Fypon Beam Mantel Rough Sawn, Beam Mantel Hand Hewn Installation Instructions Manual

Beam Mantel

Installation Instructions

Beam Mantel

Installation Instructions

fypon.com

Hand Hewn

Rough Sawn

Fypon® Beam Mantels look so realistic, it’s difcult to
distinguish them from real wood. They are lightweight
and require no additional structural support.

Our installation instructions provide information about
all the tools, hardware and wood mounting blocks or

2x4 or 2x6 you need to successfully install Fypon

Beam Mantels.

Support mounting blocks or 2x4 or 2x6 required for
installation are based on Beam Mantel length.

Support Mounting Block Table

Beam Length

Up to 60"

60" to 78"

78" to 90"

Wood Mounting

Block (Qty.)

3

4

5

Note: If using a 2x4 or 2x6, it should t the inside width and
height of the beam.

2

Beam Mantel

Installation Instructions

fypon.com

Item Description for Beam Mantel with Mounting Blocks Attached (Fig. 1)

Tools and Supplies required for Beam Mantel Installation

Ladder 3/16" Drill Bit

Tape Measure Circular or Hand Saw

Level Power Drill

Reciprocating Saw Spade Bit

Caulk Gun 1-½" Trim Screw (Fig. 5)

Painters Caulk Wood Blocks (Fig. 3)

Pencil Stud Finder

Safety Glasses Screwdriver

Polyurethane Compatible Filler Polyurethane Compatible Adhesive

Sandpaper 3/4" x 4" Toggle Bolts (Fig. 2)

Paintbrush 3" Flat Head Fasteners (for drywall or wood) (Fig. 4)

Paint / Stain 1/4" x 2-¾" Flat Head Tapcon Screw (for masonry) (Fig. 6)

3

Beam Mantel

*

Installation Instructions

fypon.com

Parts required for Beam Mantel Installation

Item Description Figure

1

2

3

4

5

6

*A 2x4 or 2x6 the length of the mantel can be used as well.

Beam Mantel

3/16" x 4" Toggle Bolt

Wood Mounting Blocks or 2x4 or 2x6*

3" Flat Head Fasteners (for drywall or wood)

1-½" Trim Screw

1/4" x 2-¾" Flat Head Tapcon Screw (for masonry)

Fig. 1 Fig. 2

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Fig. 3

*8x10 Beam Mantel requires a 2x6 wood block.

Fig. 5

Fig. 4

Fig. 6

4

Beam Mantel

Installation Instructions

fypon.com

Step 1 - Stain or paint Beam Mantel. See nishing guidelines on fypon.com.

Step 2 - Measure the wall for placement of the Beam Mantel and mark several points.

Place level on markings, level and draw a guideline across the width of the wall where
mantel will be placed. (Fig. 7)

Fig. 7

Step 3 - Cut wood mounting blocks from a 2x4 or 2x6 or use a 2x4 or 2x6 the length of the Beam
Mantel. Mounting Blocks or 2x4 or 2x6 support need to match the inside width of Beam Mantel.
Drill one hole into the center portion of each mounting block with a 1/4" drill bit and two holes at
the top corners, 3/4" from top and sides of the mounting block. (Fig. 3)

Note: if using a 2x4 or 2x6 the length of the beam, determine where to drill holes along the length of the 2x4 or 2x6 based on Step 4.

Fig. 3

5

FOR DRYWALL

Beam Mantel

Installation Instructions

fypon.com

Step 4A - Measure placement of the mounting blocks or
distributed distance between them (see Support Mounting Block Table on page 2), use a stud nder
to ensure area behind façade is clear for installation of screws and toggle bolt, to secure mounting
blocks or

Step 5A - Hold each mounting block to the wall or place the 2x4 or 2x6 on the wall, center it on the
guideline. Using a Phillips head screwdriver, insert into top pre-drilled 1/4" holes at the top corners
and center of the mounting block or 2x4 or 2x6 and dimple wall. Remove blocks or
2x4 or 2x6 and use spade bit to drill 5/8" hole needed for toggle bolt.

2x4 or 2x6

to the wall.

2x4 or 2x6

on the wall. With an equal

Fig. 8

Step 6A - Screw two 3" at head fasteners in the pre-drilled holes on the top corners of the wood
mounting block or into each area of the 2x4 or 2x6. Insert toggle bolt into the middle pre-drilled hole
of the mounting block or 2x4 or 2x6 and securely attach the wood mounting block or 2x4 or 2x6 to the
wall. Repeat for all mounting blocks. Lightly mark the centerline of each mounting block or centerline
where holes have been placed along the 2x4 or 2x6 (top and bottom) on the wall to align where
fasteners (1-½" trim screws, Fig. 9) will attach Beam Mantel to mounting blocks or 2x4 or 2x6.

Fig. 9

6

Beam Mantel

Installation Instructions

fypon.com

Step 7A - Apply PL Premium or adhesive to the top and bottom of the wood mounting blocks
or along the top and bottom of the 2x4 or 2x6 where the Beam will be attached. (Fig. 10)

Fig. 10

Step 8A - Apply PL Premium or adhesive to the sides of the Beam Mantel (Fig. 11 and 12). Press the
Beam Mantel to the wall over the mounting blocks or 2x4 or 2x6. Insert 1-½" trim screws through
Beam Mantel into wood mounting block or 2x4 or 2x6 approximately 1" from the wall (Fig. 13 and

14). Ensure trim screws are installed vertically without an angle for maximum hold. Countersink
screw about 1/8" and apply ller. Touch up with paint or stain.

