UltraDeck

Product Installation Guide

The advantages of UltraDeck

Low Maintenance Technology
Only requires periodic cleaning to remove dirt and other organics. Spend more time enjoying your deck rather than maintaining it. UltraDeck uses state of the art equipment to specially blend plastic and wood fibers. Polyethylene coatings are available with UltraDeck Fusion decking and railing.

Great Investment In Your Home Solid Reputation Finished Look Environmentally Friendly
Made with recycled materials.

UltraDeck is a top selling composite deck.

Intended For Outdoor Use Durable Easy To Work With

Resists splintering, cracking, rotting, and insects. No special tools required; easy as working with wood.

Hidden fasteners and color matched composite screws create a finished look.

Solid and Hollow Profiles Available. Ten Year Limited Warranty

Warranty information can be found at www.midwestmanufacturing.com

Installation Tools ..................4 Fasteners ..............................4 Deck Framing Tips ...............5 Cladding Installation ............5 Fusion and Rustic Solid Plank Instructions.......7 Installing 4x4 Posts & Post Sleeves......................8 U-Top-It Post Option.............8 Rustic and Natural Railing Instructions: Method 1 ........................9-10 Method 2......................10-11 Method 3 .....................12-13 Pinnacle Railing Instructions.................15-16 Fusion Railing Instructions ........................14 Pinnacle Bracket Instructions ........................16 Plank Endcaps ......................7 Rustic and Natural Plank Instructions ................6

Who is UltraDeck? UltraDeck is the manufacturer of UltraDeck decking, railing and fencing. UltraDeck is a division of Midwest Manufacturing which has been in business since 1969. Midwest Manufacturing's continual growth has helped it become one of the largest manufacturers of building products in the Midwest. UltraDeck's headquarters and manufacturing facility are located in Eau Claire Wisconsin. As an UltraDeck customer, you can count on us to provide you with reliable products and service at a great price. Why are UltraDeck decking and railing products a superior choice over traditional wood products? UltraDeck products perform with long lasting durability and performance that you can't get from wood. UltraDeck won't rot, wrap, or splinter; and beside from a periodic cleaning require no maintenance. PAGE 2

Frequently Asked Questions

What is the lifetime value of Ultradeck? Because UltraDeck never rots or warps and painting and staining are not required, however with pressure-treated wood decks, these costs add up over time. After four years, the total cost of owning an UltraDeck deck equals the cost of a pressure-treated wood deck with maintenance. Over the life of the purchase, UltraDeck offers a far greater value than wood. Clean it periodically during the year and you're done so you can spend more time enjoying your outdoor living space, rather than working on it. How do you clean UltraDeck decking? UltraDeck can be cleaned with soap and water or any product made for washing composite decking. There is also a how-to-video on cleaning on our website.

Can I put a hot tub on UltraDeck? The substructure of a deck determines whether it can support a hot tub. UltraDeck is not a load-bearing product and the joist of the structure should be used as the support mechanism. Any load bearing pillars/legs should be placed directly above a deck joist or sister joist in this application.

Can I paint or stain my UltraDeck? UltraDeck does not need painting or staining to maintain its looks. If desired though only the brushed side of UltraDeck Natural may be stained with a good quality composite deck stain after one year of adequate weathering. Always follow the stain manufacturers recommendations and keep in mind that staining is not a one time application and will add maintenance to your low maintenance decking.

Can UltraDeck be used in docks and water front decks? We have seen UltraDeck used in many of these applications. As long as installation instructions are followed UltraDeck will work well and be very aesthetically pleasing in waterfront applications. PAGE 3

Can UltraDeck be placed over a solid surface? UltraDeck can only be installed over a solid surface when using a sleeper system. A sleeper system is a buffer between the solid surface and the decking. Water must be able to flow through and away from the deck and adequate airflow is necessary.

 Drill

Safety Glasses

Building a deck is a rewarding project you can do with few tools. As with any project, be sure and use all necessary protection, i.e. eyewear, safety boots. Here is a list of items you might need to complete your deck: Fasteners Construction Calculator Chalk Line Square and Level Circular Saw (with carbide blade) or Miter Saw Hacksaw Rubber Mallet Screw Driver/Drill Driver Bits

Installation Tools

Tape Measure

Figure 1

Fasteners

3/4'' Screws
DekMount Hidden Fastening System

Figure 2

Joist

UltraDeck T-Clips are another hidden fastener option specifically designed for use with the UltraDeck Fusion and Rustic Solid planks. In addition to their finished look, they naturally gap the planks at 3/16 - saving you time measuring. Fusion and Rustic Solid planks are specially designed with a lip on the edges to accept the UltraDeck T-Clips. See figure 2. For conventional fastening, use color-matched composite deck screws or 2-1/2'' quality deck screws. Composite deck screws are recommended because they will pull shavings into the screw hole, eliminating the mushrooming effect, and therefore, pre-drilling and countersinking are only required at the ends of the planks and spindles. Always pre-drill and countersink screws when using 2-1/2'' quality deck screws. Keep screws at least 3/4'' away from edge/end to prevent splitting. Do not over tighten fasteners! If 3/4'' from the edge/ends of plank is off of framing material, an additional nailer board is needed to attach plank.

