installation and technical guide

Transcription

INSTALLATION AND
TECHNICAL GUIDE
©2010 AZEK Building Products
Why AZEK ...
®
AZEK Building Products is
fueled by forward thinking.
We continually refine
product lines and redefine
entire product categories.
www.AZEK.com
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AZEK Deck
AZEK Deck Colors
AZEK Deck Double Dare
AZEK Deck Installation Guidelines
AZEK Deck Basic Installation
ESR-1667 Building Code Report
CCRR-0101 Code Compliance Research Report
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AZEK Porch
AZEK Porch Colors
AZEK Porch Installation Guidelines
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AZEK Rail
AZEK Rail Types and Accessories
AZEK Premier and AZEK Trademark
Rail Installation Guidelines
– Tallboy Surface Mount Bracket
– Surface Mount Bracket
– 45o Rail
– Glass Panel
– Hidden Fasteners
AZEK Reserve
Rail Installation Guidelines
– Tallboy Surface Mount Bracket
– 45o Rail
– Reserve Connector Kits
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ESR-1481 Rail Report
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AZEK Product Warranty Information
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Looks Great Now and
For Years to Come.
We’re no strangers to better
performance. AZEK has over
20 years experience in cellular
pvc manufacturing.
Market demand is moving from
wood and composite to the new
category of stain resistant decking.
AZEK Deck is pioneering
this new generation.
www.AZEK.com
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Limited
Lifetime Warranty
Long Lasting
Durability
Stain
Resistant
Resistant to moisture and insects
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AZEK Deck Colors
NEW! Arbor Collection™
o™
Morad
The Arbor Collection
is available in the
following sizes:
1” x 5 1/2” x 12’
1” x 5 1/2” x 16’
1” x 5 1/2” x 20’
d
Redlan
Rose™
™
Acacia
Terra Collection
AZEK Deck Harvest
Collection has building
code listing ESR-1074 &
CCRR-0101
Kona™
The Terra Collection
is available in the
following sizes:
1” x 5 1/2” x 12’
1” x 5 1/2” x 16’
1” x 5 1/2” x 20’
Fawn™
™
edona
olor! S
New C
e™
r! Taho
lo
o
C
New
harvest Collection™
Scratch
Resistant
stone
Brown
The Harvest Collection
is available in the
following sizes:
1” x 5 1/2” x 12’
1” x 5 1/2” x 16’
1” x 5 1/2” x 20’
1” x 3 1/2” x 16’
ray
Slate G
Clay
*
White
*White is only available in 20’.
rim Joist Cover Sizes
1/2” x 8” x 12’*
1/2” x 11 3/4” x 12’
*Available in Harvest Collection colors only.
Depending on environmental conditions, AZEK Deck colors may
appear to lighten over time as part of the natural weathering process.
Actual colors may vary slightly from photographs.
To request samples, go to AZEK.com.
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Scratch
Stain
Scratch
Composite
Stain
Wood
Split
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AZEK Deck beats other decking
options - wood or composite!
AZEK
Take the AZEK Deck
Split
Double Dare
Stain resistant
AZEK Deck resists staining from stubborn stainmakers
like ketchup, cooking grease and red wine.
Scratch resistant
AZEK Deck resists scratching from patio furniture,
people and pets even in high traffic areas.
Split resistant
AZEK Deck resists splitting from
fasteners placed close to the edge.
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INSTALLATION GUIDELINES
AZEK Deck should be installed using the same good building principals used to install wood or composite decking and in accordance with the local building codes and the installation guidelines included
below. AZEK Building Products Inc. claims no liability or responsibility for the improper installation of
this product. Since all installations are unique, it is the sole responsibility of the installer to determine
specific requirements in regards to each decking application. AZEK Building Products recommends that
all designs be reviewed by a licensed architect, engineer or local building official before installation.
STORAGE
•
•
•
•
•
tore AZEK Deck on a flat and level surface.
S
Do not stack bundles over 8 units high.
When possible, leave factory applied protective wrap on the product to help protect against dirt and debris.
Use care when handling product with a forklift as forks can easily damage the material.
If banding is used, use protective corners to prevent indents from the bands.
PREPARATION
Follow these guidelines for best deck installation.
•A
ZEK Deck is one-sided with the grain side up for the walking surface.
• If using AZEK Deck materials on an existing joist structure, check to make sure all joists are level, structurally
sound, and there are no nails or screws protruding.
•P
roper joist spacing is required for proper installation.
For correct joist spacing:
• Do not exceed 16” center to center for applications with deck board perpendicular to joists.
• D
o not exceed 12” center to center for commercial applications.
• F
or deck boards on a 45° angle, such as a herringbone pattern, the joists should not exceed 12”
center to center.
C
B
A
16"
16"
16" Basic installation
substructure
16" on center maximum joists.
(12" for commercial applications)
12"
picture frame installation
substructure
16" on center maximum joists plus
additional support for the picture
frame structure. (12" for commercial
applications)
Diagonal Installation
Substructure
12" on center maximum joists.
TOOLS REQUIRED
AZEK Deck materials can be installed using similar tools as you would use to install wood decking
or composite decking.
•C
orded or cordless driver/screw gun may be used.
•S
elf-feeding screw guns can be used.
• Miter saw with a fine-toothed, carbide-tipped finish trim blade (12”-60 tooth minimum) works well for cutting.
•A
s with wood or composite decking, safety glasses should be worn during the entire installation process.
FASTENERS
• Expansion and contraction are most significant where
extreme temperature change may exist.
• Best practice is to cut and fasten the deck boards
as soon after cutting as possible.
• When ambient temperature is above 32°F, install
the boards together tightly at splices or miters.
• When ambient temperature is 32°F or below, allow
approximately a 1/16” gap on each end of the run.
• Be sure to fasten ends of boards, splices, or abutments
to building or structure securely into framing using 2
screws which are positioned within 1/2” of each board
end or joint.
• Provide a 1/8” to 1/4” gap between deck boards.
Some area building codes may require double joisting when
joining boards end to end. Always check with your local
code authority for specific requirements before installation.
STAIR CODE COMPLIANCE
In order to meet the AC 174 Requirement for stair
loading, the following method of construction is
necessary:
1.
CARE AND MAINTENANCE
To keep your AZEK Deck looking its best:
• It is recommended that you wash your deck
periodically with ordinary household products
to remove stains, dirt and debris.
•T
o remove rust stains, use a household cleaner
such as a toilet bowl cleaner.
•A
void the use of rubber-backed mats, tarps, pool
toys, and other non-porous items on the deck for
any extended period of time as these items may
cause discoloration to the decking surface.
•S
ome products, such as sunblock and insect
repellent, contain chemicals that may alter the
surface of AZEK Deck. Check product labels
and consult with the manufacturer as to product
compatibility with plastic materials, such as AZEK
Deck, prior to use on or near AZEK Deck.
For ice removal:
•M
ost products containing calcium chloride can
be used without damage to the deck surface.
•T
hese products may leave a white residue which
can be cleaned using the cleaning guidelines
above.
2.
3.
(These guidelines may not cover every care and maintenance scenario
encountered. For additional questions about care and maintenance,
call (877) ASK-AZEK.)
EXPANSION AND CONTRACTION
AZEK Deck boards will have minimal expansion and
contraction with changes in temperature, unlike wood
whose size will fluctuate with moisture changes. The
expansion and contraction encountered may result
in slight gaps which might be noticed at the ends of
boards or in splice joints. Fastening the deck boards
according to the Installation Guidelines will help
minimize expansion and contraction.
7.500
For additional information, visit WWW.AZEK.COM
* Tiger Claw is a registered trademark of Tiger Claw Incorporated. * Cortex is a registered trademark of Handy & Harman Corporation.
AZEK Deck materials can be installed using similar
fasteners as you would use to install wood or
composite decking.