Fig. 11

Fig. 12 Fig. 13

7

Beam Mantel

Installation Instructions

fypon.com

Fig. 14

FOR WOOD OR CONCRETE

Step 4A - Measure placement of mounting blocks or 2x4 or 2x6 on the wall, with an equal

distributed distance between them (see Support Mounting Block Table on page 2) use a stud
nder to ensure area behind façade is clear for installation of screws for securing mounting blocks
or 2x4 or 2x6 to the wall. (If stone or masonry brick, no need to use the stud nder, use Tapcon
screws.)

Step 5B - Hold each mounting block or 2x4 or 2x6 to the wall, center it on the guideline. Using a
Phillips head screwdriver, insert into top and center drilled 1/4" holes and dimple the wall. If stone
or masonry brick, drill a 3/16" hole in the wall (needed for the Tapcon screws), for each hole on
the wood mounting block or each hole in the 2x4 or 2x6. (Fig. 15)

Fig. 15

Step 6B - Insert three 3" at head fasteners into the mounting block or 2x4 or 2x6 and securely
attach the wood mounting block or 2x4 or 2x6 to the wall. (Fig. 16) Lightly mark the centerline of
each mounting block or 2x4 or 2x6 where holes have been drilled along the width of the 2x4 or
2x6 (top and bottom) on the wall to align where fasteners (1-½" trim screws, Step 8B) will attach
Beam Mantel to blocks or 2x4 or 2x6. (If stone or masonry brick, use Tapcon screws.)

Fig. 16

8

Beam Mantel

Installation Instructions

fypon.com

Step 7B - Apply PL Premium or adhesive to the top and bottom of the wood mounting blocks
or 2x4 or 2x6 where the Beam Mantel will be attached. (Fig. 17)

Fig. 17

Step 8B - Apply PL Premium or adhesive to the sides of the Beam Mantel (Fig. 18 and 19).
Press the Beam to the wall over mounting blocks or over 2x4 or 2x6. Insert 1-½" trim screws
through Beam Mantel into wood mounting block or 2x4 or 2x6 approximately 1" from the wall
(Fig. 20 and 21). Ensure trim screws are installed vertically without an angle for maximum hold.
Countersink screw about 1/8" and apply ller. Touch up with paint or stain.

Fig. 18

9

Beam Mantel

Installation Instructions

fypon.com

Fig. 19 Fig. 20

Fig. 21

Beam Mantel Testing

Fypon® polyurethane Beam Mantels were tested to ASTM D1929 – IGNITION TEMPERATURE EVALUATION ON
BEAM MANTEL POLYURETHANE FOAM USING FOAMRESIN-R MATERIAL, and shown to be safe from ignition
at a temperature of 300 degrees Celsius or 572 degrees Fahrenheit. As a comparison, wood (soft woods, such
as pine, cedar, redwood, r, poplar, etc.) will ignite at 180 degrees Celsius or 300 degrees Fahrenheit.

Weight Load Capacity

Testing by a third-party lab showed a weight load capacity of up to 200 lbs.

Fire Code Information Using Fypon Beam Mantels

Refer to International Residential Code Information for Fireplace Mantels; Section R1001.11 Fireplace Clearance
and National Fire Code Information for Fireplace Mantels.

General Installation Notes

Any adhesives, sealants, llers or paint used must be compatible with the material that is being installed (see
manufacturer’s recommendations in the Finishing and Adhesives section below). Always use corrosion-resistant
mechanical screws along with manufacturer’s recommended adhesive product when installing all Fypon products.
This combination provides a secure, long-lasting bond. Countersink all fasteners about 1/8" and ll with product
compatible ller. Exterior installations should be nished using a manufacturer’s recommended caulk to prevent
water inltration behind siding, windows and doors.

Finishing and Adhesives

Fypon polyurethane products are factory primed. Depending on product location, always use interior / exterior­grade PUR compatible adhesives, sealants and llers when installing Fypon products. Consult the manufacturer’s
recommendations for your particular climate and the substrate you are installing to.

IMPORTANT

Please read these installation guidelines thoroughly before beginning installation. Please note that these guidelines are provided only to assist
with the installation of Fypon millwork products. Modied procedures may be required in order to meet specic situations, unique applications
and local building codes. The manufacturer does not, under any circumstances, warrant the installation of its products. Be sure to wear
appropriate protective clothing, gloves and safety glasses when working with any tools. Installer should check for and relocate all electrical
wiring within the proposed installation area, as needed (be sure to disconnect all electric power before working with any electrical wiring and
follow all applicable local electrical codes and safety procedures).

10

1750 Indian Wood Circle | Maumee, OH 43537 | Phone: [phone] U.S. and Canada

Fax: [phone] U.S. and Canada | fypon.com | [e-mail]

Fypon warrants all of our products to be free from defects in material and workmanship for as long as the original owner of the residential dwelling owns the property.

For complete homeowner lifetime limited warranty details, exclusions and limitations, please see your purchase location or visit www.fypon.com.

©2019 Fypon, LLC. All rights reserved. Fypon and the Fypon Logo are trademarks of Fypon, LLC. Fypon, LLC, and its parent company Therma-Tru Corp. are part of Fortune Brands Home & Security, Inc. All trademarks are property of their respective owners.

Publication No. BMNTLINSTALL 2/19