AZEK Rail User Manual

Page 1

TRIM MOULDING DECK PORCH RAIL PAVERS

AZEK Rail

Install Guide

Installing AZEK Rail with CableRail by Feeney® .......................................................................... 1

Installing CableRail by Feeney® for AZEK Rail ........................................................................... 7

Installing AZEK Rail Stairs with CableRail by Feeney® ............................................................10

Installing CableRail by Feeney® Stairs for AZEK Rail ...............................................................14

Notes .................................................................................................................................................... 18

• Please read all instructions completely before starting any part of the installation.

• AZEK Rail should be installed using the same good building principles used to install wood or composite railing and in accordance with the local building codes and the installation guidelines included below. AZEK Building Products Inc. accepts no liability or responsibility for the improper installation of this product.

• AZEK Rail may not be suitable for every application and it is the sole responsibility of the installer to be sure

that AZEK Rail is t for the intended use. Since all installations are unique, it is also the installer’s responsibility to determine specic requirements in regards to each Rail application.

• AZEK Building Products Inc. recommends that all applications be reviewed by a licensed architect, engineer or local building ofcial before installation. If you have any questions or need further assistance, please call

AZEK Customer Service at 877-ASK-AZEK (877-275-2935) or visit our website at www.azek.com.

• AZEK Railing is tested as a whole system and should be used that way. It is not intended to be used in conjunction with other railing systems or fasteners.

• The following Installation Guidelines are applicable for installation of AZEK Premier, AZEK Trademark, and AZEK Reserve Rail Systems (except AZEK Reserve over post applications).

• IMPORTANT: Make sure the DRIVE TOOL/DRILL is congured or set to use the SCREW setting when driving

and/or tightening all FASTENERS.

• SAFETY: Always wear goggles when handling, cutting, drilling and fastening materials.

• Failure to install this product in accordance with applicable building codes and AZEK’s written Rail Install Guide may lead to personal injury, affect rail system performance and void the product warranty.

Page 2

Installing AZEK Rail with CableRail by Feeney

•

Miter Saw

•

Drill Bits: 7/64”,1/4”, 3/16”,

2.64”

2.72”

3.5”

2.63”

Premier

Plate

Fitting

Intermediate Base

Intermediate

Baluster

Mounting Bracket (4

)

Post Sleeve (2)

Support Block (2)

Post Skirt (2)

AZEK Rail Custom Rail Packs are available in 10’, 8’ and 6’ lengths.

Visit www.azek.com/installation to view AZEK installation videos. Consult your local building codes for guard and handrail requirements.

Measuring Your Railing Area

• Measurements are from center to center of the posts. Kits are produced in 10’, 8’ and 6’ to allow for ﬁ nished end cuts

and angles.

•Determine how many 10’, 8’ and 6’ AZEK Rail Custom Rail Packs you need and check to be sure you have all the

components (and quantities) listed in the chart shown to the right.

Important Information

•AZEK Rail 10’, 8’ and 6’ Rails are designed not to

exceed 10’, 8’ and 6’ from center of post to center of post, respectively.

•For stair applications maximum rail length must not exceed 91”.

•4x4 lumber posts should be installed plumb.

•Cut slowly, using a ﬁ ne tooth saw blade to avoid chipping.

•Cannot be installed using Secure Mount Post.

•For 42” railing, use 54” Post Sleeve.

Component Dimensions

2.63”

Quick-Connect

3.5”

Trademark

Top Rail

2.73”

Trademark

Bottom Rail

Fitting

5.38”

2.64”

Reserve Top

Rail

3.5”

2.05”

Reserve

Bottom Rail

Quick-Connect Swivel

Fitting

3.5”

Premier Top

Rail

2.72”

Premier

Bottom Rail

1.8”

2.05”

1.8”

2.72”

6.32”

2.05”

5.5”

6.32”

6” x 6” Post Sleeve

5.5”

Tools Required

Components Needed For Installing

The AZEK Rail Section

Hardware included in Hardware Kits:

Components available separately for mix-and-match rail systems

Additional Components Needed for Each System

Post Cap (2)

Top Rail (1)

Support Rail (2)

Intermediate

Base Plate

Intermediate Baluster

Bottom Rail (1)

Foot Block (2)

