EZ Handrail EZF7254W, EZ8RBZ, EZBCW-LP, EZ6CW, EZPRW-W, EZ8RW, EZBCDT-LP, EZTUPHB, WH6RHB, EZPRBZ-W Installation guide

EZ Handrail EZF7254W, EZ8RBZ, EZBCW-LP, EZ6CW, EZPRW-W, EZ8RW, EZBCDT-LP, EZTUPHB, WH6RHB, EZPRBZ-W Installation guide
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R LIANT R
Care and Maintenance
COD
OM
EC
P
While most powder coat finishes are tougher and much more flexible than
conventional solvent based paints, they are about the same hardness as
automotive paint and can scratch. To clean a powder coated surface, use the
same care and methods you would use to clean your car. Gently wash with a
clean, soft cloth and a mild detergent followed by a clear water rinse. Even
though most powder coatings are highly resistant, certain solvents can harm
them. Avoid contact with nail polish remover, paint or lacquer thinner, motor
oils, transmission and brake fluids or solvent based cleaning fluids. If any of
these should contact the powder coated surface, immediately wipe the area
with a soft, clean cloth, and wash as described above.
Congratulations!
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For assistance call Madden Manufacturing
573-365-7085
You are on your way to a maintenance
free handrail system that is easily
assembled and installed. With your
system, you’ll feel safe being protected
by the tremendous strength of its
aluminum alloy components, plus be
comforted knowing the hardened
powder coated finish will last year
after year.
Please take a moment to read
the instructions before you begin
assembling your project.
Contents
Introduction
Tools You Will Need (not included)
Components and Assembly Instructions
Post Installation with Welded Base Plate
Post Installation with Separate Mounting Flange
Installation into wood/composite decking/concrete
Pre Sizing and Cutting Top and Bottom Rails (prior to assembly)
Railing Assembly and Installation
Mid Support Stabilizer
Stair Railing Assembly and Installation
Stair Railing Helpful Hints & Apps
Gate Instructions
Care and Maintenance
2
3
4
5
6
7
8
9
10
13
14
15
BC
Please take a moment to read the instructions
before beginning your installation.
Tools You Will Need
(not included)
A B C D E F G H I J -
Level
Chop Saw (60 to 80 tooth wood blade)
Safety Glasses
5/16" Hex Bit Driver
1/4" Hex Bit Driver(long shaft)
Tape Measure
Screw or Impact Gun
Pencil
Drill Bits: 1/8" metal/wood, 1/4" wood,
1/4"x 4"concrete Masonary
(2) pcs 10" 2 x 4 lumber to support
railing during installation (optional)
Ear Protection
Notice
For saltwater
environments we
recommend grade
18-8 stainless
steel fasteners
or equivalent.
Stainless steel
fasteners not
included.
A
Introduction
Check the contents of box with these instructions to verify all parts are
present. This will allow you to become familiar with the components of
your new system.
• Inspect all component parts for familiarity
• Layout recommended tools
• Before cutting any component, know its use – “measure twice
and cut once.”
• The included wood fasteners (gray head) are ACQ treated lumber approved.
• The included concrete fasteners are for brick (Tapcon)
and concrete (Wedgebolt).
B
C
D
E
F
G
H
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I
J
For assistance call Madden Manufacturing
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2
Components and Assembly Instructions
Components
A.
B.
C.
D.
E.
F.
G.
Top Cap
Top Snap
1" Sq. Balusters
Bottom Channel
Top Post Mount
Bottom Post Mount
1 ½" Fasteners
Post Installation with Welded Base Plate
Start by ensuring that you have a solid and level mounting surface for your
post(s). Washers or galvanized/stainless metal shims (not included) may be
used to plum posts.
Post Mounts are installed with railing
sections in later steps. Mounts shown for
informational purpose only in this step.
Optional 3 x 3 Posts
(order separately)
Stair
Adjustable
Mount
Level
Mount
IMPORTANT: The distance
between posts should not exceed
6 ft. when installed above ground
level(24"). Always refer to your
local building department for
building code clarification.
