ATLANTIS Spectrum Top Rail System Instruction Manual

ATLANTIS Spectrum Top Rail System

Specifications
The Spectrum Top Rail system is designed for use with Spectrum Railing posts. It is made from aluminum and powder-coated to match the standard Spectrum post colors and finishes.

Product Usage Instructions

Tools Needed

• Power Drill
• Drill Bit Set
• Tape Measure
• Pencil
• Silicone Caulk
• Ratchet & Socket Set
• Miter Saw with a Non-Ferrous Carbide Tipped Blade
• Gloves
• Safety Glasses
• Level
• Allen Wrench Set
• Phillips Driver Bits
• Phillips Screw Driver

Top Rail Installation

1. Positioning the Posts: Place the Spectrum Railing posts in the desired locations along the railing area.

2. Installing the Posts: Secure the posts using appropriate hardware provided.

3. Dry-Fitting the First Sections of Top Rail: Temporarily place the top rail sections to ensure proper fit before permanent installation.

4. Where to Cut the Top Rail: Measure and mark where the top rail needs to be cut to fit the railing area.

5. Installing Stair Rail & First Level
   Section: Follow specific instructions for installing stair railings and the initial section of the top rail.

6. Installing the Remaining Sections: Continue installing the top rail sections along the railing area.

7. Installing a Spectrum Gate Kit: If applicable, follow instructions for installing a gate kit within the railing system.

FAQ

• Q: Can the Spectrum Top Rail system be used with other railing systems?
  A: No, the top rail is specifically designed for use only with the Spectrum System.

• Q: Are additional components required for installing the top rail system?
  A: Hardware and additional components are included in the system package, but specialized tools offered by Atlantis Rail may be needed for cable installation on Spectrum Systems.

• Q: How can I contact Atlantis Rail Systems for support?
  A: You can reach Atlantis Rail Systems at 800-541-6829 or 508-732-9191. Visit their website at www.atlantisrail.com for more information.

Top Rail Installation
This instruction set will lead you through the process of installing the Spectrum Top Rail system on top of your Spectrum Railing posts. Top rail is designed for use only with Spectrum System. The simple design allows installers to handle a variety of rail transitions using a small set of components. The top rail system is made from aluminum and is powder coated to match the standard Spectrum post color(s) and finish.

TOOLS NEEDED
Here is a list of tools needed to install your Spectrum Top Rail System. Most of the required tools are common.

• Power Drill
• Drill Bit Set
• Tape Measure
• Pencil
• Silicone Caulk
• Ratchet & Socket Set
• Miter Saw with a
• Non-Ferrous Carbide
• Tipped Blade
• Gloves
• Safety Glasses
• Level
• Allen Wrench Set
• Phillips Driver Bits
• Phillips Screw Driver

Specialized tools offered by Atlantis Rail
These tools are mainly used for installing cable on Spectrum Systems

TOP RAIL COMPONENTS

SURFACE MOUNT POSTS

FASCIA MOUNT POSTS

HARDWARE & ADDITIONAL COMPONENTS

• S. Surface Mount Standard Post Hardware Kit (4) 5/16”x4.5” (S0905-HD04)
• S. Surface Mount -EC Post Hardware Kit (4) 3/8”x5” (S0905-HD05)
• T. Fascia Mount Standard Post Hardware Kit (3) 5/16”x4.5” (S0904-HD03-*XX)
• U. Fascia Mount -EC Post Hardware Kit (5) 3/8”x5” (S0904-HD05-*XX)
• W. EC Post Adapter Plate (P0904-*XX50-EC)

• “XX” in the part number is the color designation. Replace with “BK” for black, “MT” for metallic silver, “WH” for white, “BR” for dark brown or “SP” for one of the special colors.

WARNINGS

STORE YOUR ORDER INDOORS TO KEEP DRY! Some items in your order have been shrink wrapped with a protective poly film. Avoid expos-ing these items to harsh weather and moisture
to avoid damaging powder coated surfaces. When you’re ready to install product, remove the protective shrink wrap before or immediately after installation.

