Balustrades & Columns Look and feel of wood without the maintenance Most non-corrosive fasteners are concealed Variety of styles and sizes define both indoor and outdoor spaces Make porches, patios, balconies and stairways more elegant and inviting Structurally reinforced with PVC, aluminum and steel
Balustrades & Columns 1 2 3 BTR7X96 7" Top Rail BAL5X22BE Beaumont Baluster BBR7X96 7" Bottom Rail 4 BTR12X96 12" Top Rail 5 BAL6X24AY Ashley Baluster 1 6 BBR12X96 12" Bottom Rail 2 3 Define Your Boundaries Balustrade Systems & Columns This design accent is excellent for defining living space. With Fypon balustrade systems and columns, you can transform any ordinary porch, patio, balcony or stairway into an impressive, sophisticated space. With distinctive styles and sizes available, balustrades and columns are made from non-corrosive parts that keep their beauty with little maintenance. Most fasteners remain totally hidden to provide a clean, classic appearance from any view. And all parts are composed of the same durable urethane material featured in all of our products. Baluster rails, newels and porch posts are reinforced. For easy installation and ordering, complete systems are available with all the essential components. For installation instructions, visit the Product Support section at www.fypon.com. 4 6 5 108 www.fypon.com Phone 800.446.3040 Fax 800.446.9373 U.S. and Canada
How to Order Remember to Order Adhesive A urethane-based adhesive must be used on all joint surfaces. See page 138 to order PL Premium Adhesive. Balustrade Systems Fypon smooth, white balustrades are available in three systems: 5," 7" and 12." This size designates the width of the top and bottom rail. For ease of ordering, we've grouped the products within these systems. In addition to these three sizes, we now offer a new stone-textured system, which has a 6"-wide top and bottom rail. Planning Your Layout Balusters For each baluster, we have noted a " " dimension, which is the maximum center-to-center distance between balusters that still does not allow a 4" ball to pass through at any point. The number of balusters you need can be found by dividing the rail span, in inches, by the center spacing dimension shown or smaller. NOTE: When dividing gives you a fractional result, always round up to the next whole number. Example BAL3X20CC requires 5" on center spacing Classic Baluster BAL3X20CC 2 1 /2" 20" 3 1 /2" 5" BAL3X28CC 2 1 /2" 28" 3 1 /2" 4 15 /16" Sample Chart Each category chart includes a product photo, part numbers and product dimensions. The accessory matches for each part are listed, if applicable. Remember to Order Adhesive A urethane-based adhesive must be used on all joint surfaces. See page 138 to order PL Premium Adhesive. Rail Installation Kit Contents Balustrade rail installation kits are sold separately. Order two kits per rail section unless otherwise specified. BRK5 Connects both ends of one 5" rail to newel, porch post or wall. Order two kits per section. Kit Contents: (2) 2" wide x 1 ½" x 2" Angle Brackets (6) #14 x 2 ½" Stainless Steel Flat-Head Screws BRK6-7 Connects both ends of one 7" rail to newel, porch post or wall. Order two kits per section. Kit Contents: (2) 4" wide x 1 ½" x 2" Angle Brackets (8) #14 x 2 ½" Stainless Steel Flat-Head Screws BRK12 Connects both ends of one 12" rail to newel or wall. Order two kits per section. Kit Contents: (4) Bear Claw Brackets (16) #12 x 3 /4" Pan-Head Screws (4) 5 /16" 18 x 5" Hex-Head Cap Screws (2) 1 /4" 20 x 2" Flat-Head Phillips Thread Cutting Screws (4) 5 /16" Clip Nuts (4) 1 1 /2" O.D. x 5 /16" I.D. x 3 /64" thick Fender Washers BRK12ANGLBKT Connects both ends