•D
ue to the durability of AZEK Deck products, a
high-quality fastener is recommended that meets
the following specifications:
•S
tainless Steel
•M
inimum Screw Size: #7
• Minimum Length: 2 1/4”
• For salt water coastal applications, we suggest
using the above minimum fastener requirements
in 316 stainless steel.
• Color-matched stainless steel deck screws are also available. Your AZEK Building Products dealer
can assist with more information on these products.
•H
idden Fasteners:
•T
he Tiger Claw®* TC-P and Fastenmaster’s
Cortex®* are two hidden fastener systems
commonly used by contractors installing
AZEK Deck. Before using other types of hidden
fasteners, check with the manufacturer of the
fastener and/or AZEK customer service to ensure
compatibility. BASIC INSTALLATION
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16" Centers | 12” Centers
This completed deck substructure is
ready for installation.
Use 12” on center when deck boards are
not applied Perpendicularly (90° angle)
to the joists, and on commerical applications.
Set and Square
Set the first deck board on the substructure and square the board to the framing. Notice how the ends of the boards
overhang the edge of the framing.
Screw Depth
To contersink your screws, adjust the
depth on your driver to drive the screw
to a depth of 1/32” to 1/16” below the top
surface of the deck board. For best results,
the screws should slightly penetrate the
surface, similar to installing dry wall.
NOTE: If you cut the deck boards to their exact length
prior to installing, fasten the boards immediately after
cutting to limit expansion and contraction. (Refer to
“Expansion/Contraction”.)
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Screw spacing
When fastening, always position screws
3/4” to 1” from the side of the board.
AZEK Deck components should not split
or crack if screws are needed closer to
the edge.
No Pre-Drilling
Drive screws through the deck board as
shown above. Use two screws per joist to
secure properly.
Butting Boards on a run or miter
Ends should fit tightly together. Use two
screw fasteners per board end. Place
screws within 1/2” of board end (countersinking slightly). Fastners should be
properly fastened to underlying joist.
AZEK Deck should be installed using the same good building principals used to install wood or composite decking and in accordance with the local
building codes and the installation guidelines included above. AZEK Building Products Inc. claims no liability or responsibility for the improper installation
of this product. Since all installations are unique, it is the sole responsibility of the installer to determine specific requirements in regards to each decking
application. AZEK Building Products recommends that all designs be reviewed by a licensed architect, engineer or local building official before installation.
www.AZEK.com
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Board spacing
Use a spacer to create a gap of 1/8” to
1/4” between each deck board. Fasten
and space deck boards until surface is
covered. Optional spacer: edge of a carpenter’s square (as shown above). Spacers are available at most lumberyards.
Obstructions
Use a jigsaw to easily cut around
obstructions such as posts for railings,
as shown above.
cutting preparation
Check to make sure that each board is
fastened securely along its entire length.
Allow the deck board to overhang the
rim joist a maximum of 1/8”, use a chalk
line to mark the location in order to cut
the boards to length. This will insure
proper rim joist cover fit.
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cutting deck boards to length
Use a circular saw with a fine-toothed,
carbide-tipped finish trim blade to cut
off the edges of the overhanging boards.
A 20-grit diamond-tipped blade with a
miter saw can also be used.
No Pre-Drilling
Use an AZEK Deck rim joist cover to
cover the face of the rim joist and the
edge of the deck boards. Apply an
exterior-grade construction glue to the
back of the rim joist cover. Be careful not
to get glue on the deck surface.
Rim Joist Cover
Attach rim joist covers using screws
roughly 12” on center.
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Better than wood or
composites, AZEK Porch
resists stains and scratches.
Great looking and built to
handle the high traffic that any
porch encounters, AZEK Porch
can be used in covered or
uncovered applications.
With AZEK Porch, you’ll make
a lasting good impression and
leave many of the hassles of
wood maintenance behind.
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Limited
Lifetime Warranty
Building code listing ESR-1667 & CCRR-0101
Scratch
Resistant
Stain
Resistant
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AZEK porch Colors
Porch Boards are
available in the
following sizes:
1” x 3 1/8” x 10’
1” x 3 1/8” x 12’
1” x 3 1/8” x 16’
stone
Brown
ray
Slate G
Resistant to
moisture and insects
Perfect for covered or
uncovered applications
Actual colors may vary slightly from photographs.
To request samples, go to AZEK.com.
Depending on environmental conditions, AZEK Porch colors may
appear to lighten over time as part of the natural weathering process.
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www.AZEK.com
INSTALLATION GUIDELINES
AZEK Porch should be installed using the same good building principles used to install wood porch products.
Additionally, local building codes and the installation guidelines should be followed. AZEK Building Products claims no
liability or responsibility for the improper installation of our porch product. Since all installations are unique, it is the sole
responsibility of the installer to determine specific requirements in regards to each porch application. Best practice is to
have all porch designs reviewed by a licensed architect, engineer or local building official before installation.
PREPARATION
EXPANSION AND CONTRACTION
Joists should be sloped at 1/4” per foot away from
the house to facilitate drainage.
• When fastened properly, AZEK Porch will
demonstrate minimal changes due to expansion
and contraction. The expansion and contraction
encountered may result in slight gaps which might
be noticed at the ends of boards or in splice joints.
Best practice is to cut and fasten AZEK Porch
boards as soon after cutting as possible.
• If using AZEK Porch board on an existing porch,
remove existing flooring and make sure joists are
structurally sound, free of nails and spaced at a
maximum of 16” center to center.
• For new construction, space joists at 16” on
center maximum and slope the joists away from
the house at 1/4” per foot.
• If installing porch plank at 45˚ angle, space joists
at 12” centers.
• Be sure to install sufficient wood blocking below
areas where railing posts will be installed.
•P
rovide proper structural support below AZEK
Porch where load bearing columns are present.
• Items related to stair construction, structural
framing or any other general construction
questions should be reviewed with the local code
authority, engineer, or architect.
TOOLS
•A
ZEK Porch can be installed using the same tools
you would use to install wood porch products.
• Corded or cordless driver/screw gun may be used.
• Self-feeding
screw guns can be used. Check with
manufacturer for compatibility with AZEK Porch.
•M
iter saw with a fine-toothed, carbide-tipped finish
trim blade works well for cutting.
•A
s with installing a wood porch, safety glasses
should be worn during the entire installation process.
FASTENERS
• Listed are several suggested fastening methods. Additional fastening methods may exist for AZEK Porch.
• Minimum #7 x 2” 305 stainless steel trim head
screw with #17 drill point.
• When using a pneumatic flooring nailer, we
suggest using barbed/serrated 2” stainless steel
cleat “T” nails or “L” cleats.
• For salt water coastal applications, we suggest using
the above minimum fastener requirements in 316
stainless steel fasteners.
• Please contact fastener manufacturer to ensure availability, compatibility, and proper use with AZEK Porch.
www.AZEK.com
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• When ambient temperature is above 32˚F, install
the boards together tightly at splices or miters.
• When ambient temperature is 32˚F or below, allow
approximately a 1/16” gap on each end of the run.
•B
e sure to fasten ends of boards, splices, or
abutments to building or structure securely into
framing using a screw which is positioned within
1/2” of each board end or joint.
INSTALLATION DETAILS
• AZEK Porch is one-sided with the grain side up
for the walking surface.
• Install starting board with grooved edge against
the house or on the outside edge of the porch if
the boards will run perpendicular to the house.
• Attach the starting board by first installing
fasteners down through the board at the edge
nearest the groove.
• Then attach at each joist by driving a fastener
through the tongue at the approximate angle
shown in the Diagram 1.
Diagram 1
INSTALLATION DETAILS (continued)
STAIR DETAILS
•F
asteners should seat approximately 1/16” into the
surface of the product above the tongue as shown
to allow for complete insertion of the next board.
• AZEK Porch may be used for stair treads.
