Failure to install and finish this product in accordance with applicable building codes and LumberCon written instructions may lead to personal injury, affect product performance, violate local building codes, and void the product warranty.
When cutting LumberCon or any concrete product it is necessary to wear a mask, if there is a change of breathing dust. You can also assist in dry cutting on a job site by using a large fan or blower to direct dust away from you. Always wear eye protection.
Cutting LumberCon is easy with the right equipment. The use of a standard: Woodworking 7-1/4” circular saw, Gas powered cut saw, A box/chop saw, or a common 4” grinder is fine. However, the needed blade type for this application should be with small openings.
Here are a few to list:
- 7” Norton model #50508-038 available at Lowes or equivalent
- 7” Norton model #50509-038 available at Lowes or equivalent
- 7” DeWalt model #DW4702 available at most home improvement stores or hardware
- 4-1/2” Norton Wet Dry model #50505-038 or equivalent
- 12” Monster D11150- 866-688-1032 or equivalent
- 14” Virginia Abrasives model STD-series part 425-03013 or equivalent
Cutting Square Cuts
When cutting square cross LumberCon with any of the mentioned tools it is best to start from one side and move your tool across the plank. Please be sure to keep both sides of cut supported, best to cut on top of a piece of dimensional lumber like the size plank you are using, or a sheet of plywood. The piece must be supported all the way to the end of the board with the scrap you are cutting supported too. This will prevent cracking prematurely or breaking off too early.
It is strongly recommended to take the blade while saw is in operation and scribe a saw cut along your marked line and continue to cut continuously through the board with each stroke. We can direct you to a video to watch for a better understanding. When you get to the wire you will know it. I find it best to cut through one wire continuously at a time and then proceed back and forth to cut through the remaining part of the plank till you hit the wood that the LumberCon plank is resting on.
For more precise finish cuts or clean up it recommended to a 4” grinder. We often use battery operated grinders for this application because there are no cords that get in the way.
When completing the cutting the ends of the boards. You will need to use one of the following to prevent the wires from being exposed to the elements.
Cutting Curved Patterns
You can cut curved patterns, arches, circles and more with LumberCon.
- To cut an arch or curve you will need to use a smaller blade saw, like a 7-1/4” skill saw with a proper blade. This cut is a bit trickier because you will have to use the saw like a free cutting method. We have custom cut arches and circles this way the whole blade cannot be pushed down into the LumberCon plank but more on top of it all the way through the scribed line you created first. Sometimes you can use a hand grinding 6”-7” electric grinder too. When you again get to the wire be sure to cut each one at a single time and then continue to finish the cut equally all the way through the plank. -see video on our (Campsite install of LumberCon) or Annapolis driveway project.
- Drilling hole- again the only issue you have when drilling a large hole or any hole is to stay clear of the wire by a minimum 1/4”. If you need a round hole, you would use a diamond hole saw similar to those used for cutting granite. You will have to find the depth to be correct or score from both sides sometimes. Cutting or nicking the prestressed strand can compromise the integrity of the plank. Please review the drilling video attached.
Drilling through LumberCon for Fastening
It is extremely important to understand the proper way to drill through LumberCon if using fasteners that are mentioned below. Careful use of masonry drill bits must not be within a ¼” from the PRESTRESSED WIRES That are buried with in the board. Must be to the left or right of the wire when drilling for fastening. With an 8 inch plank only one connection screw is needed centered within width of the plank.
Drilling and Fastening with Steel Fasteners
- Drilling through LumberCon is not difficult but several cautious items and directions must be considered here.
- Do not use an SDS Hammer drill on our product. The reason for this is that the constant pounding up and down from the hammer drill will cause severe damage to the bottom side of the board when the drill finally comes through the plank.
- The use of a battery operated and or small drill style electric combination drill and hammer option is perfect. This type of drill acts more like a rotary hammer drill and minimizes the damage to our product when you drive the bit through the LumberCon to make your hole.
- Depending on the style of fastener you are using, please create your hole through LumberCon a little larger than the diameter of the fastener you are using. The pressure to secure our planks is not through the tightness of the fastener around the hole, but the size of the hole you create into the structure you are creating.
LumberCon Drilling How-To
This video shows how to work with our LumberCon. Setting Tapcon screws in the surface and how close to the edge
LumberCon Drill Setting Screws
This video shows how to work with LumberCon and how to drill through the Plank Board into a subframe of wood.
This generic video shows the how to drill through concrete and use Tapcons drill bits vs. wood bits the differences
Drilling through LumberCon is not difficult but several cautious items and directions must be considered here.
Do not use an SDS Hammer drill on our product. The reason for this is that the constant pounding up and down from the hammer drill will cause severe damage to the bottom side of the board when the drill finally comes through the plank.
The use of a battery operated and or small drill style electric combination drill and hammer option is perfect. This type of drill acts more like a rotary hammer drill and minimizes the damage to our product when you drive the bit through the LumberCon to make your hole.
Depending on the style of fastener you are using, please create your hole through LumberCon a little larger than the diameter of the fastener you are using. The pressure to secure our planks is not through the tightness of the fastener around the hole, but the size of the hole you create into the structure you are creating.
Fastening of Our 2x8 and 2x12 Planks
There are several means to fasten our planks to your subframe whether it be Steel, Wood, Composites. All these types of mechanical fasteners can be used for almost all three and depending on the look that you wish to accomplish is up to you.