The DekMount Hidden Fastening System can be used with solid or hollow planks, and is highly recommended for plank installation because it provides a clean, finished look. Start from the wall or house and work to the outer rim joist. The DekMount Hidden Fastening System is available in 8' long stainless steel (155-1372) or brown powder coated finish (155-1376). When using the DekMount Hidden Fastening System, 3/4'' triple coated premium screws (available in 1lb. & 5lb. boxes, skus 229-1004 & 229-1002) are recommended for bracket to joist and plank to bracket connections. See figure 1.

UltraDeck T-Clips
Figure 3

Ring Base Post Sleeve

PAGE 4

Lag Bolts Included

Surface Mount

UltraDeck surface mount plates work well for mounting 4x4 posts for UltraDeck railings to existing decks and cement patios. Treated 2x8 blocking will need to be mounted flush with underside of deck if lag bolts do not go directly into joist. Complete the look by adding UltraDeck post sleeves and ring bases to cover the 4x4 post and UltraDeck surface mount plate. See figure 3.
Low-Maintenance Composite Decking

A solid foundation is crucial to a strong, level deck. Use a treated wood or cedar substructure. Always check local building codes before beginning construction. Like other composite decking, UltraDeck products are not approved for structural load bearing use. Once you decide which way you will run your deck planks, determine the amount of joist spanning needed. Always adjust joist span to accommodate deck patterns and stairs. See Figures 4, 4-A and 5. Be sure foundation is level.

Deck Framing Tips

Figure 4

Joist Spanning

Reminder: Remember to use triple coated or

stainless steel screws for treated framing materials.
Figure 4-A

45 Deck Pattern
Figure 5

12'' o.c. maximum

Perpendicular Stair Pattern

12'' o.c. maximum

UltraDeck cladding can be used as skirting to cover joist members and hollow & solid board end & side profiles, 4x4 elevated support posts, stair stringers, and other exposed lumber products. Cladding will provide a professional finished look to your deck. See Figure 6A. Available in 3/8'' x 4'' x 12' in Natural and Fusion. Also available in 7/16'' x 10-1/2'' x 12' lengths in Rustic only. Use color-matched cladding screws to secure cladding to deck frame. Be sure cladding is not secured to UltraDeck planks in order to allow for proper expansion and contraction. Pre-drill and countersink two screws 1-1/2'' from top and bottom edge of joist every 16 inches.

Cladding Installation
Figure 6A

Perpendicular Deck Pattern

16'' o.c. maximum

Figure 6B

UltraDeck Cladding
Joist
oa r ds

On long runs requiring multiple pieces of UltraDeck cladding, use opposing miter cuts at the seam to reduce visible joints. See Figure 6B. Also, follow end gapping chart, Figure 9 on page 6.
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Outside Joist Cladding

ec

45 Miter Cut on Cladding

Cladding

Joist

PAGE 5

Board Dimensions and Weights: Plank Gapping

Rustic and Natural Plank Instructions

Figure 7

Natural: 5-3/16''w x 1-1/8''h, approx. 1.4 lbs. per lineal foot. Rustic Solid: 5-3/16''w x 15/16''h, approx. 2.5 lbs. per lineal foot. Rustic Reversible: 5-3/16''w x 1-1/8''h, approx. 1.4 lbs. per lineal foot. Fusion: 5-1/8''w x 1''h and weighs, approx. 1.4 lbs. per lineal foot.

UltraDeck decking MUST be gapped between planks and at the ends. Besides expansion and contraction, there are several other important reasons why decking must be gapped, including treated wood joists shrinking over time. Gapping allows for proper drainage that is needed to help keep the deck dry. Please see Figure 7 and follow the End Gapping Chart, Figure 9, to ensure your decking is properly installed and will last for many years.

UltraDeck, like other composite decking products, expands and contracts with temperature changes. Steps listed below must be followed to allow for expansion and contraction.

3/16'' to 3/8''
Figure 8

UltraDeck Side-to-side Gapping UltraDeck End Gapping

A deck board installed as a joining board at the seams will minimize the amount of visual end to end contraction by separating the end to end gap.