of one 12" rail section (four connections) to 13" newels ONLY Kit Contents: (2) Top Bracket (2) Bottom Bracket (8) 1 /4" 20 x 3" Hex-Head Bolt (4) 5 /16" 18 x 1 1 /2" Hex-Head Bolt (8) 1 /4" 20 Hex Nut (8) 5 /16" Split Lock Washer (8) 1 /4" x 1 1 /4" Fender Washers (8) #14 x 2" Phillips Pan-Head Screw Newel Post Installation Kit Contents Newel post installation kits are sold separately from the newel posts. Fasteners to mount steel base plate to floor surface not provided. Balustrades & Columns Rail Installation Kits Each rail section (span between two newel posts) will require two rail installation kits (BRK). Rail installation kits will connect both ends of one rail to a newel post, with the exception of BRK12ANGLBKT. This kit connects both ends of one section, requiring only one kit per section. NOTE: Fypon rail installation kits will not work on stair applications. Newel Posts Each newel post will require one newel post installation kit (NPK) to anchor the base of the post, as well as any post tops, balls or trim collars desired. NPK400 Secures one 6" newel post to the floor Kit Contents: (1) Steel Base Plate (1) Channel Bracket (1) 1 /2" 13 Hex Nut (1) 1 /2" Lock Washer (1) 1 /2" 13 x 72" Threaded Rod NPK600 Secures one 8" newel post to the floor Kit Contents: (1) Steel Base Plate (1) Channel Bracket (1) 1 /2" 13 Hex Nut (1) 1 /2" Lock Washer (1) 1 /2" 13 x 72" Threaded Rod NPK10 Secures one 10" newel postto the floor Kit Contents: (1) Steel Base Plate (1) Channel Bracket (1) 1 /2" 13 Hex Nut (1) 1 /2" Lock Washer (1) 1 /2" 13 x 72" Threaded Rod NPK12 Secures one 12" newel post to the floor Kit Contents: (2) 3 /8" Hex Nuts (2) 3 /8" Lock Washers (2) 3 /8" Flat Washers (2) Corner Brackets (2) 3 /8" 16 x 40" Threaded Rods (8) #10 x 3 /4" Flat Head Self Tapping Screws (1) Steel Base Plate NPK13 Secures one 13" newel post to the floor Kit Contents: (1) Steel Base Plate (1) Channel Bracket (1) 1 /2" 13 Hex Nut (1) 1 /2" Lock Washer (1) 1 /2" 13 x 72" Threaded Rod www.fypon.com Phone 800.446.3040 Fax 800.446.9373 U.S. and Canada 109
Balustrades & Columns Balustrade Systems & Columns Note: Baluster photo shown may not be an accurate representation of every size within each category. Ashley Baluster BAL2X10AY 2 1 /4" 10" 2" 5 7 /8" BAL2.5X15AY 2 1 /2" 15" 3 1 /2" 5 27 /32" BAL3X20AY 2 1 /2" 20" 2 1 /2" 5 3 /8" Rosedale Baluster BAL3X24RL 2 1 /2" 24" 3" 5 7 /16" BAL3X24AY 2 1 /2" 24" 4 1 /2" 5 3 /8" BAL3X28AY 2 1 /2" 28" 4 1 /2" 5 11 /32" BAL3X32AY 2 1 /2" 32" 4 1 /2" 5 11 /32" Square Baluster BAL3X36AY 2 1 /2" 36" 6" 5 3 /16" Classic Baluster BAL3X20CC 2 1 /2" 20" 3 1 /2" 5" BAL3X24CC 2 1 /2" 24" 3 1 /2" 4 31 /32" BAL3X28CC 2 1 /2" 28" 3 1 /2" 4 15 /16" BAL3X32CC 2 1 /2" 32" 3 1 /2" 5 1 /32 Logan Baluster BAL3X18LN 3" 18" 3" 5 19 /32" BAL3X18LNOB 3" 18" 1 1 /2" (Top) 1 3 /4" (Bottom) 5 7 /16" BAL3X20LN 3" 20" 3" 5 7 /16" BAL3X24LN 3" 24" 3" 5 7 /16" BAL3X28LN 3" 28" 3" 5 7 /16" BAL3X32LN 3" 32" 3" 5 7 /16" BAL3X36LN 3" 36" 3" 5 7 /16" BAL2X16SQ 1 3 /4" 16" 5 11 /16" BAL2X20SQ 1 3 /4" 20" 5 11 /16" BAL2X24SQ 1 3 /4" 24" 5 11 /16" BAL2X28SQ 1 3 /4" 28" 5 11 /16" BAL2X32SQ 1 3 /4" 32" 5 11 /16" BAL2X48SQ 1 3 /4" 48" 5 11 /16" Woodruff Baluster BAL3X18WF 2 1 /2" 18" 4" 5 17 /32" BAL3X20WF 2 1 /2" 20" 4" 5 7 /32" BAL3X20WFOB 2 3 /4" 20 1 /4" 3 3 /4" (Top) 4" (Bottom) 5 1 /2" BAL3X24WF 2 1 /2" 24" 4" 5 5 /32" BAL3X28WF 2 1 /2" 28" 4" 5 5 /32 BAL3X32WF 2 1 /2" 32" 4" 5 5 /32 BAL3X36WF 2 1 /2" 36" 4" 5 5 /32 110 www.fypon.com Phone 800.446.3040 Fax 800.446.9373 U.S. and Canada