• Miter Saw

• Tape Measure

• Drill

• Cable Cutters

• #2 Square Drive

Hardware Mounting Kit

4 - Mounting Brackets 2 - Support Blocks 16 - #8 x 3/4” screws 6 - #8 x 1 3/4” screws 6 - #8 x 2 5/8” screws (Stairs Only) 6 - #8 x 3” Screws 12 - #8 x 3” Green Screws T20 Driver Bit

1 - Top Rail (Reserve Top Rail sold separately) 1 - Bottom Rail 2 - Support Rails (1-Aluminum Top Support Rail for 10') Hardware Mounting Kit Support Block Mounting Templates Foot Blocks

Rail Pack

- 1 in 6’ Packs, - 2 in 8’ Packs, - 3 in 10' Packs

AZEK Rail Custom

36” Intermediate Baluster

-1 for 6’, 2 for 8’, 3 for 10'

42” Intermediate baluster

-1 for 6’, 2 for 8’, 3 for 10'

Stair Intermediate baluster

-1 for 6’, 2 for 8’, 3 for 10'

Cable

-100’ spool or 500’ spool

CableRail Components

2 - Post Sleeves 2- Post Caps 2- Post Skirts Protector Sleeves

- 42” System: 22 per Thru Post

- 36” System: 18 per Thru Post

• Drill Bits: 7/64”,1/4”, 3/16”, 1/8” 9/64”

• Extended 1/4” Drill Bit

• 2 3/8” Open-End Wrenches

36” Hardware Kit

- 9 Quick-Connect Fittings

- 9 Quick-Connect Swivel Fittings

- 18 Hanger Bolts

- 9 lock nuts

42” Hardware Kit

- 11 Quick-Connect Fittings

- 11 Quick-Connect Swivel Fittings

- 22 Hanger Bolts

- 11 lock nuts

CableRail Accessory Pack Includes:

- Quick-Connect release tool

- Lacing Needle

- Hanger Bolt Installation Tool

Support Rail

Protector Sleeve

Intermediate

Baluster

5 1/2” x 5 1/2” Post Sleeve

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Installing AZEK Rail with CableRail by Feeney

skirt.

For angled rail installations

- align angled face of Support

Block parallel to rail section.

40” above deck surface is optimal for 36” railing heights.

Optimal 40”

INSTALL POST SLEEVE

• Trim Post Sleeve to desired length.

• Slide Post Sleeve and Post Skirt over post (do not force).

• Ensure posts are

square and plumb.

If you do not have a the template, position the top of the Support Block 4” above the deck.

Template

Support

4”

7/64” Pre-drill

Post Skirt

#8 x 3” Green

Coated Screws

Block

INSTALL LOWER SUPPORT BLOCK

• Position template at bottom of post

sleeve above post skirt.

For angled rail installations

- align angled face of Support Block parallel to rail section.

45°

CUT AND ASSEMBLE BOTTOM SUPPORT RAIL

•Cut the Bottom Support Rail to length.

For sections up to 6’: Place one Foot Block in the center of the rail.

For sections 6’ to 8’: Space two Foot Blocks approximately at 1/3 intervals on the rail.

For sections 8’ to 10’: Space three Foot Blocks approximately at 1/4 intervals on the rail.

7/64” Pre-drill #8 x 3/4” Coated Screws

1/2

Center screw aligned to rail centerline

Angled Section

7/64” Pre-drill #8 x 3” Coated Screws

Bracket set

ﬂ ush to rail

face

Foot Block

Center screw aligned to rail centerline

Straight Section

1/2

Bracket set

ﬂ ush to rail

face

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#8 x 3” Green

Coated Screws

#8 x 3” Green

Coated Screws

Installing AZEK Rail with CableRail by Feeney

INSTALL BOTTOM SUPPORT RAIL

• Position rail assembly onto Support Blocks.

#8 x 3” Green Coated Screws

CUT AND PREP BOTTOM RAIL AND TOP SUPPORT RAIL

• Measure distance between the posts at the Bottom Rail and Top Support Rail.

• Cut to length.

• Attach Brackets to the Top Support Rail.

6’ sections require 1 Intermediate Baluster; 8’ sections require 2 Intermediate Balusters. 10’ sections require 3 Intermediate Balusters.

8 x 3/4” Coated Screws

Top Support Rail

Bottom Rail

Page 4

Use Intermediate Base Plate as template

Bottom Rail

Pre-drill 3/16”

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Installing AZEK Rail with CableRail by Feeney

ATTACH INTERMEDIATE BALUSTERS

Intermediate Baluster

Pre-drill 3/16”

#10 x 2” Coated Screws

For ease of installation, pre-drill screw chase with a 3/16” drill bit.