Optional Decorative
Base Cover
(order separately
A
Stair
Adjustable
Mount
E
B
F
C
D
Mount can
rotate 180º
IMPORTANT: Install
supporting lumber
below composite/wood
decking when surface
mounting posts to a
deck (Ex. A). Fasten
the 4" bolts through the
decking and supporting
underside lumber with
the provided tee nuts.
Note: When installing the post base into ACQ
lumber, use stainless steel bolts (not included)
G
Example A
2 x 10
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4
Post Installation with Separate Mounting Flange
Note: When installing “low profile” base covers with the separate
mounting flange, the horizontal thru bolts must be installed near
the bottom of the mounting flange.
1. Layout posts uniformly or as desired across entire project.
2. Ensure spacing between posts does not exceed 6 ft. for elevated decks
(or greater than local codes specify).
3. Starting at a corner post, attach post flange to deck/patio using appropriate
fasteners provided with the Post Kit. MAKE SURE TO USE ADDITIONAL
LUMBER BLOCKING UNDER THE DECK TO SECURELY FASTEN THE FLANGE!!!
In some instances, fully threaded lag screws may be necessary – but are
not included. LAG SCREWS LOOSEN OVER TIME AND REQUIRE
QUARTERLY SAFETY CHECKS.
4. Slide 3"x3" post over post flange and plum using level.
5. Drill ¼" hole (1 ½" above flange) front-to-back through the entire post and
post flange coming out on the back side. IT IS IMPORTANT TO DRILL
HOLES WITH POST PLUM.
Post Mounts are installed with railing
6. Drill 2nd ¼" hole side-to-side.
sections in STEP 5. Mounts shown for
Start hole 3/4" above the
informational purpose only in this step.
flange base. Note that hole
patterns can be modified if
necessary. Additional screws
predrilled into post and flange
will firm-up post installation.
7. Fasten post to post flange
with 3 ½" bolt, washer, and
Level
standard nut provided.
Mount
Washers must be placed
on both sides of the post.
8. After post is plum and securely
fastened, slide decorative
base cover (optional and sold
separately) over post covering
IMPORTANT: The distance between
the post flange.
posts should not exceed 6 ft. when
installed above ground level. Always
9. Secure next post using same
refer to your local building department
procedure. At this point you
for building code clarification.
may size (cut) and install
a railing section to verify
your desired layout. Then
continue to set the
remainder of the posts.
Stair
Adjustable Mount
Mount can
rotate 180º
1 1/2"
1 3/8"
3/4'
1 1/2"
1 3/8"
3/4'
IMPORTANT: Install
supporting lumber below
composite/wood decking
when surface mounting
posts to a deck. Fasten the
4" bolts through the decking
and supporting underside
lumber with the provided
tee nuts. We recommend
2" x 10"
5
Example A
IMPORTANT: When
installing the post
base into ACQ
lumber, use stainless
steel bolts
(not included)
Installation into wood/composite
decking/Non ACQ lumber:
1. Determine the 3"x 3" post location(s). Spacing between posts should be 6"
or less to meet IBC codes when installed 24" or higher above the ground.
2. We recommend the edge of the 5"x 5" base plate is fastened at least
1 3/4" in from the edge of the deck (do not lag screw into the rim joist
unless absolutely necessary).
3. Reinforce the decking with support lumber “backer board". A piece of
2"x 10" lumber cut to fit tightly between the joists and installed flat under
the decking works great.
4. Square up the post with the deck and mark all (4) holes with a pencil.
5. At your (4) pencil marks, drill a 1/4" hole through the decking and backer board.
6. Using a 7/16" socket bit in your drill, thread the 1/4"x 4" Thru Bolt into the
post plate, through the deck, and through the backer board. **
7. Thread the Tee Nut onto the 4" Thru Bolt underneath the decking
and support lumber(teeth up).
8. Tighten post firmly to deck, making sure post is plum, using shims if neccesary.
9. Slide on optional post base cover for a decorative look.
10. Attach post cap after railing has been installed using 1" fasteners
provided, or super glue.
