Step 1: measure and mark where newel post bases and elevation pads will be placed.
Lay out newel post bases first and then align pads right in the middle, you want app. 3 pads for each 7 ft. of railing. (railing can be cut) If railings join together, you want one pad right in the middle of junction (half for each rail end) Lay out pads exactly where they must be dry and mark with pencil.
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Using mortar as a glue set newel post bases and elevation pads
masonary mix mortar is used instead of glue as you would for foam balusters
water determines thickness (you want it to be butter like)
Mix these into a 5 gallon bucket. you will have app. 1 hour to work with this before it gets too dry. after that concrete starts to lose strength even if you thin it with water
Place a little bit of mortar where you marked for elevation pads/newel bases (taking them off temporarily)
Put elevation pad back on top of mortar and hit it a few times lightly with a rubber mallet (you want app. 1/4" of mortar thickness)
After you go through all of them (10-50 minutes) now that it's a little bit dry, it is time to remove excess mortar from the sides. remember, a day later if you forget, it will be much more difficult!
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Step 2: slide in 4 newel post sides into each base, (you do not need to put mortar on top of the base)
first 2 thicker ones on oposite sides to each other, then 2 thiner ones into groves. clamp both thick sides A with two clamps to hold thin sides B. fill with concrete mix (cement mixed with stones and sand is the cheapest way, or just use masonary mix...) only put caps on after top rail is installed!
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Step 3: lay bottom rails
Put mortar on each elevation pad, then put the rails on. newel posts have 1/2" groves from both sides and on the bottom into which bottom and top rails slide in
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Step 4: balusters to bottom rails
Predetermine the spacing of balusters. suggested for type 1 balusters is 2" spacing; type 2 balusters 3" spacing, but you may want to change that slightly to personalize your patio shape...
Mark the squares with pencil where balusters will be placed.
Put mortar on squares of bottom rail and roughly even it out over the entire square
Put baluster and tap it into the place so it's straight using level
place top rails on balusters, then caps on the newel posts
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Reinforcement:
Each baluster is already reinforced with a steel rebar, each railing has 2 - one on each side. newel posts are reinforced with wire mesh and some rebars.
Newel posts: a thick Re bar can be placed in a middle of a newel post (newel base has a hole in a middle)
Railings: top of balusters have grooves where you can place rebars to further reinforce the system. (this is not necessary, but a good idea if you have a long row of rail/balusters without any piers/newels)