For every 16' of plank, allow 1/16'' space for every 20 F of temperature difference between the time of installation and the maximum expected temperature (refer to end gapping chart, Figure 9). At plank ends predrill and keep screws at least 3/4'' away from plank edges to prevent splitting. Do not over-tighten fasteners! If 3/4'' from the edge of the plank is off framing material, an additional nailer board is needed to attach the plank. See figure 10.
Note: Fusion and Rustic Solid planks must be installed with the textured surface facing up for added traction. An arrow is printed on the side of all boards to indicate direction of installation and to ensure that grain pattern direction matches. The bar code and arrow on the side of the planks may be removed with rubbing alcohol.

Leave a minimum 3/16'' gap between the sides of planks. If the temperature is below 40 F at the time of installation, a 3/8'' gap is recommended. See figure 7.

Figure 9

UltraDeck Natural planks give you the option to display either an embossed woodgrain or a brushed finish. All planks will weather to a natural color over time. The brushed side can be stained after a weathering period of at least one year with a high quality stain recommended for composite decking. Due to ever changing conditions that affect board weathering, it is recommended that stain is applied to a small test portion of the deck, prior to staining entire deck surface. Be sure to follow stain manufacturers recommendations. Hollow Plank Fastening When fastening hollow planks through the top surface, screws must pass through interior channel to avoid compression of planks.

Figure 10

Current Maximum Expected Temperature Temp 70 80 90 100 110 120 40 3/32'' 1/8'' 5/32'' 3/16'' 7/32'' 1/4'' 50 1/16'' 3/32'' 1/8'' 5/32'' 3/16'' 7/32'' 60 1/32'' 1/16'' 3/32'' 1/8'' 5/32'' 3/16'' 70 --- 1/32'' 1/16'' 3/32'' 1/8'' 5/32'' 80 ----- 1/32'' 1/16'' 3/32'' 1/8'' 90 ------- 1/32'' 1/16'' 3/32'' 100 --------- 1/32'' 1/16''

END GAP DISTANCE FOR EVERY 16' OF PLANK

End Gapping Chart

End Gapping Alternative

Additional Nailer Boards Screws are 3/4'' From End of Plank 1/32'' to 1/4'' Gap

PAGE 6

Natural Shown

Low-Maintenance Composite Decking

Figure 11

Fusion and Rustic Solid Plank Instructions

UltraDeck T-Clips

Figure 12

house side

Step 1. Follow general substructure and plank installation on pages 5 and 6. Step 2. Begin by securing UltraDeck T-Clips to ledger along house side at every joist. Slide deck board into place. See figure 11. Step 3. Attach the next row of UltraDeck T-Clips and continue the process. Step 4. Pre-drill the last deck board in the outer lip and fasten to the rim joist every 8'' with 1-5/8'' triple coated deck screws. No UltraDeck T-Clip is used on the outside of the last board. See figure 12. Step 1. Follow general substructure and plank installation on pages 5 and 6. Step 2. Begin by pre-drilling plank in the outer lip and fastening plank to rim joist every 8" with 1-5/8'' triple coated deck screws. UltraDeck T-Clips are not required on the outside of the first board. See figure 12. Step 3. Next, install a row of UltraDeck T-Clips at every joist using supplied screws. Slide deck board into place. Step 4. Continue process across the entire length of the deck. Step 5. Pre-drill the last deck board plank in the outer lip and secure to rim joist using 1-5/8'' triple coated deck screws every 8''. See figure 12. For every 16' of plank, allow 1/16'' space for every 20F of temperature difference between the time of installation and the maximum temperature. See Figure 9 on page 6. If your deck has butt joints, place additional nailer boards at this connection to aid in attaching/supporting deck planks. Place two UltraDeck T-Clips at every end gap. See insert in figure 13.

Installing Fusion and Rustic Solid Planks that Run Parallel to House

Installing Fusion and Rustic Solid Planks that Run Perpendicular to House

Figure 13

A deck joining board installed at the seams will minimize the amount of visual end to end contraction by separating the end to end gap.

End Gapping Alternative

1/32'' to 1/4'' Gap

Additional Nailer Boards

UltraDeck End Gapping

Plank Endcaps - Used for UltraDeck Fusion

Figure 14

UltraDeck T-Clips

When UltraDeck hollow profiles are installed, endcaps are a great way to protect your deck because they help prevent moisture, dirt, and insect infiltration. Endcaps provide a clean professional look to your deck. Endcaps can only be used on hollow planks with 90 cuts. They are not necessary at butt joints. See figure 14. If desired, use an adhesive caulk to secure endcap to plank.

, Natural, and Rustic Reversible

Matching Plank Endcaps Available in:

Fusion - cedar and gray Rustic Reversible - cedar, gray, and redwood Natural Reversible

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PAGE 7

Step 1. First determine location and install the 4x4 treated posts to the substructure. The maximum post spacing is 6' on center. Do not notch 4x4 railing post. See figure 15. Step 2. Use blocking that is the same dimensional size as the joist members to reinforce the 4x4 posts opposite the rim joist. See figure 15.

