CHESHIRE MOULDINGS axxys evolution User manual

fitting instructions
axxys®evolution
www.axxys.co.uk

axxys®evolution is a contemporary range of stair balustrade designed to inspire.
As a modular system axxys®evolution provides the flexibility to blend components
from across the range to create a stylish, bespoke staircase and a focal point for any
living space. Clean lines and metallic details also allow axxys®evolution to make a
modern statement within more classic, period environments.
axxys®evolution has been designed not only for its quality and style, but also for its
simplicity to install. All components have been independently tested to conform to
UK building regulations, are design registered and patent pending.
Cheshire Mouldings axxys®evolution stair balustrade is a UK and International Patent and Design
Registration pending product, blending traditional turnings with modern materials. Hand and base rails
are assembled using our unique metal brackets. Balusters are fixed into place using our patented fully
adjustable baluster brackets which adjust between 90oand 45o, locking firmly into place when positioned
into the Hand and Base rail profile. These components once assembled form an innovative balustrade
solution that can be adjusted to suit any staircase pitch between 38o& 45o.
Please Note;
Cheshire Mouldings axxys®evolution is a factory pre finished system, therefore when handling and
installing please take extra care in order to not damage the finish.
Please Check;
All components should be inspected BEFORE installation commences for any damage, as Cheshire
Mouldings cannot be held responsible for any damage caused during installation.
axxys®evolution is designed for use in domestic situations and will fit most closed stair cases achieving
minimum handrail heights of 900mm on the rake and 900mm on the landings. If your staircase is longer
than 3.9m on the rake, you must install an Intermediate Newel Base, Newel Post & Handrail Connector in
order to achieve the FIRA strength standards, instructions for this are on the following pages.
axxys®evolution is manufactured to precise tolerances, however please be aware that timber is a natural
product and some distortion, expansion and sometimes shrinkage can occur.
If timber components (i.e. hand rails) are slightly oversize, gently sand or shave the timber until a tight fit
is achieved, being careful to only sand/shave the part of the component that is going to be concealed by
the metal or plastic connector.
If the timber component is slightly under size, the tolerance can be taken up by using a gap filling
adhesive.
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Existing Newel Bases
Important;
All newel bases must be cut off squarely in order for
the newel posts to sit perfectly level. Sand if required
to achieve correct level. Once level they can be
chamfered to improve the aesthetic. Please also note
that the newel connectors do not allow for any height
adjustment, so newels must be set at the correct
height to achieve building regulation standards.
axxys® evolution can be installed using the existing
staircase newel bases. If the existing newel bases
are to be used, they must be positioned central to
the stair string and front edge of the riser concerned,
and must be a minimum of 81x81xmm square, if
they measure less the sides will have to be built up
using suitable material. They must also have enough
material once cut, to achieve the dimensions shown
plus the baserail height (fig. 2 & 3).
Prior to cutting the newel bases down to the correct height, the axxys® evolution baserail must be
temporarily fitted to the string. First Lie the baserail on top of the tread nosings and push it up against the
newel bases, then mark the vertical lines and cut achieving a good finish (fig. 1)
Rest the cut baserail on top of the string, temporarily fix it in place at this stage using tacks or double sided
tape.
axxys®evolution fitting instructions
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New Newel Bases
Important;
Before removing any existing Newel Bases, please check to ensure they are non-structural.
If fitting new newel bases, they must be installed centrally to the stair string and front edge of the riser
concerned (fig. 2 & 3). Prior to fitting to the string, please follow the following instructions to cut down the
newel bases to the correct height, ensuring you cut any excess from the bottom of the newel base.
Bottom Newel Base
Using the top edge line of the baserail that you marked on the newel base prior to cutting, now draw a
vertical line up through the centre point of the newel base, making sure to intersect the baserail line. Now
measure up 175mm from the intersecting point and mark a horizontal line (fig. 2). Then finally measure the
remaining distance to the top of the newel and remove this from the bottom of the newel.
