AS RESULT IN AN UNSAFE INSTALLATION. STEP 19. Select a tread plate. For Drive Fit Stair Two Component Stair Nosings, securing clips have been attached to the bottom of the tread plate at the factory. Ensure that the securing clips are in place before proceeding with the installation of the tread plate. Replace any missing securing clips. 8

9 Figure 22 Figure 23 Figure 24 Figure 25 Extra securing clips are provided by the factory. Securing clips are spaced at 12" o.c. and a nominal 3" from each end of the tread plate. STEP 20. Place the tread plate into the installed position on the base member. For ease of installation, place the tread plate's front lock into the base member's front groove, and push the bottom leg of the tread plate into the back raceway of the base member. Press firmly with the heal of your hand until the back flange of the tread plate is flush with the top of the base member (see Figure 18 through Figure 21). DO NOT USE ANY TYPE OF MALLET TO INSTALL THE TREAD PLATE. STEP 21. For Screw Secured Two Component Stair Nosings, place the screws into the pre-drilled, countersunk anchor holes in the tread plate (see Figure 22 through Figure 25). Hand tighten the screws (see Figure 26 through Figure 29). Do not use a power screw driver to tighten the tread plate screws. DO NOT OVERTIGHTEN THE TREAD PLATE SCREWS. STEP 22. Repeat Step 18 through Step 21 for each stair nosing. 9

10 Figure 17 Figure 18 Figure 19 Figure 20 STEP 23. To avoid unsightly glue residue on the stair nosings, REMOVE THE PROTECTIVE TAPE FROM THE STAIR NOSINGS IMMEDIATELY AFTER THEY HAVE BEEN INSTALLED. STEP 24. If it becomes necessary to remove a Drive Fit tread plate from its base member, use a screw driver. Place the blade of the screw driver into the void at the back of the tread plate, the gap between the tread plate and the base member, and using a shallow wooden block to pry against, pry the tread plate out of the base member. 10

11 WARRANTY POLICY Balco, Inc. warrants to its purchasers that all products sold by it will be free from manufacturing and material defects. Any defective product will be replaced or repaired free of any charge, provided a claim is brought to our attention, in writing, within the established warranty period following the date of shipment by us and provided our examination shows the product has failed under the terms of this warranty. The established warranty period for exterior joint cover systems (Duraflex TM) is five (5) years provided the systems are installed by a Balco Certified Installer. The established warranty period for grids and mats is two (2) years. The established warranty period for all other Balco, Inc. products is one (1) year. Balco, Inc. will not be responsible for installation costs involved in such repair or replacement. Balco, Inc. shall have no obligation under this warranty if owner subjects materials to improper conditions (refer to Balco's installation instructions) This is in lieu of all other warranties, expressed or implied, and is the sole warranty extended by Balco, Inc. Our liability under this warranty is limited to repair or replacement and does not include any responsibility for consequential or other damage of any nature. It is further agreed and understood that the price stated for the seller's products is consideration for the limitation of seller's liability hereunder. REGISTERED TRADEMARKS: BALCO, INC. PATENT NUMBERS: "VINYLINES" "SAF-T-GLO" 5,782,044; 5,829,216; 5,832,678; "METAFLEX" "SAF-TEN BEVEL" 6,014,848; 6,115,980; 6,581,347; "SENTRY" "DURAFLEX" 6,942,419; 6,955,017; 6,962,026; "ILLUMI-TREAD" "METABLOCK" 7,104,717; 7,856,781; 7,946,784; "MICHAEL RIZZA COMPANY" 8,079,190; 8,245,471; 8,464,485; 8,607,519; 8,601,760; 8,646,235; Fire Resistant Joint Covers Patents Pending