AZEK Deck 1” x 3 1/2” or 1” x 5 1/2” may also be
used. AZEK Deck rim joist cover or AZEK Trim
can be used to trim out the risers.
• AZEK Porch must be fastened tight to joist.
If there are variations in framing, shims may be
required.
• To meet AC174 requirement, install stair stringers
at a maximum of 11” on center.
• Install the next board by inserting the grooved
edge over the exposed tongue on the starting
board. It may be necessary to apply light
pressure to ensure the board is engaged
completely to minimize irregularity in top seam.
• Some codes may require specific framing or
structural requirements. Check with your local
code authorities pertaining to specific stair
requirements.
• After board is fully engaged onto the starting
board, drive fasteners through the tongue at each
joist as shown in Diagram 2.
PAINTING
Diagram 2
• Painting is not recommended for AZEK Porch.
CARE AND MAINTENANCE
To keep your AZEK Porch looking its best:
• It is recommended that you wash your porch
periodically with ordinary household products
to remove stains, dirt and debris.
• To remove rust stains, use a household cleaner
such as a toilet bowl cleaner.
• Avoid the use of rubber-backed mats, tarps, pool
toys, and other non-porous items on the porch for
an extended period of time as these items may cause
discoloration to the porch surface.
Remember to countersink the fasteners slightly to
provide necessary clearance when installing the
next board.
• Continue to add boards per steps 3 and 4 until
outer edge of porch is reached.
• Final board may require removal of tongue or rip
cutting to a necessary width. Use a table saw or
circular saw to accomplish this. Attach the last
board by face fastening through the top or toe
fasten along the outer edge.
PERIMETER DETAILS
•T
here are many options for completing the look
of your AZEK Porch; a few are listed here.
• Some products, such as sunblock and insect
repellent, contain chemicals that may alter the
surface of AZEK Porch. Check product labels
and consult with the manufacturer as to product
compatibility with plastic materials, such as AZEK
Porch, prior to use on or near AZEK Porch.
For ice removal:
•M
ost products containing calcium chloride can
be used without damage to the porch surface.
• These products may leave a white residue which
can be cleaned using the cleaning guidelines
above.
(These guidelines may not cover every care and maintenance
scenario encountered. For additional questions about care and
maintenance, call (877) ASK-AZEK.)
• Rout outside edge with a carbide tipped router
bit as desired.
• Cover exposed edge with AZEK Trim or AZEK
Deck rim joist cover.
• Picture
frame the entire porch using AZEK Deck
1” x 3 1/2” or 1” x 5 1/2” (not AZEK Porch) as a
border. If this option is desired, layout porch
accordingly to accommodate variance in spacing
and height.
Strong good looks are
just the beginning.
AZEK Rail offers the look
and feel of real wood coupled
with the high durability and
low maintenance you expect
from all AZEK products.
A Style for Every Lifestyle
Premier Rail
Trademark Rail
Reserve Rail
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Classic
Luxury
High
Durability
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AZEK premier railing (available in all colors shown)
NEW COLOr! Kona
AZEK Trademark railing (available in white)
NEW COLOr! black
AZEK Trademark railing Sizes
White
brownstone
Clay
Slate Gray
AZEK premier railing Sizes
6’ x 36” x 3 1/2” Rail Kit
6’ x 42” x 3 1/2” Rail Kit
8’ x 36” x 3 1/2” Rail Kit
8’ x 42” x 3 1/2” Rail Kit
6’ x 36” x 2 1/2” Stair Kit w/ Hinge Bracket
6’ Glass Panel Rail Kit
8’ x 3 1/2” Handrail/Retainer Replacement
8’ Bottom Rail Replacement
35” Baluster Replacement
Depending on environmental conditions, AZEK Rail colors
may appear to lighten over time as part of the natural
weathering process.
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6’ x 36” x 3 1/2” Rail Kit
6’ x 42” x 3 1/2” Rail Kit
8’ x 36” x 3 1/2” Rail Kit
8’ x 42” x 3 1/2” Rail Kit
6’ Glass Panel Rail Kit
AZEK reserve railing
AZEK Surface mounts (available in all colors shown)
Tallboy
Tallboy
Tallboy
Tallboy
Tallboy
Tallboy
Surface
Surface
Surface
Surface
Surface
Surface
Mount
Mount
Mount
Mount
Mount
Mount
Bracket
Bracket
Bracket
Bracket
Bracket
Bracket
-
4” x 4” x 34”
4” x 4” x 36”
4” x 4” x 40”
4” x 4” x 42”
6” x 6” x 36”
6” x 6” x 42”
Standard Use Installation:
34” and 36” for 36” Rail Height Installation
40” and 42” for 42” Rail Height Installation
Reserve Installation:
Hidden Fastener Installation:
34” and 40” (Only)
36” and 42” (Only)
AZEK reserve railing Sizes
Surface Mount Bracket - 16”
22.5° Surface Mount Bracket - 34”
22.5° Surface Mount Bracket - 40”
Surface Mount Bracket Kit - 16”
6’ x 36” Sub-Rail Kit
6’ x 5 1/2” Top Rail
12’ x 5 1/2” Top Rail
16’ x 5 1/2” Top Rail
35” Baluster Replacement Pack
8’ Bottom Rail Replacement Pack
In-Line Connector
Post Connector
45° Connector
22.5° Connector
(available in all colors shown)
Kona
Black
White
Brownstone
Clay
Slate Gray
AZEK Accessories (available in all colors)
4” x 4”
pyramid Cap
railing Kits and Universal parts for
AZEK premier railing, AZEK Trademark
railing and AZEK reserve railing
4” x 4”
ball Cap
4” x 4”
post Skirt 2 pieces
4” x 4”
Island Cap
AZEK Accessories (available in white)
AZEK post Sleeves (available in all colors shown)
4” x 4” x 54” Post Sleeve
AZEK post Sleeves (available in white only)
22.5° 54” Post Sleeve
22.5° 115” Post Sleeve
4” x 4”
post Skirt 1 piece
6” x 6”
Island Cap
6” x 6”
post Skirt 2 pieces
22.5°
Island Cap
22.5°
post Skirt
4” x 4”
Solar Light
Cap
4” x 4”
Low voltage
Light
4” x 4”
Low voltage
Light Kit
22.5° Post Sleeve
creates a natural
45° corner
AZEK hardware (available in all colors)
Hidden Fastener Bracket Pack
Hardware Master Pack (complete set)
Bracket Pack
Rotation Bracket Pack
45° Angle Bracket Pack
Hinged Stair Bracket Pack
Glass rail
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RAILING INSTALLATION GUIDELINES
For AZEK Premier
AZEK Trademark
Please read all instructions completely before starting any part of the installation.
Each railing kit comes complete with all parts, hardware and installation guide to
install one complete rail section (excluding posts.) Railing sections have been pre-cut
to 6 ft. or 8 ft. lengths. Check to ensure that the kit is complete. Safety: Always wear
goggles when handling, cutting, drilling and fastening materials.
Note: Check local code requirements.
TOP VIEW
DECK JOISTS
NUT AND WASHER
1. POST SLEEVE INSTALLATIONS
NOTE: Post sleeves are not designed to be used in structural
applications. Therefore, they should not be used where they
may be subject to weight bearing applications such as supports
for a roof of a porch or deck. The Post Sleeve has been designed to slide
easily over a nominal wood 4” x 4” (min. 3 3/8” x 3 3/8”, max. 3 9/16” x 3 9/16”)
post after the deck sub-structure is complete and the deck boards have been
fastened. The 4” x 4” should extend down to the bottom of the rim joist and be
completely “BOXED IN” around all 4 corners for the firmest attachment (see Figure 1). At this time, make sure the 4” x 4” wood posts are level and plumb to ease
the installation of your railing system. If the nominal wood 4” x 4” post is twisted
or oversized it will be necessary to shave the 4” x 4” wood post. Next, slide the
Post Sleeve over the wood post (Do not force the Post Sleeve over the 4” x 4” as
it may eventually lead to a crack or split). Post Sleeves may also be used over a
wood post installed with a Surface Mount Bracket or over a Tallboy Surface Mount
Bracket. For installation of a wood post to concrete, refer to the Surface Mount
Bracket installation instructions or your local dealer. When using 6” x 6” post
sleeves, a minimum 5 3/8” x 5 3/8” and a maximum 5 9/16” x 5 9/16” outside post
dimension is reuired for a proper fit.