Ensure the screw ﬁ nds the screw

chase.

Screw Chase

Bottom Rail

INSTALL BOTTOM RAIL

• Place the Bottom Rail between the posts and allow the rail to rest on the Bottom Support Rail.

Bottom Rail

Bottom

Support Rail

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Installing AZEK Rail with CableRail by Feeney

TRANSFER HOLE LOCATION ONTO POST SLEEVE

• Use an extra Intermediate Baluster, rested on the Bottom Rail, as a template for the CableRail Hardware and through holes.

• Using a 3/16” drill bit to transfer your marks onto the Post Sleeve.

ATTACH TOP SUPPORT RAIL

Support

Rail

#10 x 1” Coated Screws

Pre-drill

9/64”

#10 x 1” Coated Screws

INSTALL TOP RAIL AND POST CAPS

Pre-drill 7/64” #8 x 3” Green Coated Screws

Secure Post Caps with exterior grade caulk.

Intermediate Base Plate

Intermediate

Baluster

Pre-drill 3/16” #8 x 1 3/4” Coated Screws

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Installing CableRail by Feeney® for AZEK Rail

Anchor posts should not exceed 60 feet apart during any continuous run of cable.

Drill through Post Sleeve with 1/4” bit

1/4”

Pre-drill 1/8” into 4”x4”

PRE-DRILL ANCHOR POST SLEEVE

• Using the marks on the Anchor Posts, drill a through hole only in the Post Sleeve with a 1/4” Bit drill.

1/8”

Optional - Protector Sleeves are not required on the through posts, but do offer a more

ﬁ nished appearance.

Use a dab of adhesive on Protector Sleeve if needed.

1/4” 1/4”

Drill through Post Sleeve with 1/4” bit

PRE-DRILL THROUGH POST SLEEVES

• For the through posts, drill a 1/4” hole through both the Post and Post Sleeve.

Protective Sleeve (X2)

Drill through Post Sleeve with 1/4” bit

Leave about 1” of machine thread exposed for cable take-up.

DRIVE IN HANGER BOLTS

• On Anchor Posts, screw the Hanger Bolts into the pilot holes in the Post with the Hanger Bolt Installation Tool.

• Once Hanger Bolts are all driven in, then screw on Quick-Connect Fittings.

1”

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One side of the railing will be

only Quick-Connect ﬁ ttings, the

other side will be Quick Connect

swivel ﬁ ttings and lock nuts.

Installing CableRail by Feeney® for AZEK Rail

ATTACH QUICK-CONNECT AND QUICK-CONNECT SWIVEL FITTINGS

• Screw on Quick-Connect ﬁ ttings snuggly against Post Sleeve onto one side of the railing and lock nuts onto hanger bolts on the other side.

• Screw on Quick-Connect Swivel ﬁ tting onto the Hanger Bolt with the lock

nut already installed.

INSERT AND THREAD CABLE

• When all of the hardware is in place, insert one end of the

Cable into the Quick-Connect ﬁ tting.

• Feed the Cable through the Intermediate Baluster (or through posts) with a lacing needle.

Lacing Needle

CUT CABLE TO LENGTH

Unscrew the Quick-Connect

swivel ﬁ tting from the post to

measure length of cable

Trim Cable at the ﬁ rst

cut line on QuickConnect Swivel Fittings

Insert Cable into Quick-Connect

swivel ﬁ ttings

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Page 9

Tightening Order

If necessary, the Cable can be removed from the Quick-Connect

ﬁ tting by using the

Quick-Connect Release Tool.

Installing CableRail by Feeney® for AZEK Rail

ATTACH QUICK-CONNECT AND QUICK-CONNECT CABLE FITTINGS

• Use a set of 3/8” open-ended wrenches to tighten the Cable using the “swivel” end insuring the Cable does not twist.

• Once the Cable is tight, tighten the lock nuts against the

Quick-Connect swivel ﬁ tting.

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Page 10

Installing AZEK Rail Stairs with CableRail by Feeney

INSTALL POST SLEEVES

• Trim Post Sleeve to desired length.

• Slide Post Sleeve and Post Skirt over post (do not force).

• Ensure posts are square and plumb.

Support Rails are rotated 90° for stair rail applications.