• WARRANTY REQUIREMENTS:
  • Refer to the Rail Care Guide(s) for required cleaning and maintenance guidelines. Failure to follow the required cleaning and maintenance guidelines will void the warranty.
  • ALWAYS REFER TO YOUR LOCAL BUILDING CODE OFFICIALS PRIOR TO INSTALLING
  • ANY ATLANTIS RAIL SYSTEM to ensure all code and safety requirements are met.
  • Atlantis Rail Systems is not responsible for improper or non-recommended installations.
  • ATLANTIS RAIL SYSTEMS PROVIDES A VARIETY OF MOUNTING OPTIONS FOR
  • POSTS AND RAILS USED IN OUR SYSTEMS. PRODUCTS OF THIS NATURE REQUIRE
  • THAT MOUNTING SURFACES ARE CONSTRUCTED TO BE CONSIDERED STRUCTURAL PER BUILDING CODE DEFINITION FOR THE SURFACE MATERIAL USED. Structural integrity and building code compliance of mounting surfaces are the responsibility of the end user and/or installer. The use of any of our mounting methods are at the option and decision of the end user and/or installer and should be selected to match the structural material used to create the mounting surface.
  • SPECTRUM TOP RAIL SYSTEM ACCOMM-ODATES STAIR ANGLES 0F 33 TO 38 DEGREES USING STOCK MATERIAL. SPECIAL POSTS ARE REQUIRED FOR ANGLES UNDER 33 DEG-REES AND OVER 38 DEGREES.

INSTALL TIPS

Follow the tips below to ensure a successful installation of your Spectrum Top Rail System!

• READ THE INSTRUCTIONS completely before beginning the installation.
• PLAN YOUR RAILING PROJECT. Sketch your project with the actual measurements of your deck or balcony complete with post locations.
• FIND A HELPER. Installation is best accomplished with two (2) people.
• CHECK CARTON(S) to determine part count is complete.
• ALWAYS WEAR PERSONAL PROTECTION EQUIPMENT; safety glasses, work gloves, etc.
• PLAN CUTS CAREFULLY. Expect there to be scrap pieces of top rail. Retain scrap for later use. Be careful not to scratch the powder coat finish.
• CENTER SPLICE JOINTS ON TOP OF POSTS. To ensure structural integrity, center top rail connections on top of posts using the Rail Splice and fasteners.
• DO NOT OVER-TORQUE THE SCREWS. Pre-drilling is recommended.
• PROVIDED HARDWARE TO INSTALL THE SPECTRUM TOP RAIL SYSTEM IS FOR USE WITH SPECTRUM POSTS.
• Installing Spectrum Top Rail on any other post system is not recommended.
• TOUCH-UP ANY SCRATCHES. After completing the installation of your Spectrum Top Rail System, look for any scratches and/or damage to the powdercoating. These can easily be fixed using our Spectrum Touch-Up Paint.

TOP RAIL SYSTEM INSTALLATION

Confirm the Contents of Packaging: Make sure to verify that the system components for your order are present.

POSITIONING THE SPECTRUM POSTS
RULE: There must never be an opening between posts and/or posts and structure large enough to allow a 4” sphere to pass through.

1. Position the Stair Posts: Begin by positioning the top stair post and the level transition post next to it. If there are NO stairs, proceed to “STEP 2 – Position the Corner Post”. “Inline” Scenarios (Fig. 1)
   When the level section rail transitions into stair rail in a straight line.

   • For 36” high systems, reference (Fig. A) showing the “S0904-AR73 Stair Knuckle” in use.

   • For 42” high systems, reference (Fig. B) showing the “S0904-AR68, Narrow Clamp Knuckle” in use. “Perpendicular” Scenarios (Fig. 2)
     When the level section rail transitions into stair rail at 90 degrees.

   • For 36” high systems, reference (Fig.C1, C2 & C3) showing the “S0904-AR78 – Rail Mount Knuckle” in use.

   • For 42” high systems, reference (Figs. D1 & D2) showing the “S0904-AR67, Wide Clamp Knuckle” in use.