17/8"
POST SUPPORT
MATERIAL
4" x 4" WOOD POST
17/8"
TOP VIEW
DECK JOISTS
Figure 11
Figure
1/2" x 8" or 10"
TOP VIEW
CARRIAGE BOLT
NUT AND WASHER
DECK JOISTS
POST HEIGHT CALCULATION7
Figure 1
1 /8"
POST SUPPORT
MATERIAL
NUT AND WASHER
POST HEIGHT
CALCULATION
1/"
POST SUPPORT
7 8
MATERIAL
4" x 4" WOOD POST
17/8"
36" (1) 38 (For 36")
Or
Or
4" x 4" WOOD POST
42" (2) 44" (For 42")
POST CAP
ACCESSORY
17/8"
POST SLEEVE
1/2" x 8" or 10"
CARRIAGE BOLT
1" DECK
SURFACE
36" (1) 38 (For 36")
Or
Or
42" (2) 44" (For 42")
1/2" x 8" or 10"
CARRIAGE BOLT
Figure 1
Figure 1
GRADE LEVEL
CARRIAGE
Calculate and cut Post Sleeve to required height (see Figure 2). Slide Post Sleeve
over 4” x 4” wood post into position. For 36” rail, cut Post Sleeve to a minimum of
38”. For 42” rail, cut Post Sleeve to a minimum of 44”.
3. POST SLEEVE MEASUREMENTS & CUTTING
Measure between posts, top and bottom to obtain the rail length. Also check
the opening to ensure the Post Sleeves, newel posts or walls where the rail is to
be installed are square and plumb. To obtain proper baluster spacing, measure
half the determined rail length on the retainer/bottom rail from the center of
the part. Note: This could be on a hole or from the center between holes only.
If there is not enough room to fit the bracket and baluster side by side, alter the
rail center from center hole to between holes or from between holes to center
hole (this will move your baluster 2 5/8” either direction). Be sure not to allow
any more than 4” between post sleeve and first baluster. If a rail must be cut
so that the baluster sits on the bracket, the baluster end must be notched to fit
around bracket and bracket bolt.
POST4x4
HEIGHT
CALCULATION
WOOD
POST
GRADE LEVEL
Figure 2
2" x 8" DECK JOIST
4x4 WOOD POST
POST CAP
ACCESSORY
POST CAP
ACCESSORY
POST SLEEVE
POST SLEEVE
Figure 2
(For 36")
36"38 (1)
(For38
36")
36" (1)
Or
Or Or Or
44"
(For 42")
(For
42")
42"44"(2)
42" (2)
1" DECK
1" DECK
SURFACE
SURFACE
RETAINER AND BOTTOM RAIL
CARRIAGE
CARRIAGE
BOLTS
BOLTS
RETAINER OR
BOTTOM RAIL
3/8"
CENTER SUPPORT
CENTER SUPPORT
GRADE LEVEL
GRADE LEVEL
2" x 8" DECK JOIST
2" x 8" DECK
4x4JOIST
WOOD POST
4x4 WOOD POST
POST SLEEVE
2. POST SLEEVE HEIGHT CALCULATIONS
POST
CALCULATION
BOLTS
2" x HEIGHT
8" DECK
JOIST
CENTER
SUPPORT
SUPPLIED ALLEN
WRENCH
THREADED INSERT
1/4" PAN HEAD
BOLT
RAIL MOUNTING
BRACKET
Figure 2
Figure23
Figure
Figure 3
RETAINER AND BOTTOM RAIL
RETAINER OR
BOTTOM RAIL
3/8"
RETAINER AND
BOTTOM RAIL
RETAINER OR
BOTTOM RAIL
3/8"
Place the “U” shaped end of the painted stainless steel bracket on the underside
of the retainer and bottom rail. Be sure to place the bracket just slightly inside
(1/16”) the cut edge of the retainer and bottom rail. Mark and drill pilot holes
with a 3/16” bit. Drill out the two mounting holes to 3/8”. Note: When drilling
for the bottom rail, drill through bottom wall only – do not drill through the top
surface. Using the supplied 6mm Allen Wrench, screw the threaded inserts into
the 3/8” holes from the bottom until flush. Be careful not to over torque. Next,
fasten each bracket with (2) 1/4” x 20” panhead bolts to the underside of the
retainer and bottom rail.
5. ASSEMBLE, FASTEN & SLIDE
Align the ends of each Baluster with the pre-drilled holes in the Retainer
(see Figure 5). Using the 1 3/4” # 8 wood screws, fasten the Balusters to the
Retainer first, through the pre-drilled holes. Do not over torque. Align the ends
of the Balusters with the holes in the Bottom Rail and fasten the Balusters to
the Bottom Rail through the pre-drilled holes using the 3” # 8 wood screws.
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33
SUPPLIED ALLEN
WRENCH THREADED INSERT
THREADED INSERT
1/4" PAN HEAD
BOLT
RAIL MOUNTING
1/4" PAN HEAD
BRACKET
BOLT
RAIL MOUNTING
BRACKET
Figure
3 4
Figure
BALUSTERS
4" OPENING
1 3/4" #8
WOOD
SCREWS
(SUPPLIED)
1 3/4" #8
WOOD
3" #8
SCREWS
WOOD
(SUPPLIED)
SCREWS
(SUPPLIED)
HANDRAIL
PRE-DRILLED RETAINER
PRE-DRILLED
BOTTOM RAIL
(5 7/32" O.C.)
Figure 3
HANDRA
IL
SLIDES OV
ER
RETAINER
HANDRA
IL
SLIDES OV
ER
RETAINER
5 7/32"
BALUSTERS
4" OPENING
HANDRAIL
PRE-DRILLED
BOTTOM RAIL
(5 7/32" O.C.)
BALUSTERS
4" OPENING
Figure 4
HANDRAIL
5 7/32"
3" #8
WOOD
SCREWS
(SUPPLIED)
PRE-DRILLED
BOTTOM RAIL
(5 7/32" O.C.)
5 7/32"
HANDRA
IL
SLIDES OV
ER
RETAINER
POST SLEEVE
POST SLEEVE
4. RETAINERS & BOTTOM RAIL BRACKET INSTALLATION
1 3/4" #8
WOOD
SCREWS
SUPPLIED ALLEN
(SUPPLIED)
WRENCH
3" #8
WOOD
SCREWS
(SUPPLIED)
Figure 5
Figure 4
6. CENTER RAILING SUPPORT
Fasten center support in center of railing using 1” self-tapping screws. (see Figure 6a & b)
Check Chart 1 for the proper cut length for your style of rail. Center support must be cut to meet local railing height
requirements.
CENTER SUPPORT SIZE - Premier/Premier Pro
CDN
Victorian
2 /16”
CDN
Colonial
25/8”
US
Premier/Premier Pro
45/16”
15
BOTTOM RAIL
BALUSTERS
NOTE: LEVEL RAILING PRIOR
TO MARKING & DRILLING
Figure 7
1 3/4" WOOD SCREW
1 7/16"
7/16"
4"
POST
** indicates size supplied
Figure 6b
CENTER SUPPORT SIZE - Trademark
US
Select-Flat
4 /16”
US
Select
45/8”**
US
Reserve
43/8”
CENTER
SUPPORT
BLOCK
5
CENTER
SUPPORT
BRACKET
Figure 6a
MARK & DRILL
HOLES
PRE-DRILLED
HOLES
CENTER SUPPORT
BRACKET
CENTER SUPPORT
BLOCK
** indicates size supplied
#14 x 2" SCREWS
1" SELFDRILLING SCREWS
CENTER OF BOTTOM RAIL
Chart 1
7. LEVEL & ATTACH RAILING
•
•
•
•
Place assembled railing between Posts and level. • Mark holes. • Remove assembled railing.
