Fypon Balustrade Systems Curved Railing & Safety Cables - Manual

TM
Fypon, Ltd. 1750 Indian Wood Circle Maumee, Ohio 43537 1.800.446.3040 www.fypon.com
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Curved Railing & Safety Cables
INSTALLATION INSTRUCTIONS
All top and bottom curved railings use serrated PVC pipe. Both the top and bottom railings come with PVC sleeves and the top railing only comes
with a safety cable. IMPORTANT: PVC sleeves and safety cable must be used in all curved railing installations. Newel posts should be
placed between each section of curved railing and no more than 8' apart.
Materials needed:
• Tape Measure
• Exterior Spackling
• Caulk Gun
• PVC Compatible Adhesive
• PVC Pipe Cleaner
• PVC Pipe Cement
• Pencil
• Safety Glasses
• Strap Clamps
• Combination Square
1. Rail Section Assembly
A) Measure and cut the matching top and bottom rails to length for each respective section. Cement the PVC pipe sleeves (supplied), using
PVC pipe cleaner and cement, into the PVC pipe (or pipes) at each end of both railings. Push the PVC sleeves in until flush with the rail
ends making sure the slot in the sleeves is up. Layout centerlines on both the top and bottom rails and mark the baluster positions. Drill
the appropriate size hole in the rails to accept the baluster. Tip: A drill press with a standard woodworking drill bit works well for drilling
these holes.
B) Apply a 1/4" bead of a urethane based construction adhesive on each end of the baluster. Insert each baluster into the top and bottom
rail. Lay the rail assembly on a flat surface. Use strap clamps as needed to draw the rail assembly together. Clamp tightly, make sure
assembly is square and that the balusters are square to the rail. Clean off any excess glue before it sets. After adhesive has cured, rail
assembly can be painted if desired.
2. Safety Cable Installation (Note: Safety cable is used in the top rail only)
A) Secure the flexible wire cable (supplied) at the starting point. The starting point is either a threaded hook in the wall or the 1/2" threaded
rod in the center of the newel post. For a newel post application, drill a hole in the newel post level with the center of the railing pipe. If
two pipes are present, drill the hole level with the center of the outside pipe.
B) From the inside of the newel post, feed the wire through the drilled hole to the outside of the newel post. Remove the hex nut, lock
washer and C-channel at the top of 1/2" threaded rod and place the looped end of the cable over the rod. Reattach the C-channel, lock
washer and hex nut to the 1/2" rod and tighten.
C) Run the cable through the entire length of the curved rail passing through the newel posts, if used. Note: 30 ft. and 50 ft. cable
assemblies are available when multiple rail sections with multiple newel posts are used but must be ordered separate. Make
sure the cable is in the outside pipe of the railing if the railing has two pipes. Also make sure the cable passes to the inside of the 1/2"
threaded rods in all newel posts.
D) Run the cable out of the last pipe and down through the hole in the angle bracket attached to the newel post or wall. This procedure
requires the installer to drill a 3/16" hole in the angle bracket and machine a notch at the end of the rail so that the cable will not
interfere with the installation of the railing to the newel post. This hole should be drilled in the bracket directly below where the cable is
coming out of the pipe. Adhesive should be applied to both ends of the top and bottom rails. Using a wire puller, pull the cable snug and
secure it with the mechanical collar and setscrew (supplied). Finish securing the rails to the wall or newel post by attaching them to the
angle brackets.
3. Rail Support Block Installation
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.
4. Finishing
All exposed fastener heads should be countersunk and fill with exterior wood putty. Allow the filler to cure then sand flush to the millwork
surface. Caulk any gaps and finish as desired.
• Sandpaper
• Corrosion-Resistant Fasteners
• Paint Brush
• Latex Paint
• Circular or Hand Saw
• 3/16" Drill Bit
• Power Drill
• Phillips Head Driver
• Putty Knife
• 3/4" Open End Wrench or Adjustable Wrench