FLAMRO FKS Ready Cable Duct System

Transcription

1 Mounting Instructions FLAMRO FKS Ready Cable Duct System These mounting instruction do not replace the test certificate of the fire protection cable ducts! They must be kept for the installation of fire protective ducts! FKS I-duct: P-3080/7780-MPA BS FKS E-duct: P-3103/3729-MPA BS Download at FLAMRO Brandschutz-Systeme GmbH Am Sportplatz Leiningen Phone: Fax: info@flamro.de 1

2 Table of content: 1. Fundamentals: - Statutory provision - Cable duct description - Cable duct connection 2. Type of fastening - Directly fastened to the structure - Suspended construction - Other mounting 3. Wall/ceiling connection - Mortar duct end in - Wall connection collar (WAS) 4. Duct laying - Hallway crossing - Mounting with a shaped part - Cap - Mounting with several shaped parts 5. Cable designs - Individual cable design - Cable bundle design 6. Accessory/Accessory list 7. Two-three-sided ducts 2

3 1. Fundamentals: Statutory provision: These mounting instruction do not replace the test certificate of the fire protection cable ducts! These can be downloaded at and must be kept for t he installation of fire protective ducts! In the following the test certificate of the FLAMRO FKS - Fire protective cable ducts are listed: FKS I-duct: P-3080/7780-MPA BS FKS E-duct: P-3103/3729-MPA BS The mounting instruction do not release the user from the obligation to design the fire protection ducts according to the requirements of the certificate, but serves as an aid for installation. Also, it should be noted that these instructions can not cover all relevant points of the certificates and must therefore be read when in doubt. The technical support of the FLAMRO Systeme GmbH is also available as well as the support of the responsible sales representatives. Duct description: FLAMRO FKS Fire protective cable ducts are made of a non-flammable insulation of mineral wool or calcium silicate, which are clad in steel or aluminium sheets. The galvanised steel cladding can also be factory provided in RAL colours, or painted onsite by the client during/after mounting. In addition to five standard dimensions of the inside duct cross section (wxh 60x50mm, 110x50mm, 210x50mm, 160x100mm, 260x100mm) and matching shaped parts, almost any special shaped part with different cross section dimensions can be produce. Cable duct connection: The cable duct elements are connected with each other using the stepped profile/rabbet of the insulation and sheet metal screws at the clip side of the duct. Since any length can be produced, the ducts can be accurately made at the factory. If they need to be tailored locally, the following should be noted: Within the duct run, the ducts may only butt together with stepped rabbet. A continuous cutting gap (e.g. through local cutting of the duct) requires cladding in form of an element butt (shaped part, which covers the kerf by the material strength) or rework. A continuous kerf is permissible where the duct connects with the start or end to the structure. The stepped rabbet on a mineral wool duct can be reworked simply by using a sharp knife Loose mineral wool feathers and individual specific grade are available, if it has been determined that this is required upfront. Using the FLAMRO fire-resistant adhesive KL, all ducts can be adjusted on-site. 3

4 2. Type of fastening: FLAMRO FKS Fire protection ducts may be mounted directly to the building structure, as well as suspended mounting. Since the fasteners differ, various options are provided below. Directly fastened to the building structure: For mounting directly to the building structure all approved fire protection plugs are made of metal, at least M8, in correlation with the material of the building. FLAMRO fire protection ducts may also be attached to lightweight partition walls with steel substructure (please refer to Annex 5 of the test certificates). The thread length of the screws is calculated from of the usable depth of each anchor plus the duct wall thickness (variable depending on the respective fire protection duct, see table). *) Should cable clamps, multi-function plates or washers be used, then this material thickness is added (about 2 mm). FKS Type Duct wall thickness in mm (insulation + adhesive + sheet metal) Fire protection classification Insulation Material BIK 30 M 32 and 34 *) mm I 30 Mineral wool BIK 60 M 42 and 44 *) mm I 60 Mineral wool BIK 90 M 42 and 44 *) mm I 90 Mineral wool BIK 30 K 32 and 34 *) mm I 30 Calcium silicate BIK 60 K 32 and 34 *) mm I 60 Calcium silicate BIK 90 K 42 and 44 *) mm I 90 Calcium silicate BIK 120 K 62 and 64 *) mm I 120 Calcium silicate BEK 30 M 32 and 34 *) mm E 30 Mineral wool BEK 60 M 42 and 44 *) mm E 60 Mineral wool BEK 30 K 42 and 44 *) mm E 30 Calcium silicate BEK 60 K 52 and 54 *) mm E 60 Calcium silicate BEK 90 K 57 and 59 *) mm E 90 Calcium silicate Direct mounting of the duct to a structure is done by local drilling trough the rear panel of the ducts. Here it is important to heed the hole distances. Hole centre distance: - In the duct length: The distance between the attachment screws may not exceed 300 mm. - In the duct width: One attachment screw in the centre of the duct width is sufficient for ducts with small width (e.g. 60mm inside width). Wider ducts (e.g. 260 inside width) requires two screws in width. On ducts with 4