Drill pilot holes in the Posts with a 1/4” drill bit. (Be sure to only drill through post sleeve.) • Re-position assembled railing.
Fasten the section to the post using the 14 x 2” stainless steel painted screws supplied with a #3 square drive bit.
When using Tallboy SMB be sure to use a 7/32” drill bit through post sleeve and SMB wall.
IMPORTANT: DO NOT OVER TORQUE SCREWS WHEN FASTENING RAIL TO POSTS AS THIS MAY CAUSE POST
SLEEVES TO CRACK.
8. POST CAP APPLICATION
Apply generous amount of construction grade adhesive to top edges of Post Cap and press Post Cap firmly into place.
9. FASTEN HANDRAIL TO RETAINER
Take remaining self drilling screws that were used in Step 6 and install up through the retainer into the handrail to lock it in
place. Space screws evenly over the span. For care and cleaning instructions visit our website.
RAILING CONVERSION FOR STAIRS
The assembly and installation of stair rail is the same as for horizontal rail (see over) except for changes detailed below.
Please read instructions for horizontal rail before attempting to assemble and convert to stair rail.
1. Preparation
First check the rise and run of the stairs to determine the proper stair rail angle. (see Figure 8) Check the rail opening to
ensure the sleeves, newels or walls where the stair rail is to be installed are square and plum. Measure between the Post
Sleeves to obtain the rail length. Be sure to measure between the Post Sleeves at both top and bottom.
TIP: Ensure the proper fit by cutting a test piece of wood to the previously determined length and angle and fit it into
the opening. Once the proper measurements have been confirmed, measure the handrail and retainer from the center of
each part and trim an equal amount from each side to obtain the top length measured Figure 8
between the sleeves.
3
4
2
2. Balusters Cut Balusters to proper angle, top and bottom. Keep length identical.
1. Stair Angle
3. Drilling holes Retainer and Bottom Rail
The Retainer and Bottom Rail have been factory drilled for “horizontal” rail
installations to assist with the assembly. For a stair rail installation, the Retainer and
Bottom rail holes will need to be re-drilled to match the required stair rail angle.
From the center of the top holes, draw a line the proper angle down the side of the
bottom rail to be used as a guide (see Figure 9). Using a 3/16th bit, drill through the
top hole following the angled guideline, and through the bottom of the rail making
sure to drill through as close to the center line as possible.
TIP: Use a drill guide to ensure accuracy and see our website for additional
information.
Figure
8 9
4
4. Mounting Brackets
Use the Stainless Steel Hinged Bracket included in the kit to fasten railing section to
the posts. IMPORTANT: DO NOT OVER TORQUE SCREWS WHEN FASTENING TO
THE POSTS AS THIS MAY CAUSE THE POST SLEEVE TO CRACK.
5. Assemble and Install
Assemble as per horizontal rail installation instructions Step #5.
Note: The 2 1/2” handrail is placed onto the retainer and secured using the self drilling
screws supplied.
Manufactured under AZEK Building Products U.S. Patent 6,702,259 B2
34
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For AZEK Premier
AZEK Trademark
TALLBOY SURFACE MOUNT BRACKET (SMB)
4” x 4” and 6” x 6” applications
INSTALL RAIL SECTION
NOTES:
• Cut the post sleeves to the desired length and slide
them over the SMB’s, squeezing the top of the SMB
to start the post sleeve and slide it down until flush
with the base.
•T
here are 4 sizes of Tallboy Brackets available - 34”,
36”, 40”, and 42”. For the over the post application,
use the 34/40s and for the hidden bracket system
use the 36/42s.
•H
idden fasteners will not work with Reserve over
post system.
• Tallboy Surface Mount Brackets are also available
in 22.5˚ profile in 34”/36” and 40”/42” heights.
• Place assembled rail section between the posts
and mark the bracket hole locations onto the post
sleeves as per the Railing Installation Guide
supplied with the railing kit.
PLACEMENT
• *IMPORTANT: Remove the rail section and drill
the bracket hole locations with a 7/32” diameter
drill bit (*THIS DRILL SIZE IS CRITICAL*).
Drill through both the post sleeve and SMB.
Center the Surface Mount Bracket (SMB) at each
post location and mark the mounting hole locations
on the surface. Position the open slot away from all
fastening locations.
• DO NOT OVER TORQUE THE SCREWS in the
Tallboys. Tighten only until screws are seated.
For best results, we recommend a high torque,
low speed setting on your drill.
MOUNTING INSTRUCTIONS
• With all holes drilled, place rail section
between posts and install as per the Railing
Installation Guide.
Mark SMB mounting locations onto the deck surface.
• Concrete Installation: Drill marked mounting
FINAL STEP
• Wood Installation: There must be a solid base
With all rail sections installed, tighten all the SMB base
fasteners. Install the 2 piece post skirts supplied in the
SMB kit (if you have purchased the SMB alone, you will
need to purchase a 2 piece post skirt to hide the base
and fasteners).
locations with a 3/8” diameter Masonry bit to
accept 3/8” diameter x 4” wedge anchors.
Gently tap the anchors into the drilled holes.
Some installations may require an anchor epoxy.
on which to fasten the SMB. A 5” minimum thick
blocking must be securely fastened to the structure
prior to installation of the SMB.
Note: DO NOT install SMB to decking surface only.
Make sure there is adequate structure to secure as
stated above. You may secure SMB on top of deck
surface if adequate blocking is underneath.
• For Concrete Installation: If the concrete anchors
have tightened leaving too much thread exposed
for the 2 piece post skirt to install properly, it may
be necessary to cut the top of the wedge anchor
so it no longer interferes with the skirts snapping
assembly.
The SMB is to be installed using 3/8” diameter x 5”
lag bolts (the lag bolts will require a 1/4” pilot hole
to ensure the wood foundation blocking does
not split).
FASTENING
Place the SMB over the mounting locations. Lightly
tighten the mounting fasteners so that the SMB can
still move freely, but tight enough for the SMB to sit
flush with the mounting surface.
RAILING
SECTION
RAILING MOUNTING BRACKET
SURFACE MOUNT BRACKET
SMB ADJUSTMENTS
If the SMB is out of plumb or not level, add shims to
the base of the SMB. Check for plumb and square.
Repeat until correct.
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35
2" #14ss
PAN HEAD SCREW
SMB BASE FASTENER
POST SLEEVE
2 pc. POST SKIRT
For AZEK Premier
AZEK Trademark
BRACKET PLACEMENT
Locate the Post Surface Mount Bracket.
• Tolerances for 4” x 4” pressure treated post should be
minimum 3 3/8” x 3 3/8” and max 3 9/16” x 3 9/16”.
Any pressure treated posts outside these specifications
could result in improper installation.
• Mark and drill four holes 3/8” x 4” deep to accept
3/8” x 3 3/4” Wedge Anchors.
• Place the Surface Mount Bracket over the holes and
secure to the surface using 3/8” x 3 3/4” Wedge Anchors.
MOUNTING THE POST
• Insert the pressure treated 4” x 4” into the Post Sleeve ensuring end
work fully seats down into the steel Surface Mount Bracket.
• Slide Post Sleeve over installed Surface Mount Bracket.
• Mark Rail Kit bracket holes on Post Sleeve as per Rail instructions.