- Fastening to Steel- after drilling through the LumberCon Plank using a masonry bit, you will want to pilot your hole if not using a self-tapping screw. Recommendation for the type of screw would be either stainless or 410 steel fasteners. You have the choice to use a flat head screw, hex head or even a ledger/timber style screw with a pan head style. See recommendations below.
- Fastening to Wood frame/composite- First you will pilot the hole through the LumberCon plank
- Please note that it is enough to secure our planks with only one secure fastener if there is a question or need to use more than one fastener per joist or span, you can contact our Engineering Department for question or concern. Of course, the proper size of fastener to calculate the size of pressure to secure is necessary, but too many fasteners may not be needed because LumberCon is a very stable product.
Fasteners and Means to Fasten LumberCon Planks
410 STAINLESS SCREWS
Perhaps the most versatile for using our planks to fasten to anything: steel, wood, concrete and composites. The most favorable of all is Simpson Titan brand:
For planks going into wood - TTN25400PFSS is 4” ¼” stainless buglehead Phillips style, they are made from 1-1/4”-4” they make these in hex head too model numbers TTN25400HSS I like this screw for the very good reason that they already are the same color Simpson Strong Tie TTN25400PFSS...
Another very favorable brand that you can get everywhere is Tapcon all so many sizes and shapes available at any hardware store or big box. If you don’t mind blue as the head color, you can also paint them any color with a good quality paint too.
FMHLGM412 lag screw - This screw is perfect for resting on top of the plank and pulling it down to any substructure you have, the only thing you see on the surface is a button with a torx head, the head is about 1/16” above the board and the head about ¾” if the need to counter sink is necessary that would have to be completed after the pilot hole. FastenMaster FMHLGM412-250...
We have also used utility BUTYL rolls in conjunction with screw down method. Two things this accomplishes is the sureness of the plank sticking and softening the should as pedestrian or carrying on top when mounted to steel especially. Once the butyl sets it is secure. We recommend the use of 3/8”x1/2” for the use of Planks wanting to be secured to metal joists. There are some cleaners and preparation items that also work with this method, contact the factory for more information and to order.
Two-Sided Tape (Under Review Now)
We are always and currently testing new methods right now the use of a two-sided 3M tape right now too. The tape has a 1200psi pressure attaching two products we should have results within a few more months. Contact the factory to discuss your option of installation preferences.
There are several tapes that can be used. See Amazon numbers for Tapes that should be fine, must be an exterior grade.
Bolting down our planks is also a method of direct fastening; the use of stainless fasteners should always be considered so that reaction from metal to concrete issues do not occur.
Bolt Side of LumberCon
LumberCon can be bolted side by side and is recommended when alternative strength is required for a joist or a beam. However, you need to bolt the two boards together and depending on the span and the side a minimum bolt pattern and staggering of bolts is necessary away and in-between the wires that support he structure between each plank or beam. You engineer or ours should clearly decide where the bolts should be mounted and how far apart. Minimum of 3/8-1/2” are necessary and one inch wider than the two planks with washers on both sides and lock washer and nut to make certain pressure is efficient. Specific amount of torque may be necessary ask our engineer or yours.
Concealed Fastening System
We are working on a system that is full proof. We have attempted and have designed a washer system that a cut in the side of the board would accept a heavy stainless-steel washer with a hole in the center to hold and pull down. The need for additional board support might be necessary-i.e., Tape or butyl
- First make sure that you keep when shipping, carrying and or transporting from trailer to job site that all boards especially longer than 12’-20’ are carried with two people from the ends in the “I” position not the “FLAT” position. LumberCon is strongest when transporting in this mode rather than flat mode.
- Once you have transported LumberCon Planking you can lay flat onto blocks or platform to cut or drill holes. Boards should be supported under any over hangs and cutting where it plans to be. Do not cut board to let overhang and drop. Sometimes best to cut entire board laying on a piece of dimensional lumber longer than the LumberCon to be certain no weight is not supported.
- Setting up for drilling should be the same way. Be sure to confirm with drawing and location of wires that run from length of LumberCon. Never ever drill directly over attempt to drill directly over the top of the wires. This will not work to the right or left of the plank is necessary. Keep at least ¼” away from all sides of the wire. (See photo) and refer to installation guidelines.
- Moving more than one plank at a time. If you must all planks generally are shipped on end in batches of 19. This is very heavy so the use of a forklift or other device should be considered before breaking/cutting the bands before moving on or off the truck or at the jobsite.
- Moving product from the truck/trailer or ground. Make certain there at minimum a piece of wood ¼”-3/4” underneath the width of the forklift width. Do not allow forks to touch the bottom or side of any of the planks when carrying or lifting off truck. Any direct contact might cause cracking or splitting, spauling of LumberCon planks to chip or damage. This is not part of normal care while handling and is not covered under any replacement or warranty plan. If there are any questions on how to move materials around by forklift or other means, please contact technical support at LumberCon immediately. 570-274-0400.
- LARGER PLANK/BEAMS-How to move and work with larger beams and planks. LumberCon Planks and beams that are greater than 2” material like 3x10’s and larger follow the same handling as our 2” planks, however, these are very heavy and will need to be used either with a Forklift, hoist or crane. If so, please do not use metal directly against the planks or beams. Cracking or chipping can occur and will cause blemishes in product that are not guaranteed. If you want to move with a piece of machinery and are in doubt, please consider using strapping materials, or contact our technical support. 570-274-0400