5 medium width (e.g. 110 inside width) the screws are arranged offset from each other. Multi-function sheets or cable clamps are directly mounted with the structure attachment screws. Here, the holes are already predetermined. (Shown in the illustration: Multifunction sheets with optionally available support angles, that stabilise a fully occupied cut-off tab against bending). We recommend using 40 mm washers for better load distribution, if cable clamps or multi-function sheets are not required. Moreover, the screw heads will not pull into the insulation. Suspended construction: The suspended construction is different from the direct fastening of the duct to the structure. Here, the local boreholes through the rear wall of the duct are not required. Instead, suspension is done using threaded rods M8 and fastened C- or U-profiles made from steel ( 26 x 48 x 26mm, d 2,5 mm). The clearance between the threaded rods should be 1250 mm. (for this, also refer to Appendix 5 and 6 of the test certificates). The duct lays on the C- or U- profiles and does not require additional fastening. Other mounting: Next to the previously mentioned fastening possibilities, FLAMRO FKS fire protection ducts can also be fastened using consoles or outriggers with additional threaded rods. (see illustration) Information for this can be found in the test certificates, especially in Attachment 4, 5, 6. FLAMRO FKS fire protection ducts can also be mounted to partitions with steel substructures. On the suspended mounting the removable cable cover is usually located at the upper side of the duct, which eases re-mounting. Should the available space be limited upwards, then the duct can also be rotated by 180 and mounted. This means that the cover is then on the bottom. Since the threaded rods of the suspension in the longitudinal direction may have a distance of up to 1250 mm, the length of the cover is however, 1200 mm, the arrangement may be such that every second duct cover is not supported and thus can be removed. This allows re-installation with minimal effort. 5

6 3. Wall/ceiling connection: Should a duct butt with the face to a structure, then there are two possibilities that are test certificate compliant to implement this connection: Mortaring the duct ends in: Insert the ducts about 5 cm into the wall and mortar or plaster them in. You should only select this version when later expansion is not expected. Wall connection collar (WAS) The end of the duct is fastened using a so-called wall connection collar (WAS). This has the advantages that any later installation is simpler and a smoke-tight connection to the structure is ensured. The wall connection collar consist of a 25mm thick mineral wool plate with a melting temperature above 1000 C. It can be pressed together after mounting to 15 mm. The mineral fibre mat is clad with a steel-z profile 40/40/15 mm, which is bolted to the structure. A suspended duct should be planned with the wall connection collar being 4-sided, for a direct mounting of the duct on the wall or under the ceiling consider a 3-sided wall connection collar. Shown in the illustration: Wall connection collar 4-sided all around (on a suspended duct the duct cover is on top). The cover of the duct can be easily removed for retrofitting or inserting new cables, by simply removing the attachment screws of the upper Z-cross profile. For a hallway crossing the duct mounting would start with a wall connection collar. Use a small amount of adhesive and attach the 25mm thick mineral fibre plate to the wall. Now press the blunt duct end of the connecting duct against it until the 25 mm are pressed together to 15 mm. This is the position that the duct is mounted to the structure. Bolt the Z-profile to clad the projecting mineral fibre plate also to the structure. Add more ducts until the other side of the room is reached. This is the place where adjustments are usually made and the duct is cut-to-size. The clearance from the end of the last mounted duct to the wall is the specified dimension. However, you still have to deduct the dimension of the wall connection collar to the wall, meaning 15mm (installed condition). Prior to installing the last duct piece attach the 25 mm thick mineral wool plate of the wall connection collar to the wall. Since the cut duct only considers the pressed together mineral wool, meaning 15mm, the mineral fibre mat however adds 25mm while not pressed together. This provides the problem that the last duct piece must be positioned. Without the mounting aid the duct end would tear off the mineral wool bands from the wall. Here a mounting plate is recommended that can be inserted between the mineral wool of the wall connection collar and the last piece of duct to be installed. Now the duct slides on up to the final mounting position and at the same time presses the mineral wool together to 15 mm. If the duct sits perfectly, the mounting plate can be pulled out and the wall connection seals cleanly. 6