• Drill 1/4” holes through Post Sleeve and Surface Mount
Bracket. DO NOT DRILL INTO PT 4” x 4”.
• Slide Post Skirt over Post Sleeve.
• Reset Railing Section and install as per Railing
Installation Instructions.
PRODUCTS
BILL OF MATERIALS
(A) Surface Mount
Bracket Kit:
1 - Box
1 - Steel galvanized Surface Mount Bracket
4 - 3/8” x 4” wedge anchors
1 - PVC Post Skirt
1 - Instruction sheet
1 - Box
(B) Surface Mount Bracket:
1 - Steel galvanized Surface mount Bracket
1 - Instruction sheet
PRESSURE TREATED 4” X 4” END WORK
• Cut Pressure Treated 4” x 4 1/4” shorter than Post Sleeve.
• Trim 4 sides of Pressure Treated 4” x 4” to fit into Surface
Mount Bracket.
• Slide Pressure Treated 4” x 4” into Surface Mount Bracket.
Note: Wedge anchors are for concrete installation ONLY.
For installation to wood surface refer to local building
code. (Recommended: Use minimum 3/8” x 5” lag bolts
into solid wood mass underbody).
Manufactured under AZEK Building Products U.S. Patent 6,702,259 B2
36
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For AZEK Premier
AZEK Trademark
45˚RAIL
For best results, make a test sample from a 2” x 4” to ensure proper fit prior to performing the following steps.
Perform these operations to the Handrail, Retainer and Bottom Rail before assembling the railing.
Replace the brackets in the hardware pack with 45º corner “T” brackets available at your local dealer.
STEP 1
STEP 4
For the Handrail and Retainer, perform steps #2
and #3 with the parts together. Slide the retainer
into the handrail. Fasten them together with the
1” drill quick screws supplied.
Remove the 1” quick drill screws from the retainer.
STEP 2
Repeat steps 2 and 3 for the Bottom Rail as well.
Determine the total length required from corner
to corner of the post sleeve. Mark this length on
the hand rail, retainer and bottom rail (Mark #1).
For retainer and bottom rail, ensure equal spacing
from the mark(s) #1 to the first baluster drill hole
(see figure 1, mark #1). Place mark(s) #2 at 5/16”
(half the hole diameter-see figure 1, mark #2)
out from mark #1 (towards end of rail).
Drill a 5/8” hole at each mark #2.
Length of
rail required
Mark #2
Mark #1
STEP 6
Assemble the rail section as per normal rail
installation instructions.
NOTE: The 45° Bracket is designed to mount a
rail section to the corner of a standard (square)
4” x 4” or 6” x 6” post sleeve. This is not to be
used with the 22.5° post sleeve or an AZEK Reserve
Over-Post application.
Figure 3
ut
C
Ø5/8
Hole
Pa
th
Figure 1
STEP 5
Mark #2
Mark #1
STEP 3
Cut out a 90˚ wedge up to the edge of the hole
on both sides of the handrail. Do not cut to the
back of the hole. Leave the back of the 5/8” hole
to allow the corner of the Post Sleeve to fit neatly.
(45˚ Corner “T” Brackets)
Figure 2
AZEK Building Products claims no liability or responsibility for the
improper installation of our porch product. Since all installations are
unique, it is the sole responsibility of the installer to determine specific
requirements in regards to each porch application. Best practice is to
have all porch designs reviewed by a licensed architect, engineer or
local building official before installation.
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37
For AZEK Premier
AZEK Trademark
GLASS PANEL
Read ALL instructions completely before installation.
Each railing kit comes complete with all parts, hardware
and installation guide to install one complete rail section
(EXCLUDING POSTS, CAPS and GLASS) and have been
pre-cut to 6 ft. lengths. Check to ensure the kit is
complete. SAFETY: Always wear goggles when cutting,
drilling and fastening materials.
NOTE: Check local building code requirements.
FOLLOW STEPS 1 THROUGH 4 OF THE AZEK PREMIER AND
AZEK TRADEMARK RAILING INSTALLATION GUIDELINES.
STEP 5
Place the center support at the mid point of the
Bottom Rail and attach using the 1” drill quick
screws supplied (Refer to Figure #5 of the AZEK
Premier / AZEK Trademark Installation Guide).
STEP 9
With the mounting brackets and retainer already
installed and fastened to the handrail, place the
remaining 2 rubber bumpers evenly spaced on the
underside of the retainer (approx. 6” from each
side). Place the handrail assembly on top of the
glass ensuring the rubber bumpers are centered on
the glass, and rail is centered on the post sleeve.
Mark the bracket hole location and drill the Post
Sleeve only using a 1/4” drill bit. Using a #3 square
drive bit, attach the handrail assembly to the post
sleeve using the 2” x #14 stainless steel screws that
are supplied. Ensure the rubber bumpers are
centered against the glass.
GLASS PANEL SIZING
STEP 6
Mark the “T” Bracket hole location on the post
sleeves for the Bottom Rail at (3 1/8” for US and 1
1/8” for Canada) above the deck surface. Drill the
marked “T” Bracket hole locations using a 13/64” drill
bit through the post sleeves. Install the Bottom Rail
to the Post Sleeves using (2) of the 2” x #14 stainless
steel screws supplied with a #3 square drill bit.
STEP 7
Mark the glass panel bracket hole locations above
the bottom rail, centered on the Post Sleeves at 4
1/2” and 24” for a 36” high rail, or 4 1/2” and 30”
for 42” high rail above the top of the Bottom Rail
(for Canada, add 2” to the height of the upper class
panel bracket). Using a 1/4” drill bit, drill through
the Post Sleeve only at the 4 glass panel bracket
hole locations and install the 4 glass panel brackets
using the 2” x #14 stainless steel screws supplied.
Make sure that all brackets face the same direction.
Ensure the opening is square and plumb. Measure
the opening between the posts at the top and
bottom to ensure squareness.
THICKNESS: 3/8” Tempered
WIDTH: Subtract 1 3/4” from the opening size to
allow room for the brackets and proper clearance.
HEIGHT:
US
Canada
36” Rail Height ------- 28 3/8”
42” Rail Height ------- 34 3/8”
36” Rail Height ------- 30 3/8”
42” Rail Height ------- 36 3/8”
STEP 8
Place 2 of the supplied rubber bumpers in the
center of the rail evenly spaced (approx. 6” from
each side) on the top of the bottom rail.
Remove the clamping plates from the glass panel
brackets. Place the glass against the brackets,
ensuring that the glass is centered on the rubber
bumpers and in the opening. Reinstall the glass
panel bracket clamping plates and tighten the
screws accordingly.
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38
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33
For
For AZEK
AZEK Trademark
Premier
AZEK Trademark
HIDDEN FASTENER BRACKET
IMPORTANT - Refer to the Master Installation Guide located in each Rail Kit Box or at www.AZEK.com for full assembly and installation requirements. Follow the additional steps below to install the Hidden Fastener Bracket.
MEASURING & DRILLING
RAILING ASSEMBLY
Measure and cut the Handrail, Retainer and Bottom
rail to the desired length. Figure 1
Assemble the rail section as per the Master
Installation Guide. Figure 4, Figure 5, Figure 6
Part # CMI-H-HFB
Figure 1
Figure 4
Figure 2
Drill and Install the threaded inserts into the
Retainer and Bottom Rail. Figure 2
DO NOT ATTACH THE BRACKETS AT THIS TIME
ROUTING
Route or Zip a 1/2” x 1-1/8” wide opening through
both ends of the Retainer and the bottom of both
ends of the handrail and Bottom Rail. Figure 3a
Figure 5
DO NOT CUT THROUGH THE TOP SURFACE OF THE
BOTTOM RAILAND HANDRAIL. Figure 3b
Figure 3a
Figure 3b
Figure 6
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For AZEK Trademark
For
For AZEK
AZEK Trademark
Premier
AZEK Trademark
HIDDEN FASTENER BRACKET
BRACKET INSTALLATION
RAILING INSTALLATION
Bottom Bracket: Install the brackets to the Post by
measuring from the deck up 4-7/8” (2-7/8” CDN) to
the centre of the bracket screw holes. Figure 7
Place the assembled Rail onto the Brackets and attach using the 1/2” x 1/4-20 Pan Head screws supplied in the Rail Kit Hardware Pack. Figure 10, Figure 11
NOTE: A short screw driver, small quarter drive
ratchet or right angled power driver will be required.