** Note: The 4" Thru Bolt fits very tightly into the post base plate
(especially Textured Black Posts due to thicker powder coat finish) and in
some cases must be predrilled using a 1/4" drill bit.
Installation into concrete
1. Turn the post upside down on a hard surface
and prepare to drill larger holes in base plate.
Enlarge the (4) existing post base plate holes
to 5/16" (using a 5/16" drill bit).
2. Determine the 3"x 3" post
location(s). Spacing between
Be careful to
posts should be 6' or less to
drill holes at
slight angle
meet IBC codes when installed
inward on top
24" or higher above the ground.
plate
3. We recommend the edge of the 5"x 5"
base plate is fastened at least 1 ½" in
from the edge of any concrete face
(assuming normal weight concrete).
4. Square up the post with the concrete
surface and mark all (4) holes with
a marker.
5. At your (4) marks, drill a 1/4"
masonry bit to 3 1/2" or deeper
hole into the concrete.
6. Fasten post in place with provided
1/4" x 3" Powers Wedge Bolts
7. Begin tightening the anchor with
socket wrench or impact wrench by rotating clockwise and applying
pressure in toward the concrete (make sure it is plumb).
8. Continue tightening the anchor until the head is firmly seated
against the post base plate. (Do not over tighten).
9. Slide on optional post base cover to hide fasteners. Attach post cap
after railing has been installed using 1" fasteners provided,
or use super glue.
For assistance call Madden Manufacturing
573-365-7085
6
Pre Sizing and Cutting Top and Bottom Rails
(prior to assembly)
There are two methods used when cutting the top and bottom rails to size. It is
important to cut appropriate amounts from each end of the rails so the picket
spacing from the post/wall appears symmetrical.
1. Measure the distance between your posts from the inside edge of the post
to the inside edge of the other post. Measure at the top and then at the
bottom, if the measurements are different, your posts may not be level and
may need to be shimmed.
Railing Assembly and Installation
STEP 1:
1. Place predrilled bottom channel (D) on its side using non-abrasive
work surface. Protect the painted surface from scratching.
2. Position one picket (C) above bottom channel aligning the
predrilled holes. Place baluster on flat side of channel.
3. Start both 1 ½" fasteners (G) thru bottom channel halfway into
baluster, and then tighten fasteners down fully. Tighten fasteners
until flush – DO NOT OVER TIGHTEN.
4. Repeat these steps until all balusters are secured.
2. Divide the distance between posts by two (÷2) to find the
center of the railing.
C
Option A – Measure from the “center gap:
A) Find the center “gap” (space between picket holes) of the top snap
(B),Make a pencil mark exactly in the middle of this gap (2-3/8"from
either pair of holes). Measure from the pencil mark the distance from
#2 above. Make another pencil mark 1/8" short of that (allows railing
to fit between posts when installing the completed section), repeat
at the other end.
Option B - Measure from “center baluster”
B) Choose one of the two sets of holes on either side of your pencil mark
and do the same as in Option A except starting from the center hole
instead of center of the gap.
Option C - Lay in front of installed post
Visually center rail between posts
3. Place your marked piece between the two posts and make sure there is not
more than a ¼" gap (1/8" for either side). When satisfied, make your cuts.
4. Place top snap (B) on bottom channel (D) with flat portions together. Drop
a screw through a hole to line up pieces. Cut bottom channel (D) to equal
length using the top snap (B) as a template.
MAKE SURE THE HOLES ARE ALIGNED!!
5. Cut Top Cap (A) to same length as top snap and bottom channel.
D
G
STEP 2:
1. Place predrilled top snap (B) on the opposing flat side of balusters.
2. Loosely fasten top snap to the first and the last picket making sure the
predrilled holes are aligned correctly. Next, loosely fasten a picket
near the center. Make sure not to tighten until all pickets are in place.
3. Once the top snap is loosely fastened to all pickets, stand the
upright and secure all pickets – Tighten fasteners until flush –
DO NOT OVER TIGHTEN.