Top Newel Base
The top newel base should be marked out and cut in the same way as the bottom newel base, however the
175mm dimension should be replaced with 125mm (fig. 3)
Newel Posts & Base Collar
Important;
Before you start, slide the evolution newel post into the collar to
make sure it fits snug. If the newel is too tight, the spigot on the
bottom of the newel must be eased so it slides into the collar, this
is done by using sandpaper to reduce the taper on the spigot.
Please DO NOT try to force the newel post into the collar. All
drilling operations should be accurate, straight and level.
Newel Base Collar (AXEVBC) can now be fitted to the evolution
newel, slide the collar onto the bottom spigot up to the stop,
then pre drill and secure using fixings provided (fig. 4).
For existing bases only, find the centre of the newel base top
by drawing diagonal lines from corner to corner and using the
intersecting point, from the top and centre of the newel base,
drill a hole 50mm diameter x 100mm deep (using our 50mm
spur drill) to take the newel spigot (fig. 4).
Before inserting the newel post, mark and cut the newel to a
length of 565mm measured from the top of the spigot. Once cut
to length insert the newel post making sure the collar meets with
the newel base, secure using a gap filling adhesive (fig. 4).
Repeat this step for the top newel assembly, but the newel
must be cut to 750mm to the top of the spigot.
axxys®evolution fitting instructions
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Handrail Length & End Brackets
Please Note;
The bottom newel adjustable End Bracket (AXEVEBC) is a three part
assembly, consisting of a newel connector, a handrail connector and a
handrail cap, with various fixing screws, bolts and washers. It must be
fitted with the angles in the same orientation as the rake of the stairs.
The following is a job best done by two people. First you must fit the
newel connector onto the top of the bottom newel and secure by pre
drilling and using the two 30mm screws provided, remembering to
align the connector with the handrail (fig. 5)
Now fit the top newel Round Handrail Connector (AXEVHR) to the
handrail. Slide the connector onto the handrail and secure using the
two 30mm screws provided. Now loosly assemble the remaining half
of the bracket, using the bolt and two washers provided (fig. 6).
Then with a pre-assembled spindle (instructions found
on the following pages) secured onto the baserail no
more than 99mm away from the newel, lay the handrail
assembly onto the spindle to determine the height of
where the bracket sits on the newel. Secure using two
30mm screws provided (fig. 7)
Next slide the handrail connector onto & up the handrail
until it drops into the newel connector and the bolt hole
is perfectly aligned, you can now pre drill and secure the
handrail connector in its position using the three 25mm
screws provided. Then loosely fix the handrail connector
axxys®evolution fitting instructions
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into the newel connector using the 45mm
bolt and spacer provided, making sure the
chamfered end goes into the hole first. Finish
off by inserting the cover cap (fig. 8).
With the handrail connector secure, cut the
handrail at a 90o angle in line with the newel
post, leaving 20mm protruding at the bottom
of the handrail (this can be altered to achieve a
larger or smaller gap, 20mm will leave a 10mm
gap). You can now fit the end cap securing
with two 30mm screws provided. (fig. 8).
Baluster Assembly
Please Note;
When assembling the baluster brackets onto a baluster
tube, remember to slide the baluster bracket covers onto
the tube first followed by the tube bung and finally the
baluster bracket, then lie each baluster bracket onto a
separate piece of wood to ensure that they are both level/
square with each other. Now tighten the fixing screws
prior to sliding the baluster bracket cover over the baluster
bracket, the baluster assembly is now ready to be fixed
on the hand/base rails (fig. 9).
All holes for fixing the baluster brackets should be pre-drilled. The
bottom baluster should be fixed vertically no more than 99mm from
the narrowest part of the newel post, in the same way as the top
baluster was previously (fig. 10).
In order to space the remainder of the balusters evenly measure
the distance in mm between the centre points of the 2 balusters
already fitted and divide by 148.5. Round the answer up to the next
whole number and divide the whole number back into the original
measurement and this will give you the exact spacing (fig. 10).
Example - 2264mm between centre points of balusters divided
by 148.5mm = 15.25, rounded up to 16, then take the Evolutional
measurement 2264mm divided by 16 = 141.5mm which is the
exact spacing measurement.