2. Position the Corner Posts: Refer to (Figs. E1 & E2) which shows a top view of 90-degree elbow, top rails and double posts in the corner.
   For “Non-90 Degree” angled sections, refer to Step 19.

3. Position the End Posts: Refer to (Fig. F) which shows a side view of top rail, end cap, end post and wall for help with positioning. Leave a minimum of 1” top rail overhang in order to use the “S0904-AR75 – Rail Cap”

4. Position the Mid Posts: Measure the length of each straight run (on-center) from end post to end post. Divide each measurement equally into sections no greater than 4 ft. and position your mid posts. Refer to (Fig. G)Position the Mid Posts (continued): The “Y” dimension must not exceed 4 ft. in length. Please see the examples below for a hypothetical 124” long straight run.

   • GOOD: 124” divided by 3 = 41.33”
   • BAD: 124” divided by 2 = 62”
   • INSTALLING THE SPECTRUM POSTS

5. Confirm the Positioning:

   • Use a measuring tape and to confirm the position of each post. See (Fig. H)

6. Mark & Pre-Drill:

   • Once you are sure of the positioning of the posts, mark the hole locations with a pencil and pre-drill using a 1/4” drill bit. See (Figs. I & J)

7. Secure the Posts:

   • Using the mounting hardware kits on your order, install each post securely into place. See (Fig. K)
     MAKE SURE POSTS ARE INSTALLED PLUMB! Adjustments/shimming may be necessary.
     Use silicone caulking on each lag screw head ` and secure caps firmly into place. See (Fig. L)

8. Install the Base Covers:

   • DON’T FORGET THE BASE COVERS! See (Fig. M) LEVEL SECTION POSTS

9. Install the Top Mounting Plates: Using a Philips head screwdriver, secure the top mounting plates to the top of each post using the supplied
   1/4”-20 x 1/2” flathead machine screws (part# S0910-0713). Be mindful of the plate orientation.
   For Level Sections,
   See (Figs. N1, N2 & N3)
   For Stair Sections, See (Figs. O1 & O2) DRY-FITTING THE FIRST SECTIONS OF TOP RAIL
   TIP: When dry fitting, use painter’s tape to temporarily hold rails and fittings in place.

10. Unpack and Lay Out the Top Rail Components:
    Identify the components in your shipment. Lay out the top rail sections and fittings where they will be used.

11. Start at the Top Stair Post/Level Section Transition Post:
    “Inline” Installation
    For 36” high systems

    • Attach the S0904-AR73 Stair Knuckle to the end of the Stair Rail section using a #10 x 1” Phillips panhead screw (part# P0913-0625). Pre-drill a mounting hole first, using a 5/32” drill bit. See (Fig. P1)

    • While holding the stair rail in place on the stair section, place the level section railing in place and insert the end into the knuckle attached to the stair rail. See (Fig. P2)

    • Mark the location of screw holes on the underside of the top rails for both the stair and level section. See (Fig. P3)

    • For next steps, refer to “STEP 12 – Mark and Cut Each Rail to Length”

    • Attach the S0904-AR68 Narrow Clamp Knuckle to the end of the Stair Rail section using a #10 x 1” Phillips panhead screw (part# P0913-0625). Pre-drill a mounting hole first, using a 5/32” drill bit. See (Fig. Q1)

    • While holding the stair rail in place on the stair section, temporarily attach the S0904-AR68 Narrow Clamp Knuckle onto the level section transition post. See (Fig. Q2) TIP: Coat the surface of the rubber insert with dish soap to ease installation. Make sure clamp won’t interfere with the 3/4” area needed for Cover Nuts (Fig. Q3)

    • Mark the location of screw holes on the underside of the stair rail. See (Fig. Q4)

    • For next steps, refer to “STEP 12 – Mark and Cut Each Rail to Length” “Perpendicular” Installation
      For 36” high systems

    • Disassemble the S0904-AR78 “Rail Mount Knuckle” by removing the allen bolt and nut. Position the Base of the Rail Mount Knuckle on the side of the level section top rail 3/4” from the end. The 3/4” allows for capping off the top rail end with the S0904-AR75 “End Cap”. See (Fig. R1)

    • Pre-drill mounting holes using a 5/32” drill bit. Use the #10 x 1” Phillips panhead screws (part# P0913-0625) to attach the Base to the top rail.