7 FLAMRO FKS Fire protection ducts FLAMRO FKS Fire protection ducts FLAMRO FKS Fire protection ducts Illustration wall/ceiling connection collar Consists of: Steel Z-profiles 40/40/15, sheet thickness 2mm, and mineral wool bands of material class A according to DIN with a melting point of > 1000 C; 25mm thick Mounting with anchor bolts M6, a < 250 mm, min. 2 pcs. per side Illustration wall/ceiling connection collar Consists of: Steel Z-profiles 40/40/15, sheet thickness 2mm, and mineral wool bands of material class A according to DIN with a melting point of > 1000 C; 25mm thick Mounting with anchor bolts M6, a < 250 mm, min. 2 pcs. per side Have the first fastener of the duct arranged at < 100 mm clearance from the wall surface Illustration ceiling/wall connection collar Consists of: Steel Z-profiles 40/40/15, sheet thickness 2mm, and mineral wool bands of material class A according to DIN with a melting point of > 1000 C; 25mm thick Mounting with anchor bolts M6, a < 250 mm, min. 2 pcs. per side Have the first fastener of the duct arranged at < 100 mm clearance from the wall surface Suspended construction - collar 4-sided shaped Direct mount to wall/ceiling - collar 3-sided shaped Direct mount to ceiling - collar 3-sided shaped Wall connection collar 4-sided, duct suspended mounted Wall connection collar 3-sided, duct directly mounted to wall Wall connection collar 3-sided, duct directly mounted to ceiling FLAMRO FKS Fire protection ducts Illustration floor/ceiling/wall connection collar Steel Z-profiles 40/40/15, sheet thickness 2mm, and mineral wool bands of material class A according to DIN with a melting point of > 1000 C; 25mm thick Mounting with anchor bolts M6, a < 250 mm, min. 2 pcs. per side Have the first fastener of the duct arranged at < 100 mm clearance from the wall surface FLAMRO FKS Fire protection ducts Illustration wall/ceiling connection collar Direct mount to wall - collar 2-sided shaped State prior to fastening: Steel Z-profile 40/40/15.2 mm Mineral wool bands 25 mm thick Anchor bolts M6, a< 250 mm Duct insulation Wall connection collar 3-sided, duct direct installation (here, 2- sided duct) upright mounting State after fastening: Steel Z-profile 40/40/15.2 mm Mineral wool bands pressed together to 15mm Anchor bolts M6, a< 250 mm Duct insulation Wall connection collar section upper illustration prior to installation lower illustration after installation 7

8 4. Duct laying In the following you see two - often occurring - standard possibilities for installation. Hallway crossing: The duct installation starts at a wall using a wall connection collar or the motored in duct end. The duct element is either installed directly to the ceiling, at the side at the joist or as a suspended construction with threaded rods and U-profiles. After the first duct element has been installed further duct elements are placed up to the opposite wall. Here it is possible that an element must be shortened. The length of the fitting piece, which is required in this case, depends on the selected connection at the wall: - When using a wall connection collar the fitting piece is 15 mm shorter than the inside width to the wall. - Should the duct end be mortared in, then the depth of the duct to the inside dimension to the wall must be added (meaning about 50 mm). On several hallway crossings where the same duct cross section is used, a so-called loss free mounting can be done, since the cut off duct end (remaining piece) of the first hallway crossing starts with the second crossing. There, as many duct elements as required to reach the opposite wall are connected. Then a cut is usually required and using the cut off remaining piece, the third hallway crossing starts (meaning the principle of laying laminate). This means that at the end of the last hallway crossing a cut of remaining place remains. Mounting with a shaped part Here the duct installation starts with a shaped part. For better presentation the following installation situation will be outlined: Angle of 90 in two abutting walls (that is, a corner of the room), to which a duct is mounted horizontally. This means that the viewer would see when looking at the wall of the duct cover. The shaped part in the corner of the room would therefore be an inside corner (see illustration). This shaped part is now installed in both direction until the abutting walls are reached. There the duct elements are shortened as previously described. When using a T-piece proceed adequately. Here, the installation continues in three directions. 8