Pre-drill all holes for the baluster brackets after marking their position
on the hand rail and base rail, using the spacing measurement
from the previous step.
axxys®evolution fitting instructions
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Top Newel Cap or
Handrail Landing Connector
If your balustrade ends at the top of the stairs, then you
can finish off the newel with our Newel Cap (AXEVNC).
However if you have balustrade coming off the top
newel, typically at a 90oangle (for return landings please
see instructions below), then you can use our Landing
Handrail Connector (AXEVLHC).
To install the Landing Handrail Connector simply slide
it onto the top newel and secure using the 30mm
screw provided, making sure you have lined it up with
your landing baserail. It is now ready for you to insert
the handrail and secure using the two 30mm screws
provided (fig. 11).
The handrail can terminate to either a wall connector, or
to another newel to handrail connector where there is a
second flight of stairs.
Intermediate Newel on the Rake
If your staircase is longer than 3.9m (measured between
inside newel faces) then you will require an intermediate
newel for added strength.
This will require an additional newel base to be installed
at the same time as the top and bottom bases, the cut
off point for the intermediate newel base is 150mm. The
intermediate newel post must be cut to 590mm before
fitting the collar and inserting it into the base.
Next fit the intermediate connector (AXEVIC) onto the
top of the newel and secure with the two 30mm screws
provided. Then slide the other half of the intermediate
connector onto and up the handrail, once located into
the newel connector, secure to the handrail by using the
four 30mm screws provided.
Finally secure the connector assembly by inserting
the 45mm bolt and spacer provided, making sure the
chamfered end goes into the hole first. Finish off by
inserting the cover cap into the bolt hole (fig. 12).
axxys®evolution fitting instructions
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axxys®evolution fitting instructions
90oElbow for
Return Landings
Please Note;
When using a combination of
the 90
o
Elbow (AXLQT) and the
Landing Handrail Connector
(AXEVLHC)toform a returnlanding,
the minimum distance you can
achieve is 140mm from the centre
of the staircase baserail to the
centre of the landing baserail.
If you have a return landing,
then our 90oElbow (AXLQT)
can be used to achieve this,
in conjunction with a Landing
Handrail Connector (AXEVLHC)
and short piece of handrail.
Simply mitre the handrails using the
template supplied (found at the back of
this booklet), slide them into the elbow
from either side and check that the
handrails pass the screw holes. Then
pre drill and secure the handrails using
the four screws supplied and glue from
underneath (fig. 13).
Lie the assembly on top of the baserail
and behind the newel, then measure
the cut off point for the short piece
of handrail against the newel face,
remembering to include the connector
tolerance and to ensure the handrail is
in line with the baserail. Cut the handrail
at the point you have just marked.
Now slide the short handrail end into
the Landing Handrail Connector, and
secure using the two 30mm screws
provided. The completed assembly
should look like the illustration to the left
(fig. 14).
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axxys®evolution fitting instructions
Intermediate Landing Handrail Connector
for Intermediate Landing Newels
If your staircase requires an Intermediate Newel on the landing for added strength, then our Intermediate
Landing Handrail Connector (AXEVILHC) has been designed for this instance, as it will allow an Evolution
Newel Post to be connected to the Handrail. You can also rotate it any angle between 90oto 180oto suit a
multitude of configurations.
First your intermediate Landing Newel must be installed, using the dimensions from the earlier instructions
for the Top Newel. Now measure the handrail lengths you require from newel to newel (including connector)
and cut to suit. Slide both parts of the Intermediate Landing Handrail Connector onto the newel and
position correctly their orientation, then secure using the two 30mm screws provided. Finally slide the
handrails in the connectors secure using the 30mm screws provided (fig. 15).
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notes
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axxys®evolution 90oElbow Template
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axxys © 2009 axxys is a resistered trademark of Cheshire Mouldings Ltd
Axxys Stair Balustrade is Available to Order Through
Stairplan Ltd
Hortonwood 1
Telford
Shropshire
TF1 7GN
Phone [phone] www.stairplan.com
www.Tradestairs.com