Right

Wrong

MEASURE SUPPORT RAILS

• Determine measurements and angle as shown.

• Trim both the Top Support Rail and the Bottom Support Rail to those dimensions.

• Test ﬁ t rails to check

for accuracy.

Top Rail Length

Bottom Rail Length

Stair Angle

TRIM RAILS

• Transfer measurement from both Support Rails to Bottom Rail and Top Rail.

• Trim Top Rail and Bottom Rail to match the Support Rails at the appropriate angle.

Bottom

Support

Rail

Bottom

Rail

Top

Support

Rail

Top Rail

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Pre-drill 7/64”

Installing AZEK Rail Stairs with CableRail by Feeney

PREP BOTTOM SUPPORT RAIL

For sections up to 6’: Place one Foot Block in the center of the rail.

For sections 6’ to 8’: Space two Foot Blocks approximately at 1/3 intervals on the rail.

• Attach Mounting Brackets to Bottom Support Rail.

Center screw aligned with rail centerline

Pre-drill 7/64” #8 x 3/4” Coated Screws

INSTALL BOTTOM SUPPORT RAIL

• Secure Mounting Brackets.

• Trim and Attach Foot Blocks.

Pre-drill through Bottom Support Rail with 3/16” bit

#8 x 3” Coated Screws

Bottom Support Rail

Brackets must be installed to the stair tread side of the rail.

Pre-drill 7/64” #8 x 3” Green Coated Screws

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Use the Intermediate Base Plate as a Template, as shown to the right.

Installing AZEK Rail Stairs with CableRail by Feeney

PRE-DRILL BOTTOM RAIL

Pre-drill 3/16”

Bottom Rail

Use Intermediate Base Plate as template

Be sure the screw ﬁ nds

the screw chase

For easier installation, pre-drill screw chase with a 3/16” drill bit.

ATTACH STAIR INTERMEDIATE BALUSTER

• Trim Stair Intermediate Baluster to match stair angle.

#10 x 2” Coated Screws

Screw chase

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Installing AZEK Rail Stairs with CableRail by Feeney

Use a 3/16” drill bit to

transfer marks onto the

Post Sleeve

template to mark

for CableRail

Lower the rails perpendicular to the deck surface.

INSTALL BOTTOM RAIL

• Place the Bottom Rail over the Bottom Support Rail with the Intermediate Baluster(s).

TRANSFER HOLE LOCATION ON POST SLEEVE

• Use an extra Intermediate Baluster as a template to mark for CableRail hardware and through holes.

Use a 3/16” drill bit to transfer marks onto the Post Sleeve

ATTACH TOP SUPPORT RAIL

• Mark Ends of Top Support Rail.

• Rotate Rail assembly out of way to fasten Support Block.

• Secure Mounting Brackets to Posts.

b c d

#8 x 3” Green

Pre-drill

7/64”

#8 x 3” Green

Coated Screws

Pre-drill

7/64”

Coated Screws

Step 1

Step 2

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Installing AZEK Rail Stairs with CableRail by Feeney

INSTALL TOP RAIL AND POST CAPS

• Position Top Rail over Support Rail and attach with screws.

• Secure Post Caps with exterior grade caulk.

Pre-drill 3/16” #8 x 2 5/8” Coated Screws

Installing CableRail by Feeney® Stairs for AZEK Rail

Installing Cable Installation Section

PRE-DRILL ANCHOR POST SLEEVE

Scrap Baluster for drill angle

Drill a through hole only in the post sleeve with a 1/4” drill bit at the same angle as the stair run

1/8”

1/4”

Use a scrap piece of baluster trimmed at the stair angle as a guide.

Anchor posts should not exceed 60 feet apart during any continuous run of cable.

1/8”

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Installing CableRail by Feeney® Stairs for AZEK Rail

PRE-DRILL THROUGH POST SLEEVES

• Drill a 1/4” hole through both the Post and Post Sleeve at stair angle.

1/4”

DRIVE IN HANGER BOLTS

• Screw Hanger Bolts into the pilot holes at the same angle of the stairs using the Hanger Bolt Installation Tool.

1/4”

1”

Leave about 1” of machine thread exposed for cable take-up.

One side of the railing will be only

Quick-Connect ﬁ ttings, the other side will be Quick-Connect swivel ﬁ ttings and lock nuts

Bottom Anchor Post

1”

1/4”