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1. Layout newel post locations. Mark an outline of the bottom of
each post at each location on the deck.
2. Install newel connection materials (by others) to deck. (wood
post for wood deck, rebar or threaded rod for masonry deck , or
metal pipe with pipe flange for roof deck).
3. Cut and number a dedicated template from each end of every rail
section for use as a template for marking connector pin locations.
Measure railing lengths and cut 1/4" shorter than opening to
allow 1/8" minimum gap on each end for an expansion joint.
Note: Failure to allow for expansion can cause cracking or deformation
of the system.
4. Determine how many balusters per rail section are needed for
local code requirements. Compliance with code requirements is the
responsibility of the installing contractor.
5. Due to shrinkage balusters may vary slightly in overall height.
Measure each baluster and use like sized balusters in each run.
6. Measure and mark centers for each baluster location in precut
rail sections. Place the first baluster at desired spacing from
each end of the bottom rail for your code spacing and evenly space
the rest of the balusters in that section. For rails that do not
intersect perpendicular to a newel post or wall, place the first
baluster approx. 1" from the post or wall for best appearance.
6. Drill holes for baluster pipe locations in bottom rail sections.
Use minimum 1" carbide or diamond hole saw/drill bit combination
with 1/4" center pilot drill bit as plumb may vary in baluster
pipe. Swimming the drill in a circle while drilling will simplify
removing the marble rail plug.
Tip: Delay drilling for balusters and installing rail connectors
in one section on each end of the balustrade until the rest of the
system is in place to allow for any adjustment that may be necessary.
Tip: If electrical wiring is to be run through the system, put
a pilot wire through rail prior to installation of rail connectors
to allow wiring to be installed later.
7. For two pin connectors, apply PVC pipe cement to the interior
of the pipe in each bottom rail section and on the outside of the
railing connector. Insert rail connector in rail quickly and align
before cement sets. For two pin connectors, recess bracket 1/4"
into the rail. For one pin connectors, apply adhesive to each of
the two spring encased pins and insert in the two PVC pipes in each
rail section. Note: For installation of two pin connectors where
railings do not intersect perpendicular to newel posts, align railing
connection pins vertically.
8. Apply adhesive to the bottom of post liberally. Position the
post over post/deck connection as marked in item #1 and check level.
Shim as required.
9. Locate dedicated rail connector template and mark hole locations
in newel posts. Pre drill holes in newel posts for the bottom rail
connection.
10. Install drainage spacers approximately three feet on center
between newel posts. After marking spacer locations on deck, apply
adhesive to the bottom of each drainage spacer and press in place.
Quickly apply adhesive to top of drainage spacer and install bottom
rail. Align spacers with bottom rail.
11. Temporarily insert a baluster in the two extreme baluster hole
locations in the bottom rail. Place top rail in position on balusters
and mark top rail connector locations on newel post using the previously
installed rail connector as a guide.
12. Remove top rail and drill holes in newel post. Note: For electrical
wiring drill center hole also.
13. Apply adhesive to edge of each hole in the bottom rail (1/4"
bead at edge of hole).
14. Place balusters in each hole in bottom rail, and wipe off any
excess adhesive.
15. Install rail connector in top rail.
16. Apply adhesive around pipe on top of baluster.
17. Install top rail starting from one end and aligning each pipe
with pre drilled holes. Wipe off excess adhesive. Note: Be sure
to check to see if both connector pins are secured in the holes
in the newel post.
18. Immediately check balusters for square before glue sets.
19. On the inside of the newel post, apply adhesive or caulk to
fill any gaps between connector pins and newel post at connector
holes.
20. Install lanterns or other electrical lighting prior to setting
newel post.
21. Recheck newel post for level. Fill center hole in newel post
1/3 full of light weight concrete. Allow to set.
22. For finial installation, pre drill 3/8" hole in post cap,
apply adhesive to bottom of finial and bolt onto post cap. Wipe
off excess adhesive.
23. Apply a 1/4" bead of adhesive to the inside top edge of
each newel post. Install newel post cap and wipe off excess adhesive.
24. Insert expansion joint rope in the expansion joint on each
end of the top and bottom rail. Recess 1/4" for best caulk
bead adhesion.
25. Clean entire system with scrub brush and Simple Green Cleaner
to remove any dirt or stains that occurred during installation.
Use fine sandpaper for stubborn stains.
26. Caulk the expansion joint between rail and newel posts, and
the rails and the end of the top and bottom of all balusters.
IMPORTANT : Melton Classics MarbleTex™ Balustrades &
Columns are a prefinished product. Protect from dirt and stains
during installation.
(balinstposts3/98)
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