    • Reassemble the Rail Mount Knuckle.

    • Dry fit the stair rail and level rail assembly onto the posts. See (Fig. R2)

    • Mark the location of screw holes on the underside of the top rails for both the stair and level sections. See (Fig. R3)

    • For next steps, refer to “STEP 12 – Mark and Cut Each Rail to Length”

    • Attach the S0904-AR67 Wide Clamp Knuckle to the end of the Stair Rail section using a #10 x 1” Phillips panhead screw (part# P0913-0625). Pre-drill a mounting hole first, using a 5/32” drill bit. See (Fig. S1)

    • While holding the stair rail in place on the stair section, temporarily attach the S0904-AR67 Wide Clamp Knuckle onto the level section transition post. See (Fig. S2) TIP: Coat the surface of the rubber insert with dish soap to ease installation. Make sure clamp won’t interfere with the 3/4” area needed for Cover Nuts (Fig. S3)

    • Mark the location of screw holes on the underside of the stair rail. See (Fig. S4)

    • For next steps, refer to “STEP 12 – Mark and Cut Each Rail to Length”

12. WHERE TO CUT THE TOP RAIL

    • Mark & Cut Each Rail to Length:
      Measure and mark the top rail per the illustrations. Make cuts using a miter saw with a non-ferrous carbide tipped blade.

    • Stair Rail
      (Fig. T1) stair rail being cut at mid post
      (Fig. T2) stair rail being cut with proper over-hang at bottom stair post .

    • Level Section Rail
      (Fig. T3) level rail being cut at end post with proper overhang
      (Fig. T4) level rail being cut at mid post

    • (Fig. T5) level rail being cut at corner post
      Leave a minimum of 1” overhang. If there is less than 1” overhang, you will not be able to install the “rail end cap”.
      Center the cut on the post.
      For precise centering of joint on post, account for the 5/32” thickness of splice.

    • INSTALLING THE STAIR RAIL AND FIRST LEVEL SECTIONS

13. Pre-Drill mounting holes on the underside of the rails using a 5/32” drill bit. See (Fig. U1)

14. Using the #10 x 1” Phillips panhead screws (part# P0913-0625), mount the top rail to the posts. See (Figs. U2 & U3)
    INSTALLING THE REMAINING SECTIONS
    Intermediate rail sections are connected using the S0904-AR77 Rail Splice. Splice connections should be centered on post. See (Fig. V1)

15. Insert next rail section into the splice fitting and set on top of next post(s)

16. Mark the top rail and cut to length

17. Pre-drill with 5/32” drill bit and secure top rail to post using #10 x 1” Phillips panhead screws . See (Fig. V2)

18. Repeat process for each section, making rail connections as you go making sure to align the connection with the center of each mid post. “NON-90 DEGREE” ANGLED SECTIONS (45 Degree & 60 Degree)

19. For all angled sections of railing that are not 90 degrees, position posts according to the illustrations on the right so that there is less than a 4” space in between posts. See (Figs. W1 & W2).

20. The 45 & 60 degree elbows have two mounting holes on the underside.
    Pre-Drill mounting holes on the under side of the rails using a 5/32” drill bit.

21. Using the #10 x 1” Phillips panhead screws (part# P0913-0625), secure the elbow to the top rail.

    • S0904-AR45 (45 Degree Elbow) connecting sections of Top Rail.
      It is recommended that the closest edges of the posts be positioned 3-1/2” from each other so that a 4” sphere cannot pass between posts.

