Overview
This document is the installation instructions for American Structures and Design Builder Grade (hand swaged) cable system.
Builder Grade: Simple, Quick, Economical
Builder Grade is the most economical solution designed for experienced contractors who prefer the speed and ease of hand swaging in the field. The simple design is based on a tensioning stud, washer, hex nut, and acorn nut. Then, using the appropriate tools, the cable is field cut, and the hardware is hand swaged.
Important Notes and Disclaimers
- Check the shipment to ensure order is complete.
- Read the instructions completely before beginning the installation.
- Building codes vary by state, county, city, and municipalities. American Structures and Design recommendations may not comply with code requirements in all areas.
- It is the responsibility of the installer to always consult with the local building department before starting a project.
- AS&D recommends a maximum of 3 3/16" on center (o.c.) between cables.
- Wear personal protection equipment as required, such as safety glasses, work gloves, etc.
- Installation is best accomplished with two (2) people.
- Complete onsite measurements as required, do not rely on drawing measurements.
Metal Posts
Wood Posts
Builder Grade Parts
Part | Product Description | Part No. | Cable Diameter |
Tensioning Stud 5" Hand Swage | CH-TS-HS-1-5.0 | 1/8" | |
CH-TS-HS-2-5.0 | 3/16" | ||
1⁄4” Hex Nut | FS-1/4-28-NUT-18-8 | 1/8" 3/16" |
|
1⁄4” Acorn Nut | FS-1/4-28 ACORN-18-8 |
1/8" 3/16" |
|
1⁄4” Flat Washer for wood | FS-1/4- FLATW-W-18-8 |
1/8" 3/16" |
|
1⁄4” Flat Washer for metal | FS-1/4- FLATW-M-18-8 |
1/8" 3/16" |
|
Optional cable sleeve for wood posts. Sleeves are required in the following conditions: a. single shared post, cable through post installation (Fig. 6-1), two post, cable through post installation (Fig. 6-4) | CH-CS-1 | 1/8" 3/16" |
|
Optional grommet for ⅛ and 3⁄16 cable (3⁄8 hole required in metal post) | CH-GM-1-BLK PKG: 100 pieces |
1/8" 3/16" |
Recommended Tools
Drill Bits | ||
Bit Size | 1/8" Cable | 3/16" Cable |
3/16" | Intermediate wood and metal posts | N/A |
1/4" | Intermediate wood posts with cable sleeves | Intermediate metal and wood posts with cable sleeves |
3/8" | Intermediate metal posts with grommets |
Tools | Description |
Tape Measure | |
Permanent Marker | |
2 ea. 7/16” combination wrench |
|
Hand Drill | |
Rubber Mallet Recommended for use on intermediate wood posts with cable sleeves |
|
Cable Cutters Part No.: CT-CC-1, 3/16” Part No.: CT-CC-3 |
|
Cable Gripping Pliers Part No.: CT-CP |
|
Hand Swager Part No.: CT-CRIMPER |
|
Cut Off Kit Part No.: CT-CO-Kit |
|
Cable Tensioning Gauge Part No.: CT-CTG both 3/16”, 1/8” cable |
Field Drilling Holes for Posts by Others
Note: When using pre-drilled posts by ASD, skip this section and move to Step 2.
Figure 1
Cable Diameter | ||
1/8" | 3/16" | |
Part Type | Drill Hole Diameter | |
Intermediate Post | 3/16" | 1/4" |
Terminating Post | 5/16" | 5/16" |
Single Corner Post | 1/4" | 5/16" |
Off Set Single Corner Post | 5/16" | 5/16" |
Cable Termination Post Options
Figure 1-2 |
Figure 1-3 |
Single Post, Cable Through-Post Installation | Single Post, Off-set Cable Installation |
Figure 1-4 |
Figure 1-5 |
Two Posts, Cable Terminated on Each Post | Two Posts, Cable Through-Post Installation |
Measuring and Cutting Cable
Start with the longest cable lengths in case there is a miscalculation in run length. Miscalculated longer lengths can be re-used for shorter runs.
Figure 2
2A. Hand swage to hand swage straight run cable length - Measure the distance, outside-to-outside, between the terminating posts, subtract 5 3/4” and cut cable to this length.
2B. Machine swage to hand swage straight run cable length - Measure the distance, outside-to-outside, between the terminating posts, subtract 6 5/16” and cut cable to this length.
2C. Cable through post installation (Fig. 1-2 and 1-5) - Compensate length accordingly.
2D. Mark cut point - Using a permanent marker, mark the cable to the required dimension. Cut cable using Cable Cutters.