Installing 4x4 Treated Posts to Deck Substructure

Installing 4x4 Posts & Post Sleeves for Railing

Figure 16
Joist Member Reinforcement Blocking

Verify all local codes for railing heights, post spacing, and spindle spacing before construction.

4x4 Post

Joist Member

Step 3. Use (3) 3'' quality deck screws for attaching each end of blocking to joist. Step 4. Secure 4x4 treated post to the rim joist and reinforcement blocking using (2) 6'' lag screws with a minimum spacing of 5-1/4'' apart. Countersink the lag screws if using UltraDeck cladding. See figure 16.
Figure 15
U-Top-It Post 4x4 Post

Reinforcement Blocking Joist Member

Post sleeves provide a clean finished look to your deck and railing components. Post sleeve covers also protect 4x4 posts. Step 1. Cut UltraDeck post sleeve to proper length. Step 2. Slide UltraDeck post sleeve over the 4x4 treated post. Watch the recessed channel orientation when using the Natural sleeves so that all posts have the same appearance. When using Rustic and Fusion post sleeves, be sure and slide the ring base to the bottom before installing first spindle. Post sleeves are secured as the first spindle is fastened to the sleeve. See figure 17.
Figure 17 Recessed Channel

Installing UltraDeck Post Sleeve

(2) 1/2'' x 6'' Lag Screws 5-1/4'' Apart

Rim Joist

Rim Joist

U-Top-It Posts, or notched posts, are to be used only in correlation with beveled one-end spindles as shown in Method 3, page 10. Installing U-Top-It Posts on the outside of the joist (as shown above) with any other method will interfere with the position of the support blocks.

(3) 3'' Screws

Rim Joist

U-Top-It Post Option

U-Top-It Post

See the U-Top-It Post Option below on how to incorporate the U-Top-It Post into other railing methods.

Step 3. Install Post Caps Align post cap with the top of the post sleeve and slide into position. If desired, use a silicon adhesive caulk to secure post cap to sleeve.
Figure 18 Post Cap

Natural Post Sleeve

2x8

U-Top-It Post

U-Top-It Post

2x8

(2) 1/2'' x 6'' Lag Screws 5-1/4'' Apart

Rim Joist

2x8

Rim Joist If you choose to use U-Top-It 4"x 4" Posts with UltraDeck composite decking, you will be required to mount the U-Top-It Posts on the inside of the rim joist to allow for the support block to be installed. See illustration above.

Post sleeves available in 48'' and 96'' lengths. Decking and railing components are extruded products. Post cap and ring base are injection molded and will fade at a different rate than UltraDeck decking and railing components.
Note: UltraDeck Post Sleeves are designed to fit over dimensional 4x4 posts. If the 4x4 posts you are using are outside of standards, trimming or shimming of 4x4 edges may be required. Check fit of 4x4 into Post Sleeve prior to installation to your deck structure and make any changes to the 4x4 if needed.

PAGE 8

Low-Maintenance Composite Decking

Step 1. Post Sleeve Installation

When using post sleeves, install the ring base and slide it to the bottom of the post sleeve. Slide post sleeve over the 4x4 post. Measure the distance between the post sleeves and cut upper rail, lower rail, and metal insert to this length. Spindle height may vary, check spindle height and trim to desired height as needed. All rail spans over 3' require a spindle support block centered under the rail assembly. Check local building codes and cut the support block to the height required to meet local code. Attach the spindle support block to the bottom side of the lower rail by installing a screw through the lower rail into the support block. See figure 20 on page 10. Cut spindle spacer blocks from UltraDeck spindles to meet local code for spindle spacing. Two spindles will need to be pre-drilled for attaching the completed rail to the post sleeves. Using a 1/8'' drill bit, drill holes in the spindle 3-1/2'' from the top, 3-1/2'' from the bottom, and in the center of the spindle. These holes should be drilled at approximately 60 degrees to allow enough room to drive the 3'' composite deck screws through the post spindle into the post sleeve and post. These spindles will be referred to as Post Spindles. See figure 21 on page 10. Slide the spindle spacer blocks and the spindles into the profile of the upper handrail assembly. Make sure to install the Post Spindles flush on the ends of the assembly. Slide the spindle spacer blocks and spindles into the profile of the metal insert from the end. The upper handrail will then need to be slid over the metal insert. Pre-drill and fasten the spacer blocks and spindles to the top rail using 1'' corrosion resistant screws (1lb. sku 230-4100). Slide the spindle spacer blocks and the spindles into the profile of the lower rail, pre-drill, and fasten the spacer blocks and spindles to the bottom rail using 1'' corrosion resistant screws. See figure 22 on page 10.