Remember to Order Adhesive A urethane-based adhesive must be used on all joint surfaces. See page 138 to order PL Premium Adhesive. *Note: Max. rail span distance for field applications is 96." BTR5X96 8' Top Rail BTR5X144* 12' Top Rail BBR5X96 8' Bottom Rail BBR5X144* 12' Bottom Rail Top & Bottom Rails Top Bottom Rail Length 4 5 /8" 3 1 /4" 3 1 /8" 96" 4 5 /8" 3 1 /4" 3 1 /8" 144" 3 3 /4" 4 1 /2" 3 1 /8" 96" 3 3 /4" 4 1 /2" 3 1 /8" 144" NP6X48 5 1 /2" 48" NPK400 Plain Newel Post Accessories This Page PST6X6FP PST7X7F PST7X7P TC6 Secures one 6" Newel Post to the structural substrate (Kit contents are listed on page 109) Newel Post Accessories Balustrades & Columns Radius Rails Bottom Top Accessories This Page Radius Line Length B5X7 Ball Top 4 3 /8" 5 1 /4" 6 3 /4" PST7X7F PST8X7C BTRR5X60 Radius Top Rail 60" 3 1 /8" 94 1 /2" (1/4 Circle) PST3X5 Pedestal Ball Top 3 1 /2" 3" 4 3 /4" PST7X7F BBRR5X60 Radius Bottom Rail 60" 3 1 /8" 94 1 /2" (1/4 Circle) PST6X6FP Fancy Peaked Top 7 1 /16" 2" NP6X48 RSB4X4X6 Rail Accessories PST7X7F Flat Post Top 6 1 /2" 4 1 /2" 1 1 /2" NP6X48 PST7X7P Peaked Post Top 6 1 /2" 1 1 /2" NP6X48 BRK5 Rail Installation Kit RSB4X4X6 Rail Support Installation Notes Connects both ends of one 5" top or bottom rail to support structure. Order two kits per section. (Kit contents are listed on page 109.) Install under the bottom rail at a span of 48" or less. Dimensions: 4" x 4" x 7 1 /4" (May be trimmed for height.) TC6 Trim Collar 9 1 /8" 5 5 /8" 2" NP6X48 Design Tip A variety of post options is available to customize your system. Choose from structural porch posts (page 116), structural columns (page 117) or PVC column wraps (pages 124-125). 1 2 BTR12X144 Top Rail BAL6X24AY Ashley Baluster 1 4 3 4 BBR12X144 Bottom Rail PST13X13P Peaked Cap 2 3 5 5 NP12X48 Newel Post www.fypon.com Phone 800.446.3040 Fax 800.446.9373 U.S. and Canada 111
Balustrades & Columns Balustrade Systems & Columns Note: Baluster photo shown may not be an accurate representation of every size within each category. Ashley Baluster BAL4X24AY 4 1 /2" 24" 4 1 /2" 7 3 /8" BAL5X20AY 4 1 /2" 20" 3 1 /2" 7 21 /32" Logan Baluster BAL4X24LN 3 1 /2" 24" 1 3 /4" (Top) 2" (Bottom) 5 15 /16" BAL5X31LN 4 1 /2" 31" 3 1 /2" 5 15 /16" BAL5X24AY 4 1 /2" 24" 3 1 /2" 7 3 /8" BAL5X28AY 4 1 /2" 28" 4 1 /2" 7 11 /32" BAL5X32AY 4 1 /2" 32" 4 1 /2" 7 11 /32" Rosedale Baluster Beaumont Baluster BAL5X16RL 4 1 /2" 16" 4" 7 1 /4" BAL5X20RL 4 1 /2" 20" 4" 6 21 /32" BAL4X22BE 4" 22" BAL5X19BE 5 1 /4" 19 1 /8" 1 1 /8" (Top) 1 3 /4" (Bottom) 1 1 /8" (Top) 1 3 /4" (Bottom) 6 9 /32" 6 23 /32" BAL5X24RL 4 1 /2" 24" 4" 6 21 /32" BAL5X24RLOB 4 1 /2" 24" 3" (Top) 4" (Bottom) 6 3 /16" BAL5X28RL 4 1 /2" 28" 4" 6 21 /32" BAL5X22BE 5" 22" 2 1 /8" (Top) 3 3 /4" (Bottom) 7 5 /32" Square Baluster Classic Baluster BAL5X28SQ 4 7 /8" 28" 8 13 /16" BAL4X27CCOB 4 1 /4" 27" 4" 5 13 /16" BAL4X31CCOB 4 1 /4" 31" 4" 5 11 /16" BAL5X28CCOB 4 1 /2" 28" 3 3 /8" 5 29 /32" BAL5X20CC 5" 20" 4 1 /2" 7 21 /32" BAL5X24CC 5" 24" 5" 7 21 /32" BAL5X28CC 5" 28" 5" 7 1 /2" BAL5X30CC 5" 30 1 /2" 5" 7 17 /32" Woodruff Baluster BAL5X20WF 4 1 /2" 20" 4" 7 3 /16" BAL5X24WF 4 1 /2" 24" 4" 7 5 /32" BAL5X28WF 4 1 /2" 28" 4" 7 5 /32" BAL5X32WF 4 1 /2" 32" 4" 7 5 /32" 112 www.fypon.com Phone 800.446.3040 Fax 800.446.9373 U.S. and Canada