    • S0904-AR45 (45 Degree Elbow) connecting sections of Top Rail.
      It is recommended that the closest edges of the posts be positioned 3-1/2” from each other so that a 4” sphere cannot pass between posts.
      INSTALLING A SPECTRUM GATE KIT

22. Position the Latch and Hinge Posts:
    Whether installing a “Standard” Spectrum Gate Kit on a 36” or 42” Spectrum system, the in-between posts dimension will always be the same. Position the Latch Post and Hinge Post so that they are in line with each other and there is 37-1/2” in between. See (Fig. X).
    If you are installing a custom width gate, you will need to add 1-1/2” to your custom gate width to find the proper in-between posts spacing. Example: Custom Gate is 38” + 1-1/2” = 39-1/2” in-between post dimension

23. Install the Latch and Hinge Posts:
    Refer back to Steps 5-8 to properly secure the posts into place. DON’T FORGET TO INSTALL THE BASE COVERS! BEFORE YOU CAN ATTACH THE GATE

24. Attach Top Rail on each side of the Gate Opening:
    Before you attach the Gate Kit, the Latch and Hinge Posts must be fully secured to the structure and be fastened to the top rail on each side of the gate opening. The top rail should be cut flush with the edge of each post. See (Fig. Y)

25. Measure & Cut the Top Rail for the Gate to the Proper Length:
    To insure proper gate clearance, the top rail should be cut to 36” (width of the gate) so that it will be flush with the edges of the gate once it is mounted. See (Fig. Y)

26. Attach the Gate’s Top Rail:
    With the top rail centered on the Gate, mark the mounting hole locations. Pre- drill holes using a 5/32” drill bit. Use the supplied pan head screws to secure the top rail to the Gate Frame.

27. Install the Notched End Caps:
    Cap off the ends of the top rail on the Gate and on each side of the gate opening using the Notched End Caps (S0904-AR65). Pre-drill holes using a 5/32” drill bit. Use the pan head screws to secure the caps.

28. Install Hinges to the Gate & Post: Attach the gate hinges to the frame being mindful of your desired configuration and the orientation of the hinges. Hinges attach eas-ily using the supplied through-post hardware (cap screws, barrel nuts and 1/4” washers).

29. Install Latch to the Gate & Post: Attach the gate latch to the frame being mindful of your desired configuration and the orientation of the latch. Attach using the supplied through-post hardware (cap screws, barrel nuts and 1/4” washers).

Top Rail installation is COMPLETE when each fitting is fastened to the top rail and top rail is fastened to the each post!For instructions on installing and tensioning the HandiSwageTM Studs, Cable, Cover Nut Sets and Cable Grommets,
refer to the Spectrum System Installation Instructions (pages 8-11).

Spectrum Top Rail Product Specifications

Spectrum Top Rail Components

Part Number              Description Use

S0904-AR48-XX| Top Rail – 4 ft.| Powder coated aluminum top rail section – 3-1/2” x 1-5/8”
S0904-AR72-XX| Top Rail – 6 ft.| Powder coated aluminum top rail section – 3-1/2” x 1-5/8”
S0904-AR96-XX| Top Rail – 8 ft.| Powder coated aluminum top rail section – 3-1/2” x 1-5/8”
S0904-AR73-XX| Stair Knuckle| Adj. fitting for connecting inline stair rail to 36” level sections
S0904-AR78-XX| Rail Mount Stair Knuckle| Adj. fitting for connecting perpendicular stair rail to 36” level sections
S0904-AR76-XX| Clamp Stair Knuckle| Adj. fitting to connect stair rail to 42” post (1.57”x1.57”)
S0904-AR68-XX| EC Clamp Stair Knuckle – Narrow| Adj. fitting to connect inline stair rail to 42” -EC post (1.57”x2.5”)
S0904-AR67-XX| EC Clamp Stair Knuckle – Wide| Adj. fitting to connect perpendicular stair rail to 42” -EC post (2.5”x1.57”)
S0904-AR45-XX| 45-Degree Elbow| Used where rail sections meet at 45 degree angle
S0904-AR60-XX| 60-Degree Elbow| Used where rail sections meet at 60 degree angle
S0904-AR74-XX| 90-Degree Elbow| Used where rail sections meet at 90 degree angle corner
S0904-AR75-XX| Rail Cap| Installed on the exposed end of top rail for a finished look
S0904-AR65-XX| Rail Cap, Notched| Installed On/Near Gates to allow maximum clearance
S0904-AR77-XX| Wide Rail Splice| Splices/Mates rail sections and conceals cut ends
Spectrum Post Kits

