DURAWALL Installation

DURAWALL Installation
Tools Needed
• 4 – Post spacing rails
(2 x 3½ x 94")
• Rebar ½" x 6' , 2 per Line Post
• Rebar ½" x 8' , 2 per End Post
• Concrete/Quickrete® and Gravel
• #10x1" flat head self taping screw
• PVC Cement Glue
SET ALL CORNER, END and GATE POSTS
End Channel
NOTE: Post depth and diameter will be determined by local weather and soil conditions.
Materials available
for Order
• Posts 4"x4"x102"
• Stackable Wall Panels 35.5" x 3¼" x 93½"
• 3½" x 3½" x 145" post (will be cut and ripped
in field to provide 2 end channels. Each line
post takes two end channels)
• 1½" x 1½" x192" trim cap for top panel
(cut to fit in field)
• End Channel Cover
• Rebar Separator Clips
• Panel Connecting Metal Dowels
• Wall Mount Brackets and Screws
1. Measure down from top of post and make a pencil line 73" on two (2) sides of post.
Position the bottom of the wall mount bracket with the pencil mark and attach bracket to the
post using two (2) screws. See Figure 2
Post
73"
Ground Level
Note: For high wind areas, ensure that the wall sits at ground level. The ground will act as a
solid bottom stiffener to the wall.
Concrete
Filling
5"
10" Diameter
29"
}
• String and Marking Line
• Level (Line Level)
• Post Level
• Speed Square
• Safety Glasses
• Post Hole Digger
• Working Gloves
• Shovel
• 7¼" Circular saw with abrasive and
carbide tip metal cutting blade
• Electric of cordless screw gun with
extension bit for #10 flat head screw
• Hammer
• Table Saw with 10", 90 Tooth Blade
MATERIALS Needed
B:
2. Excavate all holes for End and Corner posts first, 10" in diameter & 34" deep.
Figure 2
3. Wet mix concrete and place approximately 10" of wet concrete into bottom of first hole.
4. Install post into hole at proper location and make sure that pencil line that was marked on post is
at finished grade. Posts should have a height of 73" above ground level and 29" below.
BEFORE YOU START, CHECK THE FOLLOWING:
5. Plumb the post and fill hole with concrete.
1. That you meet local codes for frontage locations, property lines, fence heights and any permit requirements.
C: SET LINE POSTS
2. Check with your local utility companies to locate underground pipelines, power lines or cables.
DuraWALL Illustration
94"
End Channel Cap
Attach a string line across the top of the End and Corner posts to mark the desired height of the Line posts as shown in
Figure 3 & 4. Now stake out the positions of the Line posts along the string line. Note: The distance between posts is
94" to accept the 93½" wall panel length. Dig holes 98" on center.
DuraWALL Cap
Post
4"x4"x102"
Runs will rarely measure out to an exact full number of wall panels. Keep the Line posts on 98" centers and position
the final Line post to a smaller distance from the End post. Then cut the last wall panel down to size.
End-Channel
1½"x3½"
1. Now start installing the Line posts following steps 1 through 5 above (B).
71½"
73"
2. After installing a post, move to the next post in line and make sure that the top of the posts are all on the same level
as the string level and that all spacing between posts is 94" for full length panels.
String
String
LEVEL
29"
LEVEL
98"
Stake
Post On Center Distance
Stake
Concrete filled footing & post
34"
Concrete
Filling
10"
Post
Wall Post
Stakes
Post Hole
10"x38"
Post
Concrete
Filling
Post
Figure 3
Posts
Post
Figure 4
3. Repeat these steps until all posts are set.
A:
PREPARE WALL LAYOUT BEFORE STARTING INSTALLATION
1. Locate property lines.
2. Drive stakes into the ground along property line. Then stretch a string between
each stake and extend the string 2' beyond property line as shown in Figure 1.
Mark post locations with stakes.
D:
String
3. Most wall installations will require that some panels will need to be cut down to fit in
a particular run. DuraWall panels are designed to be cut easily.
Refer to Cutting Down DuraWall Panels Section.
4. For gate posts, refer to gate section for actual gate opening size.
5. DuraWall is designed to be installed on final grade.
3'
All End and Gate posts require concrete on the outside base and inside the post.
NOTE: Before filling gate posts with concrete, make sure that the gate hardware is installed
following the instructions in the gate section.
5'
Start-Wall
Post
4'
Stake
String
Figure 1
a. When Durawall is installed correctly, the gap between the wall and the ground should be minimized.
The mortar joints from one section to another will be straight and will be continuous with the same finished
appearance as a standard block wall system.
b. The final Grade between posts may have to be removed or filled with materials.
FILL INSIDE OF END POSTS WITH RE-BAR & CONCRETE
1. Each End or gate post takes 2 pieces of ½" x 96" diameter rebar located at
opposing corners of post as shown in Figure 5.