Remember to Order Adhesive A urethane-based adhesive must be used on all joint surfaces. See page 138 to order PL Premium Adhesive. *Note: Max. rail span distance for field applications is 96." BTR7X96 8' Top Rail BTR7X120* 10' Top Rail BTR7X144* 12' Top Rail BBR7X96 8' Bottom Rail BBR7X120* 10' Bottom Rail BBR7X144* 12' Bottom Rail Top & Bottom Rails Top Bottom Rail Length 7" 5 1 /2" 5 1 /4" 96" 7" 5 1 /2" 5 1 /4" 120" 7" 5 1 /2" 5 1 /4" 144" 5 1 /2" 7" 5 1 /4" 96" 5 1 /2" 7" 5 1 /4" 120" 5 1 /2" 7" 5 1 /4" 144" Post Top Sold Separately NPCP8X48 Corner Panel Newel Post NPSP8X48 Straight Panel Newel Post NPK600 Newel Installation Kit Panel Newel Post Top View Accessories This Page 8" 8" 47 3 /4" 47 3 /4" PST9X9FP PST10X10P PST10X10F TC8-8 Secures one 8" newel post to the structural substrate. (Kit contents are listed on page 109.) Newel Post Accessories Balustrades & Columns BRK6-7 Rail Installation Kit RSB4X4X6 Rail Support RSB4X4X6 Installation Notes Rail Accessories Connects both ends of one 7" top or bottom rail to support structure. (Kit contents are listed on page 109.) Install under the bottom rail at a span of 48" or less. Dimensions: 4" x 4" x 7 1 /4" (May be trimmed for height.) Bottom Top B5X7 Ball Top PST3X5 Pedestal Ball Top PST8X8FP Fancy Peaked Top Accessories This Page 4 3 /8" 5 1 /4" 6 3 /4" PST10X10F 3 1 /2" 3" 4 3 /4" PST10X10F 9 3 /8" 3" NP8X48 Plain Newel Post PST9X9FP Fancy Peaked Top 10 3 /8" 3" NPCP8X48 NPSP8X48 NP8X48 Newel Post NPK600 Newel Installation Kit 7 1 /2" 48" Secures one 8" newel post to the structural substrate. (Kit contents are listed on page 109.) Accessories This Page PST8X8FP PST10X10P PST10X10F TC8 Decorative Newel Post PST10X10F Flat Post Top PST10X10P Peaked Post Top PST11X11FP Fancy Peaked Top PST12X12F Flat Post Top 9 1 /2" 6 1 /4" 2" 9 1 /2" 3" NP8X48 NPCP8X48 NPSP8X48 NP8X48 NPCP8X48 NPSP8X48 13 5 /32" 4 1 /2" NP10X48 11 7 /16" 10 1 /2" 1 5 /16" NP10X48 Post Top Sold Separately NP10X48 Newel Post NPK10 Newel Installation Kit 10" 48" Secures one 10" newel post to the structural substrate. (Kit contents are listed on page 109.) Accessories This Page PST11X11FP PST12X12F TC8 Trim Collar TC8-8 Trim Collar 11 1 /8" 7 5 /8" 2" NP8X48 11 1 /8" 8 1 /8" 2" NPCP8X48 NPSP8X48 www.fypon.com Phone 800.446.3040 Fax 800.446.9373 U.S. and Canada 113
Balustrades & Columns Balustrade Systems & Columns Note: Baluster photo shown may not be an accurate representation of every size within each category. Ashley Baluster BAL6X24AY 5 1 /2" 24" 4 1 /2" 8 3 /8" Rosedale Baluster BAL5X16RL 4 1 /2" 16" 4" 7 1 /4" BAL5X20RL 4 1 /2" 20" 4" 6 21 /32" Beaumont Baluster BAL5X24RL 4 1 /2" 24" 4" 6 21 /32" BAL5X24RLOB 4 1 /2" 24" 3" (Top) 4" (Bottom) 6 3 /16" BAL5X28RL 4 1 /2" 28" 4" 6 21 /32" BAL5X19BE 5 1 /4" 19 1 /8" 1 1 /8" (Top) 1 3 /4" (Bottom) 6 23 /32" BAL7X25RL 6 3 /4" 24 1 /2" 3" (Top) 4 1 /2" (Bottom) 6 15 /16" BAL5X22BE 5" 22" 2 1 /8" (Top) 3 3 /4" (Bottom) 7 5 /32" BAL7X28RL 6 3 /4" 28" 6" 8 29 /32" BAL5X31BE 5 3 /4" 31" BAL5X34BE 5 3 /4" 33 7 /8" 2 17 /32" (Top) 4 1 /32" (Bottom) 3 31 /32" (Top) 5 15 /32" (Bottom) 6 27 /32" 6 7 /8" Square Baluster BAL6X22BE 6 3 /16" 21 7 /8" 2 1 /16" (Top) 3 11 /16" (Bottom) 7 15 /16" Classic Baluster BAL5X28SQ 4 7 /8" 28" - 8 13 /16" Woodruff Baluster BAL7X24CC 7" 24" 6" 9 15 /32" BAL7X28CC 7" 28" 6" 9 3 /8" BAL7X28CCOB 7" 28" 3 13 /32" 7 17 /32" BAL5X20WF 4 1 /2" 20" 4" 7 3 /16" BAL5X24WF 4 1 /2" 24" 4" 7 5 /32" BAL5X28WF 4 1 /2" 28" 4" 7 5 /32" BAL5X32WF 4 1 /2" 32" 4" 7 5 /32" BAL6X28WF 5 1 /2" 28" 4" 8 5 /32" 114 www.fypon.com Phone 800.446.3040 Fax 800.446.9373 U.S. and Canada
Remember to Order Adhesive A urethane-based adhesive must be used on all joint surfaces. See page 138 to order PL Premium Adhesive. BTR12X96 8' Top Rail BTR12X120* 10' Top Rail Top & Bottom Rails Top Bottom Rail Length 11 7 /8" 9" 5 1 /4" 96" 11 7 /8" 9" 5 1 /4" 120" NPCP13X48 Corner Panel Newel NPSP13X48 Straight Panel Newel Panel Newel Post 12 1 /2" 47 3 /4" 12 1 /2" 47 3 /4" Top View Accessories This Page PST13X13FP PST14X14F PST14X14P Balustrades & Columns BTR12X144* 12' Top Rail 11 7 /8" 9" 5 1 /4" 144" Post Top Sold Separately NPK13 Newel Installation Kit Secures