S0905-XX36| 36” Surface Mount Post Kit (1.57”x1.57”x 34.38”)| Pre-drilled, powder coated 316 stainless post for 36” height rail
S0905-XX42| 42” Surface Mount Post Kit (1.57”x1.57”x 40.38”)| Pre-drilled, powder coated 316 stainless post for 42” height rail
S0905-XX42-EC| 42” Surface Mount End/Corner Post Kit (1.57”x2.5”x 40.38”)| Use in 42” Surface mount systems as end/corner post
S0905-XX38-ST| 38” Surface Mount Stair Post Kit (1.57”x1.57”x 38.13”)| Slotted, powder coated 316 stainless post for 36” height stair rail
S0904-XX36| 36” Fascia Mount Post Kit (1.57”x1.57”x 42”)| Pre-drilled powder coated 316 stainless post for 36” height rail
S0904-XX42| 42” Fascia Mount Post Kit (1.57”x1.57”x 48”)| Pre-drilled powder coated 316 stainless post for 42” height rail
S0904-XX42-EC| 42” Fascia Mount End/Corner Post Kit (1.57”x2.5”x 48”)| Use in 42” Fascia mount systems as end/corner post
S0904-XX38-ST| 38” Fascia Mount Stair Post Kit (1.57”x1.57”x 45.75”)| Slotted, powder-coated 316 stainless post for 36” height stair rail
Post Mounting Hardware

S0905-HD04| Surface Mount Post Mounting Hardware Kit (w/ Caps)| (4) 5/16” x 4-1/2” hex lag screws for mounting into wood
S0905-HD05| EC Surface Mount Post Mounting Hardware Kit (w/ Caps)| (4) 3/8” x 5” hex lag screws for mounting into wood
S0904-HD03-XX| Fascia Mount Post Mounting Hardware Kit (w/ Caps)| (3) 5/16” x 4-1/2” hex lag screws for mounting into wood
S0904-HD05-XX| EC Fascia Mount Post Mounting Hardware Kit (w/ Caps)| (5) 3/8” x 5” hex lag screws for mounting into wood
 |  |
Accessories|  |
P0904-XX50-EC| End/Corner Post Adapter Plate| Adapter plate allows -EC Posts to accept Aluminum Top Rail
S0904-AR61-XX| Rail End Cap, Male| Installed into the end of top rail near and on gate
 |  |
Tools|  |
P0904-P001-XX*| Touch-Up Paint (6 oz. aerosol)| Touch-up any scratches on powdercoat finish
C0731-TK01-2| HandiSwage Combination Wrench Set – 3/8” & 7/16” (2 pk)| Used to install the HandiSwage™ Cover Nut Sets
C0989-00HD| Cable Cutter| Cleanly cuts up to 5/32” diameter cable
E0113-H600| Hand Swage Tool| Crimps HandiSwage™ fittings onto cable
E0115-H600| Bench Swage Tool| Crimps HandiSwage™ fittings onto cable
E0113-HG00| After Swage Gauge| Use to confirm that the “after swage” dimension is correct
E0114-0000| Cable Grip Pad (3 pack)| Use with vice grips during the cable tensioning process
E0916-1000| Grommet Install Tool| Makes installing cable grommets easy

• “XX” in the part number is the color designation. Replace with “BK” for black, “MT” for metallic silver, “WH” for white, “BR” for dark brown or “SP” for one of the special colors.

©2023 All Rights Reserved ▪ Atlantis Rail Systems, RailEasyTM and HandiSwageTM are registered trademarks of Suncor Stainless, Inc. ▪ www.atlantisrail.com

References

• Atlantis Rail Systems - Steel Cable Railing - Home

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