All methods recommended for spans of 6' or less. Method 1 differs from Methods 2 & 3, in that it has spacer blocks between spindles. It also requires no pre-drilling of metal insert. Method 1 meets ICBO-ESAC174 Code.

UltraDeck Rustic and Natural Railing Instructions - Method 1

Step 2. Sizing Spindles, Upper Handrail, Handrail Insert & Lower Rail

Step 3. Spindle & Handrail Preparation

Step 4. Handrail Assembly

Step 5. Rail Unit Installation

Place the completed rail section between the posts and temporarily support rail unit on 2x4 blocks, trimmed to length, to ensure proper height from the deck surface. Secure the rail to the post sleeves using (6) #10 3'' composite deck screws through the pre-drilled holes in the Post Spindles. Align post cap with the top of the post sleeve and slide into position. If desired, use a silicone adhesive caulk to secure post cap to sleeve.

Step 6. Install Post Caps

Step 7. Stair Rail Assemblies

When using components for stair rail it may be necessary to cut angles to match stair slope.

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PAGE 9

Figure 19

UltraDeck Rustic and Natural Railing Instructions Method 1 - Continued

Figure 20
Spindle

Figure 21

Post Spindle

Metal Insert

Lower Handrail Support Block

Post Sleeve

4x4 Post

Figure 22

Spindle Spindle Spacer Block

Figure 23
Post Sleeve

Handrail

Spindle

1'' Corrosion Resistant Screws

Post Spindle

Step 1. Post Sleeve Installation

Mark your spindle spacing on the metal insert according to local building codes. Using a 1/4'' drill bit, pre-drill holes in the metal handrail insert where each spindle will be attached. Pre-drilled holes need to be centered on the metal insert to accommodate the screw head clearance channel in the upper handrail. See figure 24 on page 11. Two spindles will need to be pre-drilled for attaching the completed rail to the post sleeves. Using a 1/8'' drill bit, drill holes in the spindles 3-1/2'' from the top, 3-1/2'' from the bottom, and in the center of the spindles. These holes should be drilled at approximately 60 degrees to allow enough room to drive the 3'' composite deck screws through the post spindles into the post sleeve and post. These spindles will be referred to as Post Spindles. See figure 26 on page 11.
PAGE 10

Measure the distance between the post sleeves and cut the upper rail, lower rail and metal insert to this length. Spindle height may vary, check spindle height and trim to desired height as needed. When using components for stair rail it may be necessary to cut angles to match stair slope.

When using post sleeves, install the ring base and slide it to the bottom of the post sleeve. Slide post sleeve over the 4x4 post.

All methods recommended for spans of 6' or less. Method 2 differs from Methods 1 & 3, in that it has no spacer blocks between spindles, requires pre-drilling for metal insert, and lower rail profile is identical to top rail.

UltraDeck Rustic and Natural Railing Instructions - Method 2

Handrail

Secure spacer blocks and spindles to the handrail with 1'' corrosion resistant screws (1# sku 230-4100). Repeat this process for the top handrail.

Spindle Support Block

Deck Surface

Step 2. Sizing Spindles, Upper Handrail, Handrail Insert & Lower Rail Step 3. Spindle Preparation

Low-Maintenance Composite Decking

Bore the center on each end of the spindle with a 1/8'' drill bit to accept #10 3-1/2'' premium deck screws. Slide spindles into the profile of the metal insert from the end and begin attaching spindles working from the center toward the outside using quality #10 3-1/2'' premium deck screws. Make sure to install the Post Spindles flush on the ends of the assembly. Using a 1/8'' drill bit, pre-drill the lower rail to match the holes pre-drilled in the metal insert. Position the lower rail so the spindles will rest on the top side of the rail. Secure the spindles to the rail from the underside using quality #10 3-1/2'' premium deck screws. Slide the upper rail on to the metal insert. Dish soap may be used as a lubricant. See Figure 24. All rail spans over 3' require a spindle support block centered under the rail assembly. Check local building codes and cut the support block to the height required to meet local code. To install the support block on the rail system, cut a 6'' piece of metal insert, slide the support block into the metal insert and secure it with a quality deck screw. Slide the metal insert with support block attached into the profile of the lower handrail. See figure 25. Place the completed rail section between the posts and temporarily support rail unit on 2x4 blocks, trimmed to length, to ensure proper height from the deck surface. Secure the rail to the post sleeves using (6) #10 3'' composite deck screws through the pre-drilled holes in the Post Spindles.