one 13" newel post to the structural substrate. (Kit contents are listed on page 109.) BBR12X96 8' Bottom Rail BBR12X120* 10' Bottom Rail 9" 11 7 /8" 5 1 /4" 96" 9" 11 7 /8" 5 1 /4" 120" Newel Post Accessories *Note: Max. rail span distance for field applications is 96." BBR12X144* 12' Bottom Rail 9" 11 7 /8" 5 1 /4" 144" Bottom Top Accessories This Page RSB4X4X6 Rail Accessories B10X13 Ball Top PST13X13F Flat Post Top 8 7 /16" 10" 12 7 /8" 12 1 /2" 8 21 /32" 1 1 /2" PST13X13F PST14X14F B10X13 NP12X48 BRK12 Rail Installation Kit Installation Notes Connects both ends of one 12" top or bottom rail to 12" newel post or other support. Order two kits per section. (Kit contents are listed on page 109.) BAL7X25RL Connects both ends of one 12" top and bottom Rail to BRK12ANGLBKT Baluster Reinforced 13" newel post ONLY - Order one kit per section. Rail Installation Kit (Kit contents are listed on page 109.) RSB4X4X6 Rail Support Install under the Bottom Rail at a span of 48" or less. Dimensions: 4" x 4" x 7 1 /4" (May be trimmed for height.) PST13X13FP Fancy Peaked Top PST13X13P Peaked Post Top PST14X14F Flat Post Top 13 1 /4" 4 19 /32" NP12X48 NPCP13X48 NPSP13X48 12 1 /2" 1 1 /2" NP12X48 14" 8 11 /16" 3 1 /8" B10X13 NPCP13X48 NPSP13X48 Newel Post PST14X14P Peaked Post Top 14" 5" NPCP13X48 NPSP13X48 Accessories This Page NP12X48 3-pc Newel Post 12" 48" 12" PST13X13FP PST13X13F PST13X13P PST14X14X3P NPK12 Newel Installation Kit Secures one 13" newel post to the structural substrate. (Kit contents are listed on page 109.) www.fypon.com Phone 800.446.3040 Fax 800.446.9373 U.S. and Canada 115
Balustrades & Columns Stone Balustrade System & Columns Balustrade Systems & Columns Note: Baluster photo shown may not be an accurate representation of every size within each category. Euro Stone Baluster Stone Balustrade System Half Round Column Kit Stone Balustrade System Projection HRC15X168ST 15" 167 3 / 16" 7 1 / 2" BAL5X28EUST 5 11 /32" 27 27 /32" 7 5 /8" Top & Bottom Rails Stone Balustrade System Ships in four pieces: (1) Cap Half (1) Shaft Top Half (1) Shaft Bottom Half (1) Base Half Kit ships in four pieces and creates a single half column. Order two kits to create a full column. BTR6X96ST 8' Top Rail BTR6X120ST 10' Top Rail BBR6X96ST 8' Bottom Rail BBR6X120ST 10' Bottom Rail Top Bottom Rail Length 6" 4 1 / 2" 4" 96" 6" 4 1 / 2" 4" 120" 6 7 / 32" 5 7 / 32" 4 27 / 32" 96" 6 7 / 32" 5 7 / 32" 4 27 / 32" 120" Newel Post Stone Balustrade System Projection HRCBCC96X12ST 22 3 / 8" 110 1 / 4" 11 3 / 4" Ships in three pieces: (1) Cap Half (1) Shaft Half (1) Base Half Half Round Column Kit Stone Balustrade System Accessories This Page Kit ships in three pieces and creates a single half column. Order two kits to create a full column. NP8X48ST 8" 48" 12" PST10X10PST NPK600 Newel Installation Kit Secures one 8" newel post to the structural substrate. (Kit contents are listed on page 109.) Post Top Stone Balustrade System PST10X10PST 5 11 /32" 3" 118 www.fypon.com Phone 800.446.3040 Fax 800.446.9373 U.S. and Canada
PARTS LIST ITEM QTY A PORCH POST INSTALLATION KIT (PPK6) (SEE STEP 3C) 5 1/2" x 5 1/2" Trim Collar 2 2" Wide x 1 1/2" x 2" Angle Bracket 4 MATERIALS NEEDED INSTALLATION GUIDE #14 x 2 1/2" Stainless Steel Flat Head Screw 12 B C D E F G H Porch Post (PP6X96) Baluster Top Rail (BTR5X96 or BTR5X144) Baluster Baluster Bottom Rail (BBR5X96 or BBR5X144) Rail Support (RSB4X4X6) Post Top (PST7X7P shown or PST7X7F) Newel Post (NP6X48) J BALUSTER RAIL INSTALLATION KIT (BRK5) (SEE STEPS 5A, 5B) 2" Wide x 1 1/2" x 2" Angle Bracket 2 #14 x 2 1/2" Stainless Steel Flat Head Screw 6 K NEWEL POST INSTALLATION KIT (NPK6) (SEE STEPS 4A, 4B, 4C) 3/8" - 16 Hex Nut 2 3/8" Lock Washer 2 3/8" USS Flat Washer 2 1/4" x 4 1/2" Diameter Steel Top Mounting Plate 1 3/8" - 16 x 50" Threaded Rod 2 The has been tested and meets the following BOCA National Building Code/1993 Criteria if assembled according to manufacturer s guidelines: 1/4" x 3 1/2" x 3 1/2" Steel Base Plate Note: Fasteners to mount Steel Base Plate to floor surface not provided. 