D
C
G
B
Picket Fastener Spacing Diagram
Cut same
amount from
each end
2 3/8" (midpoint)
Cut same
amount from
each end
4 3/4"
4 3/4"
Hole dimension:
3/16"
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STEP 3:
1. Align the top cap (A) with your top snap making sure one end is flush.
Starting at one end, squeeze the top cap and top snap (B) together until
it pops in place. Continue snapping down the top cap until reaching
the end of your railing.
2. Slide the top post mounts (E) and bottom post mounts (F) over the
ends of your railing (4 mounts total).
3. Place assembled railing section between posts. If the handrail section need to be shortened, CUT EQUAL LENGTHS FROM BOTH ENDS
OF THE RAILING. Example: If the railing is 3" too long, cut 1 1/2" from
each end.
STEP 3B
IS ONLY NECESSARY WITH 8 FT RAILING SECTIONS
(MID SUPPORT NOT INCLUDED WITH 6 FT RAILINGS)
MID SUPPORT STABILIZER
(INSTALLATION IS OPTIONAL for section under 8')
Note: Assemble with 1 1/2" fasteners included with pickets.
1. Pre-drill pilot holes to attach Bottom Rail Snap on the top of the Mid
Support creating a “T” configuration as shown.
2. Fasten Bottom Rail Snap to Mid Support using 1 1/2" picket fasteners.
3. Once your railing is installed, place Mid Support at center of rail. If
necessary, measure from ground to bottom rail and cut the Mid Support
proper height.
4. Snap the horizontal section of the Mid Support to the bottom rail of your
railing section. Note: Upward pressure must be applied to your railing
section in order to slide and snap the Mid Support Stabilizer in place.
Quick Install:
Fasten Bottom Rail Snap
to Mid Support in "T"
Configuration and install
under bottom railing at
the center of the section
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10
STEP 4:
Hint: Place railing section on edge of 2x4 lumber to fasten bottom post
mounts.
1. Ensuring the gap from the top of the deck (ground) to the bottom of the
bottom channel (D) is less than 4", and that the top of the rail meets
your code requirements, vertically center your railing. Now attach the
bottom post mounts (F) to the existing or post using the proper
fasteners (C) provided. Reminder: Typically residential minimum handrail
height is 36" and commercial handrail height is 42".
2. Ensuring your railing is centered vertically on the post, fasten the top post mount (E) using the proper fasteners provided.
3. Now move to the other end of the railing section. Using a level (or resting railing on edge of 2 x 4 lumber) confirm your railing section is
positioned at the correct height. Vertically center on post and fasten the
2nd bottom post mount using the proper fasteners provided.
4. Vertically center the top rail to the post and fasten the 2nd top post
mount using the proper fasteners provided.
5. Fasten the top post mounts (E) to the top (A) on non-visible side of railing. PILOT HOLE MUST BE DRILLED! Use the 1" self tapping
fasteners provided. Repeat steps for bottom rail mounts (F).
Note: Refer to Post Installation Page near beginning of instructions for proper
post installation
Stair Railing Assembly and Installation
STEP 1: STAIRS
1. Review the instructions and make yourself familiar with the included items.
2. Measure the stair rise and run then determine the angle using the
rise/run chart on the following page. We also recommend verifying your
angle using an angle finder app on your Android or iPhone – see
recommendations on the following page. Make sure to measure the angle
at the top, middle and bottom of stair run!
3. Set your miter box/chop saw to the appropriate stair slope angle and
cut each end of the picket (B) (baluster). MAKE SURE YOU CUT BOTH
ENDS PARALLEL TO ONE ANOTHER SO TOP AND BOTTOM RAILS ATTACH
PROPERLY. ALSO ALIGN THE SCREW CHANNELS!!!
4. Visually verify the picket angle is correct by setting between top and
bottom rails and holding in place on stair slope. Carefully cut the
remainder of the pickets EXACTLY THE SAME SIZE!
5. After all the pickets are cut fasten them to the bottom channel (A) using
the 1 ½" fasteners provided in your railing kit. (Note: if the stair slope is steep, the 1" fasteners included with the Pivot Mount Kit (sold
separately) may install easier. Be sure to use the same fasteners at the
top and bottom of the pickets).