Figure 12
Figure 7
Figure 10
With the bracket centered
on the Post, mark and drill
the Post with a 7/32” drill
bit for the Steel Surface
Mount bracket or 1/4”
through Post Sleeve only for 4” x 4” pressure
treated lumber. Figure 8
Figure 11
Figure 8
Attach the bracket
to the Post using the 2” x #14 Stainless
Steel screws supplied in
the Master Rail Kit using
a #3 Robertson or #3
Philips driver bit. Figure 9
Figure 12
Figure 9
Under Strandex Canadian Patent #2153659,
US Patent #5516742 and Composatron US Patent #6702259
40
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For AZEK Reserve Railing
Read all instructions completely before starting any part of the installation. Each sub rail kit comes complete
with all parts, hardware and installation guide to install one complete sub-rail kit. (EXCLUDING TOP RAIL, POSTS,
SKIRTS AND CAPS) sub-rail kits have been pre-cut to 6’ or 8’ lengths. Check to ensure the kit is complete.
SAFETY: Always wear goggles when cutting, drilling, and fastening materials.
NOTE: Check local building code requirements prior to installation.
IMPORTANT NOTES
• 5 1/2” Top Rail is sold separately and comes in 6’, 8’, 12’, and 16’ lengths. Use the Top Rail Connectors with all
joints including Post, In-Line, 45˚ and 22.5˚ to ensure a proper fit between parts.
• For best results, we recommend the use of the Tallboy Surface Mount Brackets for the most
secure and strongest method of attachment.
• Post sleeves are designed to be installed within the height of the rail system they are being used
with and are NOT designed for structural use.
1. POST INSTALLATIONS
The 4” x 4” and 6” x 6” post sleeves have been designed to slide easily over the rust proof coated Tallboy.
Follow the Surface Mount Bracket instructions for wood deck or concrete slab before installation of the Post
Sleeves. Pressure treated wood 4” x 4” or 6” x 6” can also be used but is not recommended due to uncontrolled
swelling, cracking and twisting of the wood. A minimum lumber size of 3 3/8” and a maximum of 3 9/16” is
required for proper fit of sleeves. A tight fit is not recommended. When using 6” x 6” post sleeves, a minimum
5 3/8” x 5 3/8” and a maximum 5 9/16” x 5 9/16” outside post dimension is reuired for a proper fit.
IMPORTANT: DETERMINING POST HEIGHT
4” x 4” CENTER POST
For 36” railing height, the post sleeve must be cut to 34”.
For 42” railing height, the post sleeve must be cut to 40”.
6” x 6” MAIN POSTS
For other than column full height 6” x 6” post installations, cut the main 6” x 6” Post Sleeve a minimum of 2” higher than
the desired rail height or 38” for a 36” rail or 44” for a 42” rail.
NOTE: If wood posts are being used, small shims may be used if excessive gaps are present in the post sleeves.
Figure 1
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41
2. RAIL MEASURING AND CUTTING
Measure between post sleeves, top and bottom,
to obtain the rail length. Also check rail opening to
ensure the posts, newels or wall where the rail is to
be mounted are plumb and square. To obtain proper
baluster spacing, be sure to measure and cut
retainer and bottom rail an equal distance from
the center.
TIPS: See our website www.AZEK.com for:
• Optional cut technique to equally divide rail kits,
i.e., make 2 rail sections from one rail kits.
• How to cut and position railing on the Post
Sleeve at a 45˚ angle.
Figure 2
3. RETAINER & BOTTOM RAIL BRACKET
INSTALLATION
Place the U shaped end of the bracket on the
under side of the bottom rail and retainer just
slightly inside (1/16”) the cut edge. Mark and drill
pilot holes with a 3/16” drill bit. Drill holes
to proper size using a 3/8” drill bit.
NOTE: When drilling the bottom rail, drill through
the bottom wall only - do not drill through the top
surface wall. Using the Allen Key supplied, screw
the threaded insert into the 3/8” holes from the
bottom until flush. Be careful not to over tighten/
torque. Fasten brackets using the 1/4” x 20” pan
head bolts to the underside of the retainer and
bottom rail.
NOTE: The hidden fastener brackets will not work
in the over the post application for the Reserve Rail
system due to the placement of the brackets.
Figure 3
42
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4. ASSEMBLE AND FASTEN
6. CONNECTION TO POSTS
Align the ends of the baluster with the pre-drilled
holes in the retainer (see figure 4).
Using the #8 stainless steel wood screws,
fasten the ends of the baluster to the retainer first,
through the pre-drilled holes, then fasten the other
ends of the balusters to the bottom rail (be careful
not to overtighten/torque the screws.)
4” x 4” Center Post, Corner Post and 6” x 6”
Main Posts Center the assembled rail sub section
between the post sleeves and position the bottom
of the retainer approximately 1/16” above the top
of the 4” x 4” center post. Mark the bracket hole
locations and drill with a 1/4” drill bit.
Fasten the section to the post using the #14 x 2”
stainless steel painted screws supplied with a #3
square drive bit.
NOTE: For the 4” x 4” center post and corner post,
the bottom of the retainer should sit at the top of
the post to allow the top hand rail to pass over the
4” x 4” center post.
For a center post corner application a 6” Top Rail
Corner Connection Hardware Pack is required.
Figure 4
#6-1: 6” x 6” Main Posts, 45˚ Connection
Follow the 45˚ Rail Installation Instructions
or visit our website at www.AZEK.com for
details. A 45˚ Hardware Pack is required for
this installation.
NOTE: When fastening brackets to post sleeves DO NOT
OVER TORQUE the screws. Once the screws are “seated”
they are tight.
5. CENTER RAILING SUPPORT
Attach the stainless steel center support bracket
to the pre-cut center support using the 1 remaining
#8 wood screw. Install the support assembly in the
center of the underside of the bottom rail using the
1” screws supplied in the sub kit.
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7. INSTALL ALL SECTIONS
Before installing the top rail, ensure all sub rail
sections are installed.
#8-1: Install Corner 6” Top Rail over Center Post
Follow the directions as per step #8. Cut Top Rails
with corresponding 45˚ angles approximately 1/8”
shorter than a piece for a tight fit to allow room for
the joiner piece. Before installation of the Top Rail,
insert both Top Rails into the joiner.
Place the loose assembled Top Rail pieces onto the
retainer, find the proper seating location and firmly
press Top Rails onto the retainers.
(NOTE: Caulking may be used to seal the joiner
to the Top Rail if desired.) A 4” x 4” Over-Post
Connection Hardware Pack is required for this
application.
9. FASTEN THE 6” TOP RAIL TO RETAINER
8. INSTALL 6” TOP HAND RAIL
After all sub rail sections have been installed, measure
the length between the 6” x 6” main posts and cut
the Top Rail.
Use the remaining 1” stainless steel screws supplied,
fasten up through the retainer into the underside of
the Top Rail to lock it in place. Space screws evenly.
For additional holding strength use caulking
between the Retainer and the Top Rail.
Figure 5
(NOTE: Use the System Connectors, sold separately,
at all joint connections to ensure proper fit).
Place the cut Top Rail onto the retainer of the
previously installed sub Rails and over the 4” x 4”
center posts. (NOTE: If the top Rail is tight over the
4” x 4” Center Post, the retainers may be misaligned.