1 1615.8.2 Guard Design and Construction 1615.8.2.1 In-Fill Areas L OPTIONAL DECORATIVE TRIM COLLAR (TC6) 5 1/2" x 5 1/2" Trim Collar 1 CHECK APPLICABLE BUILDING CODES since this procedure may require alterations to meet applicable building code regulations. The manufacturer does not, under any circumstances, warrant the INSTALLATION of its products. The installation guidelines are to be used as suggestions for successful installation. 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). www.fypon.com Phone 800.446.3040 419.445.0116 U.S. and Canada Fax 800.446.9373 419.445.4440 U.S. and Canada 32
INSTALLATION GUIDE 6" Balustrade System PARTS LIST ITEM QTY A PORCH POST INSTALLATION KIT (INCLUDED WITH PORCH POST, SEE STEP 3C) Galvanized Column Mounting Plate 2 #14 x 2" Stainless Steel Sheet Metal Screw 4 MATERIALS NEEDED B C D E F G H Porch Post (PP8X96) (Includes Installation Kit) Baluster Top Rail (BTR6X96 or BTR6X144) Baluster Baluster Bottom Rail (BBR6X96 or BBR6X144) Rail Support (RSB4X4X6) Post Top (PST10X10P shown or PST10X10F) Newel Post (NP8X48) J BALUSTER RAIL INSTALLATION KIT (BRK6-7) (SEE STEPS 5A, 5B ) 4" Wide x 1 1/2" x 2" Angle Bracket 2 #14 x 2 1/2" Stainless Steel Flat Head Screw 8 K NEWEL POST INSTALLATION KIT (NPK8 - NPK10) (SEE STEPS 4A, 4B, 4C) 3/8" - 16 Hex Nut 2 3/8" Lock Washer 2 3/8" USS Flat Washer 2 1/4" x 6 1/2" Diameter Steel Top Mounting Plate 1 3/8" - 16 x 50" Threaded Rod 2 1/4" x 3 1/2" x 3 1/2" Steel Base Plate Note: Fasteners to mount Steel Base Plate to floor surface not provided. 1 L OPTIONAL DECORATIVE TRIM COLLAR (TC8) 7 1/2" x 7 1/2" Trim Collar CHECK APPLICABLE BUILDING CODES since this procedure may require alterations to meet applicable building code regulations. The manufacturer does not, under any circumstances, warrant the INSTALLATION of its products. The installation guidelines are to be used as suggestions for successful installation. 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). 33 www.fypon.com Phone 800.446.3040 419.445.0116 U.S. and Canada Fax 800.446.9373 419.445.4440 U.S. and Canada
PARTS LIST ITEM QTY A PORCH POST INSTALLATION KIT (INCLUDED WITH PORCH POST, SEE STEP 3C) Galvanized Column Mounting Plate 2 #14 x 2" Stainless Steel Sheet Metal Screw 4 MATERIALS NEEDED INSTALLATION GUIDE B C D E F G H Porch Post (PP8X96) (Includes Installation Kit) Baluster Top Rail (BTR7X96, BTR7X120 or BTR7X144) Baluster Baluster Bottom Rail (BBR7X96, BBR7X120 or BBR7X144) Rail Support (RSB4X4X6) Post Top (PST10X10P shown or PST10X10F) Newel Post (NP8X48) J BALUSTER RAIL INSTALLATION KIT (BRK6-7) (SEE STEPS 5A, 5B ) 4" Wide x 1 1/2" x 2" Angle Bracket 2 #14 x 2 1/2" Stainless Steel Flat Head Screw 8 K NEWEL POST INSTALLATION KIT (NPK8 - NPK10) (SEE STEPS 4A, 4B, 4C) 3/8" - 16 Hex Nut 2 3/8" Lock Washer 2 3/8" USS Flat Washer 2 1/4" x 6 1/2" Diameter Steel Top Mounting Plate 1 3/8" - 16 x 50" Threaded Rod 2 1/4" x 3 1/2" x 3 1/2" Steel Base Plate Note: Fasteners to mount Steel Base Plate to floor surface not provided. 1 L OPTIONAL DECORATIVE TRIM COLLAR (TC8) 7 1/2" x 7 1/2" Trim Collar CHECK APPLICABLE BUILDING CODES since this procedure may require alterations to meet applicable building code regulations. The manufacturer does not, under any circumstances, warrant the INSTALLATION of its products. The installation guidelines are to be used as suggestions for successful installation. 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). www.fypon.com Phone 800.446.3040 419.445.0116 U.S. and Canada Fax 800.446.9373 419.445.4440 U.S. and Canada 34