Swaging Tensioning Studs
3A
Preparation - Insert one end of the cable into the tensioning stud, ensure cable is fully inserted into the tensioning stud.
3B
First swage - Using the Hand Swager, swage cable approximately 1/8” from the end of the tensioning stud.
Note: Use the die on the Hand Swager that corresponds with the cable diameter being installed.
3C
Second swage - Rotate tensioning stud 180 degrees from first swage, position the Hand Swager 1/8” from first swage and swage a second time.
3D
Third swage - Rotate tensioning stud 180 degrees from second swage, position the Hand Swager 1/8” from second swage and swage a third time.
Stringing Swaged Cable Through Posts
Figure 4-1
*Washer for Metal Post Part No.: FS-1/4- FLATW-M-18-8 |
4A. Insert swaged tensioning stud - Through the drilled hole in the first terminating post.
4B. Washer and Hex Nut installation - Slide washer onto tensioning stud BEFORE installing the hex nut. Thread the hex nut onto the swaged tensioning stud, ensure approximately ¼” of thread is visible to allow for acorn nut attachment.
4C. Stringing cable - String the bare end of the cable through the intermediate posts at the appropriate holes until the swaged tensioning stud is tight against the originating terminating post. Do NOT string cable through final terminating post.
4D. Swaging second tenstioning stud - Swage the second tensioning stud following the instructions in Steps 3a – 3d.
Figure 4-2
4E. Insert swaged tensioning stud - Through the drilled hole in the second terminating post.
4F. Second washer and hex nut installation - Slide washer onto tensioning stud BEFORE installing the hex nut. Thread the hex nut onto the swaged tensioning stud until there is no slack or sagging of the cable.
Note: Ensure approximately 1/4” of thread is visible to allow for acorn nut attachment.
4G. Cable Tensioning - Using the Cable Gripping Pliers, grip the cable next to the tensioning stud shank on the inside of the terminating post. Using a 7/16” open end box wrench, tighten the hex nut to ASD's engineering requirements based on post spacing or site specific engineering specifications. Measure tension using the Cable Tensioning Gauge. Release the Gripping Pliers when the process is complete.
Notes:
1. If the tensioning stud is too long and the threads are no longer available, go back to the original terminating post and take up the slack.
2. Leave at least 1/4" thread for acorn nut attachment on both ends of the cable run.
3. For aesthetic purposes, the tensioning studs can be threaded evenly using the hex nut so that the visible portion of the shanks are even, as long as there is at least 1/4" of visible thread.
Complete Tensioning, Cut Off Excess Threads, and Install Acorn Nut
Figure 5-1
5A. Continue installing, swaging, and tensioning - All cables to ASD's engineering requirements based on post spacing or site specific engineering specifications.
5B. Excess thread removal - Using the Cut Off Kit and a hand drill, carefully cut off the tensioning stud excess threads, leaving approx. 1/4" of threads to attach the acorn nut.
Note: Be sure to protect the finish on your posts and deck from contact with the cutoff wheel disc and sparks during the cutoff operation.
Figure 5-2
5C. Acorn Nut attachment - Thread the acorn nut onto the cut ends of the tensioning stud.
5D. Using two 7/16" combination wrenches - Hold the hex nut and rotate the acorn nut clockwise to "lock" the nuts firmly together.
5E. Completed acorn nut attachment.
Note: If threading the acorn nut on the tensioning stud is difficult, grip the cable using the Cable Gripping Pliers and remove the hex nut to clean-up the tensioning stud threads. Then re-thread the hex nut back onto the tensioning stud.
Final Installation Examples
Figure 6-1
Single Post, Cable Through-Post Installation
Figure 6-2
Single Post, Off-set Cable Installation
Figure 6-3
Two Posts, Cable Terminated on Each Post
Figure 6-4
Two Posts, Cable Through-Post Installation
Inspection Checklist for Cable Installation
- Check for missing cables.
- Ensure consistent spacing between cables.
- Using the Cable Tensioning Gauge, verify each cable is tensioned to ASD's engineering requirements* based on post spacing or site specific engineering specifications.
- Confirm all hardware is installed: washers (angled washers where applicable), hex nuts, acorn nuts, sleeves and grommets.
- Verify hex and acorn nuts are locked together, without any gaps, preventing them from backing out.
- Check terminating posts for excessive bowing (slight bowing is expected). If posts are excessively bowing, loosen cables, re-tension (ref. Figure 5-1) according to ASD's engineering requirements* based on post spacing or site specific engineering specifications.
- Periodically inspect all cables for proper tension.
- Thermal expansion may cause the cables to sag and loosen over time. Re-tension cables accordingly.