To correct this problem, loosen the #14 x 2” stainless
steel screws holding the top brackets, reinstall
Top Rail and retighten the screws.)
Railings manufactured under Strandex Canadian Patent # 215695 and US Patent # 5516742
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TALLBOY SURFACE MOUNT BRACKET (SMB)
4” x 4” and 6” x 6” applications
INSTALL RAIL SECTION
NOTES:
• Cut the post sleeves to the desired length and slide
them over the SMB’s, squeezing the top of the SMB
to start the post sleeve and slide it down until flush
with the base.
•T
here are 4 sizes of Tallboy Brackets available - 34”,
36”, 40”, and 42”. For the over the post
application, use the 34/40s and for the hidden
bracket system use the 36/42s.
•H
idden fasteners will not work with Reserve over
post system.
• Tallboy Surface Mount Brackets are also available
in 22.5˚ profile in 34”/36” and 40”/42” heights.
• Place assembled rail section between the posts
and mark the bracket hole locations onto the post
sleeves as per the Railing Installation Guide
supplied with the railing kit.
PLACEMENT
• *IMPORTANT: Remove the rail section and drill
the bracket hole locations with a 7/32” diameter
drill bit (*THIS DRILL SIZE IS CRITICAL*).
Drill through both the post sleeve and SMB.
Center the Surface Mount Bracket (SMB) at each
post location and mark the mounting hole locations
on the surface. Position the open slot away from all
fastening locations.
• DO NOT OVER TORQUE THE SCREWS in the
Tallboys. Tighten only until screws are seated.
For best results, we recommend a high torque,
low speed setting on your drill.
MOUNTING INSTRUCTIONS
• With all holes drilled, place rail section
between posts and install as per the Railing
Installation Guide.
Mark SMB mounting locations onto the deck surface.
• Concrete installation: Drill marked mounting
FINAL STEP
• Wood Installation: There must be a solid base
With all rail sections installed, tighten all the SMB base
fasteners. Install the 2 piece post skirts supplied in the
SMB kit (if you have purchased the SMB alone, you will
need to purchase a 2 piece post skirt to hide the base
and fasteners).
locations with a 3/8” diameter Masonry bit to
accept 3/8” diameter x 4” wedge anchors.
Gently tap the anchors into the drilled holes. Some
installations may require an anchor epoxy.
on which to fasten the SMB. A 5” minimum thick
blocking must be securely fastened to the structure
prior to installation of the SMB.
Note: DO NOT install SMB to decking surface only.
Make sure there is adequate structure to secure as
stated above. You may secure SMB on top of deck
surface if adequate blocking is underneath.
• For Concrete installation: If the concrete anchors
have tightened leaving too much thread exposed
for the 2 piece post skirt to install properly, it may
be necessary to cut the top of the wedge anchor
so it no longer interferes with the skirts snapping
assembly.
The SMB is to be installed using 3/8” diameter x 5”
lag bolts (the lag bolts will require a 1/4” pilot hole
to ensure the wood foundation blocking does
not split).
FASTENING
Place the SMB over the mounting locations. Lightly
tighten the mounting fasteners so that the SMB can
still move freely, but tight enough for the SMB to sit
flush with the mounting surface.
RAILING
SECTION
RAILING MOUNTING BRACKET
2" #14ss
PAN HEAD SCREW
SMB ADJUSTMENTS
If the SMB is out of plumb or not level, add shims to
the base of the SMB. Check for plumb and square.
Repeat until correct.
SMB BASE FASTENER
POST SLEEVE
2 pc. POST SKIRT
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45
45˚RAIL
For best results, make a test sample from a 2” x 4” to ensure proper fit prior to performing the following steps.
Perform these operations to the Handrail, Retainer and Bottom Rail before assembling the railing.
Replace the brackets in the hardware pack with 45º corner “T” brackets available at your local dealer.
STEP 1
STEP 4
For the Handrail and Retainer, perform steps #2
and #3 with the parts together. Slide the retainer
into the handrail. Fasten them together with the
1” drill quick screws supplied.
Remove the 1” quick drill screws from the retainer.
STEP 2
Repeat steps 2 and 3 for the Bottom Rail as well.
Determine the total length required from corner
to corner of the post sleeve. Mark this length on
the hand rail, retainer and bottom rail (Mark #1).
For retainer and bottom rail, ensure equal spacing
from the mark(s) #1 to the first baluster drill hole
(see figure 1, mark #1). Place mark(s) #2 at 5/16”
(half the hole diameter-see figure 1, mark #2)
out from mark #1 (towards end of rail).
Drill a 5/8” hole at each mark #2.
Figure 1
Length of
rail required
STEP 5
STEP 6
Assemble the rail section as per normal rail
installation instructions.
NOTE: The 45° Bracket is designed to mount a rail
section to the corner of a standard (square)
4” x 4” or 6” x 6” post sleeve. This is not to be used
with the 22.5° post sleeve or an AZEK Reserve
Over-Post application.
Mark #1
ut
C
Ø5/8
Hole
Mark #2
Pa
th
Figure 3
Mark #2
Mark #1
STEP 3
Cut out a 90º wedge up to the edge of the hole
on both sides of the handrail. Do not cut to the
back of the hole. Leave the back of the 5/8” hole
to allow the corner of the Post Sleeve to fit neatly.
(45˚ Corner “T” Brackets)
Figure 2
AZEK Building Products claims no liability or responsibility for the
improper installation of our porch product. Since all installations are
unique, it is the sole responsibility of the installer to determine specific
requirements in regards to each porch application. Best practice is to
have all porch designs reviewed by a licensed architect, engineer or
local building official before installation.
46
www.AZEK.com
rAILING INSTALLATION GUIDELINES
rESErvE CONNECTOr KITS
In order to ensure beautiful installation of Trademark Reserve railing, we have four easy-to-use decorative connector
kits to fit every angle: In-Line Top Rail Connectors, 22.5° Top Rail Connectors, 45° Top Rail Connectors and Post
Connectors. Please see below for information on each application.
CUTTING THE TOP RAIL
When cutting the top rail, allow for approximately
1/8” gap per side between corresponding top rails
to ensure adequate space for the In-Line, 22.5° or
45° Top Rail Connectors.
CONNECTOR INSTALLATION
Slide the appropriate Top Rail Connector onto
the top rail. Slide the other top rail into the other
end of the connector with the assembled top rails
over the railing section. Press the top rails onto
the retainer, ensuring that they sit fully onto the
retainer. (TIP: If top rail is too snug to easily push
on, loosen the #14ss screws on the post brackets so
that the rail can be adjusted. Be sure to retighten
the screws when top rail is installed.)
22.5° Top Rail Connector
POST CONNECTOR
The Post Connector allows for a flush clean
attachment to the post. Add a liberal amount of
caulking to the post side of the connector inside
the lip to adhere the connector to the post and
slide it onto the pre-cut Top Rail. Install the Top
Rail onto the sub rail Retainer, post side first as
per instructions. (NOTE: Remove any excess
caulking with a damp cloth).
Post Connector
45° Top Rail Connector
In-Line Top Rail Connector
for additional information, visit WWW.AZEK.COm
www.AZEK.com
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50
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53
Limited Lifetime
Warranty
Limited Lifetime
Warranty
For complete AZEK Deck, AZEK Porch, AZEK Premier, AZEK Trademark
and AZEK Reserve Railing warranty information, visit www.AZEK.com
AZEK Premier
AZEK Trademark
AZEK Premier
AZEK Reserve
Limited 10-Year Warranty
Limited 20-Year Warranty
Color Railing
White Railing Only
54
www.AZEK.com
AZLDBTM 12/09
AZEK Building Products
801 Corey Street • Scranton, PA 18505
www.AZEK.com • (877) ASK-AZEK
(877) 275-2935

installation and technical guide

Transcription

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