Step 4. Handrail Assembly

UltraDeck Rustic and Natural Railing Instructions Method 2 - Continued

Step 5. Rail Unit Installation

Step 6. Install Post Caps

Align post cap with the top of the post sleeve and slide into position. If desired, use a silicone adhesive caulk to secure post cap to sleeve.
Figure 24 Figure 25
Deck Screw 6'' Metal Insert

Figure 26

Post Spindle

Upper Handrail

Metal Insert

Spindle

Support Block

Metal Insert

Cut a 6'' length of metal insert, fasten support block to metal insert, then slide metal insert with attached support block to center of lower handrail. Figure 28
Post Sleeve

Lower Handrail

Lower Handrail

Support Lower Block Handrail

6'' Metal Insert

Support Block

Post Sleeve

4x4 Post

Figure 27

Post Spindle Lower Handrail

32'' Spindle

Handrail Spindle

Post Spindle

Spindle Support Block

Deck Surface

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PAGE 11

Cut a notch into the post sleeve to match your U-Top-It post. This can be done by sliding the post inside the post sleeve and marking the depth of the notch. Use a square to transfer this mark to the outside of the post sleeve, using this as your starting point, mark the notch to the desired height and cut. If all of the U-Top-It posts are uniform a template can be developed at this point to speed up the cutting of notches in the post sleeves. See figure 29 on page 13. When installing U-Top-It posts to the perimeter joist, it is recommended that all lag bolts/screws are countersunk so as not to damage post sleeve. Connect U-Top-It post directly to perimeter joist. Once U-Top-It post is installed, slide post sleeve over the post. See figure 29 on page 13.

Step 1. Post Sleeve Preparation

All methods recommended for spans of 6' or less. Method 3 differs from Methods 1 & 2, in that it has no spacer blocks between spindles, requires pre-drilling for metal insert, and beveled one-end spindles are secured to perimeter joist. U-Top-It posts are used in place of traditional 4x4 posts.

UltraDeck Rustic and Natural Railing Instructions Method 3

Step 2. Post Sleeve Installation

Step 3. Sizing Spindles, Upper Handrail & Handrail Insert Step 4. Spindles & Handrail Insert Preparation

Mark your spindle spacing on the metal insert according to local building codes. Using a 1/4'' drill bit, pre-drill holes in the metal handrail insert where each spindle will be attached. Pre-drilled holes need to be centered on the metal insert to accommodate the screw head clearance channel in the upper handrail. See figure 30 on page 13. Two spindles will need to be pre-drilled for attaching the completed rail to the post sleeves. Using a 1/8'' drill bit, drill holes in the spindles 3-1/2'' from the top, 3-1/2'' from the bottom, and in the center of the spindles. These holes should be drilled at approximately 60 degrees to allow enough room to drive the 3'' premium deck screws through the post spindles into the post sleeve and post. These spindles will be referred to as Post Spindles. See figure 31 on page 13.

Measure between post sleeves and trim upper handrail and metal handrail insert to fit. Spindle height may vary, check spindle height and trim to desired height as needed. When using stair rail components it may be necessary to cut angles to match stair slope.

Step 5. Handrail Assembly

Bore the center on the top end of the spindle with a 1/8'' drill bit to accept #10 3-1/2'' premium deck screws. Slide spindles into the profile of the metal insert from the end and begin attaching spindles. Work from the center toward the outside using quality #10 3-1/2'' premium deck screws to secure the spindles. Spindles must be centered in the metal insert to ensure ease of assembly when installing handrail. Make sure to install the drilled Post Spindles flush on the ends of the assembly.

Step 6. Attach Handrail to the Handrail Insert

Slide the upper rail on to the handrail insert.

Position the upper rail assembly between the post sleeves to meet or exceed local building code height requirements. At this point you may want to trim U-Top-It posts and post sleeves to a desired height. Position the rail assembly square on the post sleeve to align the bottom of the spindles with the joist board. Secure the post spindles to the post sleeves using (6) #10 3'' composite deck screws through the pre-drilled holes. Maintaining the same spindle spacing as the top rail, pre-drill with 1/8'' bit and secure the bottom of the spindles to the joist board using #10 3'' premium deck screws. See figure 32 on page 13.
PAGE 12

Step 7. Rail Unit Installation

Low-Maintenance Composite Decking

Align post cap with the top of the post sleeve and slide into position. If desired, use a silicone adhesive caulk to secure post cap to sleeve.

