Synthetic Stone Balustrade System Radius Post to Post Installation Instructions

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. Drill out (using masonry or diamond bit) 5/8” hole diagonally (ex. 10 o’clock & 4 o’clock) in the end of rail sections to receive connector pins.
4. Cut and number a dedicated template from both ends of every rail section for use as a template for marking connector pin locations. Measure railing lengths and cut 1/2” shorter than opening to allow 1/4” minimum reveal on each end for an expansion joint. Note: Failure to allow for expansion can cause cracking or deformation of the system.
5. Determine how many balusters per rail section are needed for local code requirements. Compliance with code requirements is the responsibility of the installing contractor.
6. Due to normal shrinkage balusters may vary slightly in overall height. Measure each baluster and use like sized balusters in each run.
7. 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.
8. 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. For installation without bottom rail, drill holes in deck to receive baluster pipe.

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.

9. Position the newel post over post/deck connection as marked and check level. Shim as required. Do not allow any moisture to get inside the newel post during installation. Trapped moisture inside the newel post may cause the post to crack.
10. Locate dedicated rail connector template cut from the end of the rail you are installing and mark two of the pipe locations on the newel post. Mark top right and bottom left pipe location. Predrill holes in newel posts for the bottom rail connection. Apply adhesive to each of the spring encased pins and insert into the top right and bottom left pipes in the rail end. Use only two pins per rail end.

Mtexbalpostpostinst510(5/10)

1. Install drainage spacers 6” from the end of each rail, and then two feet on center underneath the bottom rail. 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. Note: rails on steps do not require spacers.
2. Temporarily insert a baluster in the two extreme baluster hole locations in the bottom rail being careful to check for code spacing. 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. Note: Balusters for stairs should be cut to slope of stair without cutting through baluster pipe.
3. Remove top rail and drill holes in newel post using template as in #9. Note: For electrical wiring drill center hole also.
4. Apply adhesive to edge of each hole in the bottom rail (1/4” bead at edge of hole).
5. Place balusters in each hole in bottom rail and wipe off any excess adhesive.
6. Install rail connector in top rail (See step 7).
7. Apply adhesive around pipe on top of baluster.
8. Install top rail starting from one end and aligning each baluster pipe with predrilled 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.
9. Immediately check balusters for square before glue sets.
10. On the inside of the newel post, apply adhesive or caulk to fill any gaps between connector pins and newel post at connector holes.
11. Install lanterns or other electrical lighting prior to setting newel post.
12. Recheck newel post for level. Fill newel post no more than 1/8th full of FiberCrete™ matrix and allow to set to secure post in place.
13. For finial installation, predrill 3/8” hole in post cap, apply adhesive to bottom of finial and bolt onto post cap. Wipe off excess adhesive.
14. 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.
15. 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.
16. 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.
17. Caulk the expansion joint between rail and newel posts, and both ends of the balusters with recommended polyurethane caulk.

IMPORTANT: Melton Classics MarbleTexTM Balustrades & Columns are a prefinished product.

Store in a dry area prior to installation and protect from dirt and stains during installation.