6. Straighten the pickets by hand and fasten the top snap (D) to the
top of the pickets.
7. Slide the Top and Bottom Pivot Mounts onto the ends of each rail.
Set the railing section in place.
8. Position railing at proper height and mark or pilot holes in posts.
9. Attach pivot mounts to posts with railing section in proper position
10. After railing is securely in place pilot and secure fastener through pivot
mount into top rail on non visible side of railing. Repeat for bottom rail.
Typical stair slope
is 32.5 to 35 degrees
Using iphone app
Manually make a pencil mark
and cut with chop saw
You have completed your level railing Installation.
Stairs and gate instructions follow.
For questions or a video
demonstration visit
www.maddenmetals.com
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11
For assistance call Madden Manufacturing
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12
Stair Railing Helpful Hints & Apps
Gate Instructions
RUN (TREAD LENGTH)
11" 11.5" 12" 12.5"
13" 13.5"
14"
RISE
10"
10.5"
5"
27°
25°
24°
23°
23°
22°
21°
20°
20°
5.25"
28°
27°
26°
25°
24°
23°
22°
21°
21°
5.5"
29°
28°
27°
26°
25°
24°
23°
22°
21°
5.75"
30°
29°
28°
27°
26°
25°
24°
23°
22°
6"
31°
30°
29°
28°
27°
26°
25°
24°
23°
6.25"
32°
31°
30°
29°
28°
27°
26°
25°
24°
6.5"
33°
31°
30°
29°
28°
27°
27°
26°
25°
6.75”
34°
33°
32°
30°
29°
28°
27°
27°
26°
7”
35°
34°
32°
31°
30°
29°
28°
27°
27°
7.25"
36°
35°
33°
32°
31°
30°
29°
28°
27°
7.5"
37°
36°
34°
33°
32°
31°
30°
29°
28°
7.75"
38°
36°
35°
34°
33°
32°
31°
30°
29°
Rise
Tread
Tip#2: Smartphones and tablets have good
(free) angle finder apps
Tip#3: Elongating (enlarging) the picket
fastener holes on top
and bottom rails makes assembly easier
Stair runs may require elongated (enlarged) holes and/or shorter fasteners to
secure pickets efficiently (shorter 1” fasteners are included with the EZ Pivot
Mount Kits).
To elongate holes, use a 13/64" drill bit in an up and down motion within the
existing hole and parallel with the rail. IMPORTANT: elongate the hole towards
the point (tip) of the mitered picket to avoid any visible modifications. Do not
widen the holes side to side.
EZ Gates can swing left or right depending on the hinge location. Standard
hinges and gravity latch are included with all EZ Gates.
Note: Self closing hinges and pool child safety latch sold separately.
Step 1
1. Verify rough opening between posts is 1" greater than width of gate.
2. Set gate in opening and visually identify where hinges will attach to
gate for the desired swing direction.
3. Measure 3” down from the very top of gate and attach hinge to
appropriate gate face using the provided fasteners.
4. Attach 2nd hinge 3” above the very bottom of the gate to the
appropriate gate face.
5. Measure 4” down from the very top of gate and attach gate latch arm to
appropriate gate face using the provided fasteners.
6. Place (2) 2x4s on edge in the gate opening so the gate may rest in place
while attaching the hinges to the post.
7. Level gate in position and fasten top hinge to appropriate post face
with a single fastener only.
8. Confirm levelness and attach bottom hinge to post using
all three fasteners
9. Complete installation of top hinge with remain two fasteners and remove 2x4’s.
Hold gate latch on latch arm, swing gate closed, mark holes
and fasten latch to post.
Available gate sizes:
Residential: 36"W x 36"H
Commercial: 36"W x 42"H
Pool Gate: 36"W x 48"H
Typical railing Heights:
Residential: 36"
Commercial: 42"
Pool Fencing: 48"-54" (check local codes)
Optional gate handrail
• Self closing hinges
• Child safety pool latch
C
B&D
C
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13
For assistance call Madden Manufacturing
573-365-7085
14
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