Step 8. Install Post Caps

Rustic and Natural Railing Instructions Method 3 - Continued

Step 9. Stair Rail Assemblies

Figure 29 Figure 30

When using components for stair rail it may be necessary to cut angles to match stair slope.
Figure 31
4x4 Post

Post Spindle Cut Notch in Post Sleeve to Match U-Top-It Post Upper Handrail

Post Sleeve

Metal Insert

42'' Beveled Spindle

U-Top-It Post

Post Sleeve

Figure 32

Post Sleeve

Post Spindle

42'' Beveled Spindle

Cladding For a more finished look, use cladding on the perimeter joist boards. Handrail

Figure 33
Post Sleeve

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Post Spindle

Beveled Spindle

Deck Surface

PAGE 13

Step 1. Post Sleeve Installation 1'' up from the bottom edge of the post sleeve, locate center and drill a 3/16" hole, one hole per post sleeve. Slide the ring base over the post sleeve until the locking dimple on the inside of the ring base snaps into the drilled hole. Slide post sleeve over the 4x4 post. See figure 34. Step 2. Sizing Spindles, Upper Handrail, Handrail Insert, & Lower Rail Measure the distance between the post sleeves and cut the upper rail, lower rail and handrail insert to this length. Spindle height may vary, check spindle height and trim to desired height as needed. Step 3. Spindle Preparation Mark your spindle spacing on the insert and lower rail according to local building codes. Using a 1/8'' drill bit, pre-drill holes in the insert and lower rail where each spindle will be attached. Two spindles will need to be pre-drilled for attaching the completed rail to the post sleeves. Using a 1/8'' drill bit, drill holes in two spindles 3-1/2'' from the top, 3-1/2'' from the bottom, and in the center of the spindles. These holes should be drilled at approximately 60 degrees to allow enough room to drive the 3'' premium deck screws through the post spindles into the post sleeve and post. These spindles will be referred to as Post Spindles. See figure 37. Step 4. Handrail Assembly Bore the center on each end of the spindle with an 1/8'' drill bit to accept #10 3-1/2'' premium deck screws. Do not use composite screws. Slide spindles into the profile of the handrail insert from the end and attach them, from the center toward the outside, with #10 3-1/2'' premium deck screws. Make sure to install the Post Spindles flush on the ends of the assembly. Position the lower rail so the spindles will rest on the top side of the rail. Secure the spindles to the rail from the underside using quality #10 3-1/2'' premium deck screws. Slide the upper rail on to the handrail insert. From the underside recessed channel of the handrail insert, attach the upper handrail using 8 #4 3/4'' screws (18 pcs. sku 233-0309; 100 pcs. sku 233-0134). Equally space screws along the length of the handrail using four screws on each side. See figure 35. All rail spans over 3' require a spindle support block centered under the rail assembly. Check local building codes and cut the support block to the height required to meet local code. To install the support block on the rail system, cut a 6'' piece of handrail insert, slide the support block into the handrail insert and secure it with a premium deck screw. Center the handrail insert into the profile of the lower handrail. See figure 36. Step 5. Rail Unit Installation Place the completed rail section between the posts and temporarily support rail unit on 2x4 blocks, trimmed to length, to ensure proper height from the deck surface. Secure the rail to the post sleeves using (6) #10 3'' composite deck screws through the pre-drilled holes in the Post Spindles. Step 6. Install Post Caps Align post cap with the top of the post sleeve and slide into position. If desired, use a silicone adhesive caulk to secure post cap to sleeve. Step 7. Stair Kits When using components for stair rail it may be necessary to cut angles to match stair slope.
PAGE 14

UltraDeck Fusion Railing Instructions

Figure 34

Figure 35

Post Sleeve

3/4'' Screws

Upper Handrail Handrail Insert #10 3-1/2" Screws Post Spindle Lower Rail

3/16" Drilled Hole 1"

Support Block Deck Screw

Figure 36

Lower Handrail

6'' Handrail Insert Support Block

Figure 37

Post Sleeve

4x4 Post

Post Spindle

Figure 38

Post Spindle

Spindle

Handrail

Post Sleeve

Deck Surface

Spindle Support Block

Note: UltraDeck Fusion railing systems feature the same high quality materials and manufacturing process as UltraDeck Fusion decking. The post sleeve kits include post sleeve, ring base, and post cap; handrail/stair rail kits include handrail, handrail insert, spindles, lower rail, lower rail support block, and screws. 4' post sleeve and 6' handrail/stair rail kits are available in white only. Black, gray and cedar post sleeve and rail components are also available.

Low-Maintenance Composite Decking

UltraDeck Pinnacle Railing Instructions

Step 1. Sizing Spindles, Upper Rail, Lower Rail, and Top Cap Measure the distance between the post sleeves and cut the upper and lower rail and top cap to this length. Spindle height may vary, check spindle height and trim to desired height as needed. See figure 39.