2. Now fill the posts with concrete to within 4" of top of post, tapping on the sides of the post
to remove air pockets in the concrete. See Figure 6
Rebar
Separator Clip
½“ Rebar
Figure 5
Pour Concrete
3. Clean up excess concrete with water before it dries.
Concrete Requirements:
4x4 line posts = approx 120 lbs
4x4 Start / End post = approx 160 lbs
End Corner
Post
Figure 6
E:
INSTALLING DuraWALL Panels on Level Ground or Grade
9. Slowly rotate the two stacked panels into position centering them between the next post in line. See Figure 8 (1,2)
NOTE: Installing the Durawall Panels requires two people.
Install End Channel to Posts
Post
End Channel
1. On a table saw rip the 3½" x 3½" x 145" posts to 3½" x 1½" x 71½" to make end-channels for posts. Cut a 2¼" x 4"
notch in the bottom of each End Channel so it can sit around the Wall Mount Bracket on the posts. Rip and cut the
1½" x 1½" x 192" pickets in half to make a finished cap rail that will be installed on top of each top panel.
2. Cut all end channels 71½" long.
Note: all line and corner posts will require two (2) end channels and all end posts require one (1) end channel.
All end channels must be fastened to each post in four (4) places (top, bottom & middles).
3. Determine where you will start installing panels. It is most efficient to install panels moving from section to section in
a clockwise direction.
4. If starting at an End Post, attach an end channel in the center of each post using four (4) 1" #10 self tapping
screws. Place the end channel around the posts base bracket and attach screws starting at the bottom.
5. Excavate away any dirt between posts that will keep panel from resting on wall mount brackets.
6. Position the DuraWall bottom panel between the posts at a slight angle. Now push the wall towards the post with
the end channel attached. The panel will need to slide into the End Channel completely. Note: Grooved edge of
panel must be in the top position. The bottom panel has 2 dowel holes on the top.
7. Lift another DuraWall panel and place it onto the bottom panel and slowly push it towards the post with the end
channel attached. This panel like the bottom panel needs to slide into the End Channel completely. The grove of
this panel must also be in the top position. The top panel has 2 metal dowels on the bottom.
8. Raise the top Panel at its outer edge until there is a 3" gap in the center. Insert the metal Dowel into the dowel hole
of the bottom panel. Lower the top panel onto the bottom panel engaging the dowels into the dowel holes.
See Figure 7
TOP WALL
GROOVED TOP
3
End Channel
Top & Bottom Wall
(Pre-assembled)
2
1
Post
Figure 8
10. With the two stacked panels in position slide down from the top, an end channel that will be attached to the post
and will secure panels to post.
11. Slide the end channel until it rests on the concrete footing See Figure 8 (3)
12. Attach the end Channel at the bottom of posts using 1" #10 self tapping screws approx 6" up from the base.
Note: Drive screw at an angle using one of the mortar lines in the wall panel as the access to attach the End
Channel to the Post.
13. Now fasten the end channel to the center and the top of the post using 1- 1" x #10 self tapping screw in the
same way.
14. Now move to next section and repeat installation instructions 1 through13.
When DuarWall is installed correctly gaps between the bottom of wall and finished grades should be minimized. Also,
the mortar joints from one section to another will be straight and will be continuous with the same finished appearance
as a standard block wall systems.
F: CUTTING DOWN DuraWALL Panels
Runs will rarely measure out to an exact full number of wall panels.
Top Wall Metal Dowel
DuraWall Panels are made to be cut down in the field to fit between posts that are less than 94" apart. See Fig. 10
1. Panels that need to be cut down need to be cut 1" less than the finished
measurement between two posts. For Example if you have two posts that are 62" apart (from inside to inside) then
the DuraWall fence panels will need to be cut at 61".
2. Place the panel that needs to be cut on a pair of saw horses.
Bottom Dowel Hole
Cut Down Wall Panels
3. From one end measure where panel needs to be cut.
4. Using a straight edge, mark the panel with pencil where panel is to be cut.
5. Using a 7¼" circular saw with an abrasive blade, cut the panel to length.
SMOOTH BASE
BOTTOM WALL
Figure 7
6. After panels are cut to proper length follow normal installation instructions for
installing Fence panels on level grounds or grades or on sloped grounds or grades.
Figure 10
G: INSTALL TOP RAIL and POST CAPS
H: INSTALLING GATES
The Top Finished rail is made using the 1½" x 1½" x 192" rails. It is best to apply the cap on the top wall section while it
is at ground level and before installation.
PREPARING GATE
1. Cut a piece of end channel material 94" long.
2. Using waterproof construction adhesive, apply a liberal amount to the inside of the end channel piece and install
onto each top section of fence panel. Make sure to not use so much adhesive that it spreads on to finished panel.
See Figure 11
Top Rail
Set privacy fence Gate Line posts 44" apart to allow for hardware and gate. Gates are 42" wide with a 2" gap to
accommodate hinge and latch. Posts should have a height of 73" off ground level to sit 2" taller than finished wall
level. Set Traditional & Perimeter gate posts 49" apart to allow for hardware and gate. Gates are 47" wide with a 2"
gap to accommodate hinge and latch. For narrower openings, gates can be cut to size.