INSTALLATION GUIDE 5", 6" and s INSTALLATION INSTRUCTIONS STEP 2B 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. STEP 1 STEP 2C STEP 2D 3. INSTALL PORCH POSTS FOR PP6X96 ONLY 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. STEP 3A STEP 3B 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. FOR PP8X96 ONLY 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. STEP 3C 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. INSTALLATION INSTRUCTIONS CONTINUED ON FOLLOWING PAGE. 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). 35 www.fypon.com Phone 800.446.3040 419.445.0116 U.S. and Canada Fax 800.446.9373 419.445.4440 U.S. and Canada
5", 6" and s (continued) INSTALLATION INSTRUCTIONS C) After cutting through the steel tubing, pre-drill holes approximately 3/4" up from the bottom of the POST using a 13/64" drill bit. These holes should enter the side of the POST at a right angle and go through both the polymer shell and the steel reinforcement. Now use a 1/2" drill bit to expand the drill holes through the polymer only (do not drill through the steel reinforcement) using the 13/64" holes as pilot holes. These 1/2" holes will allow the screw head to go all the way to the steel reinforcement. Repeat this process at the top of the POST, pre-drilling holes approximately ¾ from the top and centered on the top side. D) Paint all exposed steel at both the top and bottom of the POST, using a quality, zinc base primer spray paint (Rust-Oleum, etc.) to help prevent corrosion. STEP 4A INSTALLATION GUIDE E) Determine the proper location for top and bottom column mounting plates. Be careful to mark these locations precisely, so that the top and bottom plates line up directly above and below each other. Identify the correct location of the top plate first, 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 column mounting plate. F) Install the top and bottom column mounting plates using corrosion resistant mechanical fasteners. For anchoring into wooden floors, ceilings and other structures, stainless steel flat head screws are recommended. For installation into concrete, stone or other floor and ceiling materials, appropriate masonry and/or other fasteners must be used. G) Set the POST into place beneath the top anchor. Lift (jack) the upper structure just high enough to allow the POST to be set into place above the bottom anchor. H) Use the 13/64" holes drilled in Step 3 as guide holes to drill 13/64" holes through the column mounting plates. Firmly attach the POST to the top and bottom plates, driving the corrosion resistant screws provided all the way in so that their heads are flush against the steel tubing (four screws provided, two for the top plate and two for the bottom). I) Patch screw holes using a quality exterior grade, non-shrinking wood filler. Once the filler has dried, lightly sand any minor imperfections and paint the POST as desired using a quality exterior grade latex or oil base paint. 