Measure Distance

Spindle and Handrail Preparation for Stair Rails Lay the bottom rail on the stairs and mark the angle and length. See figure 44. Do the same with the top rail and top cap. On the lines that you marked, trim all pieces to the same angle. This angle will also be used to cut the spindles. Evenly space and mark the upper and lower rail, leaving the same amount of space on each end of the rail.
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Step 3. Spindle and Handrail Preparation Check local building codes for appropriate spindle spacing. As a rule, less than a 4'' opening between spindles will comply with most building codes. Evenly space and mark the upper and lower rail, leaving the same amount of space on each end of the rail. Using a 1/8'' drill bit, and the measurement of half the diameter of the spindle, pre-drill holes in the upper and lower rail where each spindle will be attached. Refer to figures 40 and 41. The vertical surfaces of the bottom and top rail will face the outside of the deck or steps. See figure 42.

Step 2. Attach Spindle Support Block Rail spans over 3' require a spindle support block centered under the rail assembly. Check local building codes and cut the support block from the same material used for spindles. As a rule, 3.5'' high for a support block will comply with most building codes. Attach the spindle support block to the bottom side of the lower rail by finding center of support block and marking lower rail for pre-drilling. See figures 40 and 41. Pre-drill with 1/8'' drill bit and install support block using a 3.5'' premium deck screw. Do not use composite screws.

Figure 39

Spindle Support Block: Cut to size, then measure 1/2 diameter.

Half Diam eter

Mark spot for pre-drilling

Figure 40

Figure 41
Ha

Rail in Top Position Spindle

Top Cap

Figure 42

Deck Surface

Rail in Bottom Position

Figure 43

Spindle Support Block

Figure 44

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iam

e te

PAGE 15

Using a 1/8'' drill bit, and the measurement of half the diameter of the spindle, pre-drill holes in the upper and lower rail where each spindle will be attached. Holes need to be drilled at the same angle stair rail was cut. Refer back to figures 40, 41 and 44 on page 15. Step 4. Attach Spindles to Handrail Working from the center toward the ends, attach the spindles using #10 - 3.5'' premium deck screws (sku# 2305523). Screws must be flush with the surface of the top rail to ensure proper fit of the top cap, but do not overtighten. Step 5. Installation of Mounting Brackets and Rail Assembly Place the completed rail section between the posts. At each end of rail, temporarily support the rail unit on blocks trimmed to length to ensure proper height of the rail assembly. Making sure the rail is plumb, mark the location of the top rail bracket on the post sleeve. Remove rail section and using screws provided in bracket pack, attach top rail brackets to each post sleeve where marked. Attach bottom rail brackets with screws provided in bracket pack to the bottom rail of the assembly. Hang rail assembly on top brackets. Verify rail assembly is plumb and support block is resting on deck. Attach the top brackets to the under side of rail assembly and the bottom brackets to the post sleeve on each end. See figures 45-48. Note: Pre-drill all holes before attaching brackets. If using stair rail brackets, attach parts A & B to the rail and post sleeve per package insert directions. Once assembly is set in place, tap in lock pin to secure assembly. Step 6. Install Top Cap Using 1/8'' drill bit, pre-drill four holes through the upper rail centered between spindles one at each end and two spaced between. Secure the upper rail to the top cap using 2'' premium deck screws (sku# 230-5506). See figure 49.
Step 1. Set rail assembly in place. Using a 1/8" drill bit to hold parts A and B of hinge together, transfer hole location of hinge to both post and rail assembly for pre-drilling. See figure 50.

UltraDeck Pinnacle Railing Instructions - Continued

Mounting Bracket 1-3/8" Galvanized Screws (Included with purchase of brackets)

Figure 45
Top Cap

Underside of Top and Bottom Rail

Figure 46 - Top Rail

Top Rail Rail Bracket

Figure 47

Figure 48 - Bottom Rail

Figure 50

Pinnacle Bracket Instructions

Figure 49

Arrows indicate where to pre-drill to secure the top cap to the top rail.

Step 2. Remove rail assembly from stairs and with a 1/8" drill bit pre-drill both the rail assembly and post at marked locations. See figure 51.

Repeat this step for all four corners of rail assembly. It is important to be accurate when marking holes so brackets line up in the following steps.

Step 3. Attach hinge bracket to both the post sleeve and rail assembly at all 4 corners with screws supplied with hinge. See figure 52. Do not over tighten, as this will make it hard to line up bracket parts A and B in following steps. Step 4. Set rail assembly in place and line up hinge parts in all four corners. With hinge aligned, start tapping supplied roll pin into place using a small hammer. See figure 53. Finish tapping pin in with a pin punch. See figure 54. Please note: If hinge alignment is slightly off from marking of holes in step 1, it may be necessary to have help holding rail in place while inserting roll pin.

Figure 52

Figure 53

Figure 51

Figure 54

PAGE 16

Low-Maintenance Composite Decking SKU 101-6307