MOUNT GATE
1. Position gate in the opening by blocking-up the gate so that the rails of the gate lineup with the top of the fence.
Note: The diagonal brace will run from the upper latch corner to the lower hinge corner.
2. Attach hinges to hinge post and latch catch to latch post before filling with concrete.
3. Ensure that gate posts are filled with concrete and rebar and set for 72 hrs before hanging gate.
4. Hang the gate by attaching the hinges to the gate.
5. Position latch bar on gate and secure.
Figure 11
3. Cover each End Channel with a channel cap, as shown in Figure 12. Secure the End Channel Cap
to the back of each End Channel with 2 screws on the both sides of the wall.
1¼" gap for hinges
¾" gap for latch
44"
Insert End Channel Cap and drill two screws on
each side of the outer wall going to the back of the
End Channel into the Post.
42"
2"
2"
2"
2"
End Channel Cap
2 screws
73"
Post
Post
End Channel
Post
End Channel
Post
Wall Cap
DuraWall
Wall
Wall
Figure 14
Figure 13
Figure 12
4. For high wind areas, screw the top of the End Channel into the center of the Top Wall Panel.
Cover the screw with a vinyl plug.
Still Have Questions?
Call Client Services at 1-888-483-1361
Engineered For The Southwest Sun
TM
www.duramaxbp.com
©2013 DuraMAX
DURAWALL
Installing DuraWALL Panels on Sloped Ground or Grade
INSTALLATION ON SLOPING TERRAIN
Installation on slopes is similar to that of installation on flat terrain. For the easiest installation, always start post setting
at the top of a slope and work your way to the bottom.
An 8 foot wide panel can be stepped as much as 6" per panel. For steeper slopes, you can cut the panel size to 4 or 6
feet making for a 6" drop over that width. Alternatively you can bury the wall into the ground as needed.
Additional excavation of ground between posts will need to be done to allow for proper installation of panels.
See Figure 16
The post on the down hillside of the section has been set 6" deeper than the posts on the uphill side of the section.
By doing this stepping down of posts it will make sure that when the wall panels are installed the mortar joints will
match the adjoining panel section and will be level. See Figure 15
Each wall panel will be buried into the slope on one end so as not to leave an open gap under the panel.
NOTE: burying below finished ground will not harm the panel.
1. The ground between these two posts needs to be dug out so that it is level.
If there are varying elevations, posts should be placed at the point where the slope changes, whether it’s a peak or a
valley.
2. Attach an end channel to the post on the uphill side of section using four (4) 1" #10 self tapping screws.
Place the end channel arounnd the posts base bracket and attach screws starting at the bottom.
1. Mark each post that is to be used on slopes with three pencil marks. Measure down from the top of each post and
make a line at 6" one at 73" and another line at 79". The line at 73" will be for the uphill side of the post and the line
at 79" will be for the downhill side of the post .The line at 6” is used to help with setting the height of the next post in
line. See Figure 15
3. Follow Sloping Terrain instructions 7 through 14.
4. Back fill ground next to bottom panel with dirt.
2. Excavate a hole that is 10" in diameter & 34" deep.
3. Wet mix concrete and place approximately 10" of wet concrete into bottom of hole.
End Channel Wall Caps
The posts spacing for durawall is 94" between posts. This is a critical mesurment and all posts using full length
sections of panels must be installed using this measurement. Note; use posts spacing rails (94" long) to insure
that all posts are set at correct spacing. See Figure 16
4. Place post into hole at proper depth making sure that the pencil line marked at 73" is facing the uphill side of slope
and is at a depth at finished ground or grade level or just slightly below finished ground or grade level.
94"
94"
End or Gate Post W2 #4
Rebar 90" long filled with concrete
94"
94"
71½"
73"
Finished
Grade
5. Plumb the post and fill hole with concrete.
6. Now position the wall mount brackets to the 73" and 79" marks and fasten in place with screws. See Figure 15
NOTE: Any final grading of dirt or ground between posts will be
done when installing Wall Panels
Step Down Concrete Footings
Concrete
Post
Filling
End-Channel
Step Down Concrete Footings
10"
Figure 16
7. Move to the next post in line and repeat step # 1 through 3.
8. The next post in line will be installed 6" lower than the previous post.
Level to Grade
Concrete Footings
34"
End-Channel
71½"
Post
79"
73"
9. This stepping down of posts is done so that when it is time to install wall panels
that the wall panels will have level mortar joints. See Figure 16
10. Place post into hole at proper depth making sure that the pencil line marked
at 73" is facing the uphill side.
34"
11. Plumb the post and fill hole with concrete.
Concrete
Filling
10"
Figure 15
12. Make sure that this post is exactly 6" lower than the previous post that was just set.
13. Using a string level, attach string to the previous post at the 6" mark and over the top of the posts just set and
make sure that the string line views a perfect level.
14. Continue setting all remaining posts by following instructions on setting post on level ground or grade.
15. Allow all concrete to set a minimum of 24 hours before moving onto installation of panels.
Still Have Questions?
Call Client Services at 1-888-483-1361
Engineered For The Southwest Sun
TM
www.duramaxbp.com
©2013 USP