4. INSTALL NEWEL POSTS A) the steel BASE MOUNTING PLATE within layout lines marked out in Step 1. Mount them securely to floor surface (fasteners to mount to floor surface not provided). Install and tighten the two 3/8"-16 x 50" THREADED RODS into MOUNTING PLATE. B) The NEWEL POST may be trimmed to a desired height (measure and cut from the unrouted end of the POST). Add a centered saw kerf to the bottom of the newel post for water drainage. To install the POST align the POST over the THREADED RODS. Install the steel TOP MOUNTING PLATE over the THREADED RODS into the recessed cavity of the NEWEL POST TOP which is routed to accept the hardware. Install 3/8" flat and lock washers and tighten with 3/8" nuts to100 in./lbs. torque. C) TRIM COLLARS may be used on the bottom of the NEWEL POSTS to add a finishing touch. (SEE PARTS LISTS.) Slide the COLLARS over the top of the NEWEL POST into position before the NEWEL POST TOP is fastened in place. D) Finish NEWEL POST by attaching NEWEL POST TOP. Apply urethane base construction adhesive then nail or screw TOP into position. INSTALLATION INSTRUCTIONS CONTINUED ON FOLLOWING PAGE. STEP 4B STEP 4C 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). www.fypon.com Phone 800.446.3040 419.445.0116 U.S. and Canada Fax 800.446.9373 419.445.4440 U.S. and Canada 36
INSTALLATION GUIDE 5", 6" and s (continued) INSTALLATION INSTRUCTIONS STEP 5 5-1. INSTALL 5" RAIL SECTIONS With all POSTS in position, screw ANGLE BRACKETS to the POST or wall surface. Drill 1/8" x 2 1/2" pilot hole for screws. The RAIL ASSEMBLY is positioned snugly between the POSTS and secured in place using the same ANGLE BRACKETS. This step requires three stainless steel flat head screws (#14 x 2 1/2"). A) Determine height of RAIL and fasten top ANGLE BRACKET securely to POST using two screws. B) Fasten bottom ANGLE BRACKET to underside of RAIL SECTION using one screw. C) Apply urethane base construction adhesive to the ends of RAIL that come in contact with POST. Position RAIL ASSEMBLY between POST and install remaining screws. STEP 5-3A STEP 5-1A STEP 5-1B STEP 5-2A STEP 5-2B 5-2. INSTALL 6" RAIL SECTIONS With all POSTS in position, screw ANGLE BRACKETS to the POST or wall surface. Drill 1/8" x 2 1/2" pilot hole for screws. The RAIL ASSEMBLY is positioned snugly between the POSTS and secured in place using the same ANGLE BRACKETS. This step requires three stainless steel flat head screws (#14 x 2 1/2"). A) Determine height of RAIL and fasten top ANGLE BRACKET securely to POST using two screws. B) Fasten bottom ANGLE BRACKET to underside of RAIL SECTION using one screw. C) Apply urethane base construction adhesive to the ends of RAIL that come in contact with POST. Position RAIL ASSEMBLY between POST and install remaining screws. 5-3. INSTALL 7" RAIL SECTIONS With all POSTS in position, screw ANGLE BRACKETS to the POST or wall surface. Drill 1/8" x 2 1/2" pilot hole for screws. The RAIL ASSEMBLY is positioned snugly between the POSTS and secured in place using the same ANGLE BRACKETS. This step requires three stainless steel flat head screws (#14 x 2 1/2"). A) Determine height of RAIL and fasten top ANGLE BRACKET securely to POST using two screws. B) Fasten bottom ANGLE BRACKET to underside of RAIL SECTION using one screw. C) Apply urethane base construction adhesive to the ends of RAIL that come in contact with POST. Position RAIL ASSEMBLY between POST and install remaining screws. 6. RAIL SUPPORT BLOCKS RAIL SUPPORT BLOCKS should be placed under the BOTTOM RAIL at a span of every 48" or less. These blocks can be trimmed for height. 7. FINISHING All exposed fastener heads should be countersunk and filled with automotive body filler (example: Bondo). Allow filler to cure then sand flush to the millwork surface. Caulk any gaps with a good quality exterior caulk. Any good quality latex or oil base paint can be applied over the factory finish. STEP 6 STEP 5-3B 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). 37 www.fypon.com Phone 800.446.3040 419.445.0116 U.S. and Canada Fax 800.446.9373 419.445.4440 U.S. and Canada