9 Cap: A so-called cap is used when a duct element ends in a room (e.g. during wall installation, if a cable exits the wall surface somewhere). Depending on the respective duct end and the respective duct design (using a sheet metal shackle/placing or without sheet metal shackle/placing) two different caps are available: - Cap start: Use at the duct end without sheet metal shackle/placing - Cap end: Use at the duct end with sheet metal shackle/placing The installation is done in the same manner as further duct elements, by bolting at the duct using sheet metal screws. Illustration: Front cap start, behind it the cap end. Mounting with several shaped parts: Here it must be decided on-site, which shaped part is used to start the duct installation. The objective is to not shorten the course of the duct itself but at the duct end (wall connection). When using several shaped parts the course of the duct is defined and in rare cases only the standard elements are enough. To better visualise the installed condition is shown: Imagine the hallway at which face side a wall is located. On both walls and the face side a duct should be installed. This means on the face side there is an inside corner at the left and right corner. The dimension between the two corners is defined as follows. In an ideal case one or two straight duct elements of 1200 mm (standard length) fit exactly in-between. However, in practice it often looks different. This means a duct element must be adjusted. The solution of this problem are two possibilities: Either the duct is shortened at the end without sheet metal shackle/placing and the stepped rabbet is recut (on ducts with mineral wool insulation), or a so-called element butt is used. An element butt allows a continuous kerf in the duct run, since the gap is covered with full insulating strength. The element butt is also covered with sheet cladding. The most elegant and installation friendly solution is however, a complete supply from FLAMRO, where all shaped parts and special parts are already accurately fitting early on. 9

10 Using a dimension diagram a course of the duct diagram can be prepared in which all duct elements are positions and the duct direction is already determined. Here, test certificate conforming special solutions can be designed and offered. This means that the installation time and installation costs are thereby significantly reduced. Thanks to the superior versatility of a FLAMRO FKS fire protection duct a solution for almost any application can be found. Different cross sections with reductions are possible on an I-duct of (inside dimensions wxh 0x0 mm to 1000x500 mm and stepless!) The design of a two-, three-, or four-sided duct is possible. Three-sided optionally with set but also removable cover. Illustration: Height offset Depending on the respective installation situation even exotic shaped parts can be produced test certificate conform (see illustration). Illustration: Special shaped part 5. Cable designs - Individual cable design Test certificate conform cables can be led from a FLAMRO FKS I-duct. For this purpose, grommets made of metal are flanged at one end using a union - mounting plates and bolted to the duct. (see illustration) These grommets are available with an outer diameter of 20 mm, 27 mm and 40 mm. Selectively also in separated design. The mounting plate is placed over the grommet and lead over the flange. Subsequently it is bolted with sheet metal screws to the duct bottom or the side walls. Now drilling is done through the grommet and the duct wall into the duct and a cable is inserted. For closing it off in a fire protected manner, the filler mass FLAMRO BMS or the filler kit FLAMRO BMK (available in 310 ml cartridges) is used. In total, only up to three grommets may be arranged next to each other as so-called groups. Here, the inside clearance between the neighbouring grommets must be at least as large as the diameter of the largest used grommet. The next group must have a minimum clearance of 750 mm to the first group. Here we like to refer you to Appendix 26 of the test certificate FLAMRO FKS I-duct. 10

11 The photo shows an individual or single cable strand in divided version, recognisable on the clip, which divides the two grommet halves. Here a single cable design at the duct end, meaning at the cap is shown. Should several lines, relative to a small room, be led out of the duct, then they can also be arranged on top of each other. This means that a duct with 100 mm inside height can have three grommets with a 20 mm outer diameter. (consider the inside distance of 20 m between two grommets. Three pieces of grommets at 20 mm plus two times the clearance at 20 mm results in 100 mm = inside duct height). - Cable bundle design Next to single cable designs cable bundles that are test certificate conform can also be used in a FKS I-duct. (compare appendix 25 of the test certificate FLAMRO FKS I-duct). This design is more complex than a single cable design and consists of a cover sheet that is screwed onto the duct bottom or the side wall and is manufactured individually. (size variable) In there is a calcium silicate frame that reaches through the duct wall up to the duct inner dimension. Within the calcium silicate frame is a mineral fibre plate (melting temperature > 1000 C), through which the cable is led analogous to a plate partition. On a single cable design the spandrels and hollow spaces are filled with FLAMRO BMS filler or FLAMRO BMK filler kit and the cable in front and behind the plate are coated 10 cm wide with the ablation coating FLAMRO BMA. (a pain brush suffices). 11

12 The illustration to the side shows that two next to each other placed cable bundle designs (here a branch of a T-piece) can be integrated in a cap. The about 10 cm coating of the cable with ablation coating FLAMRO BMA can be seen, which also reaches 10 cm into the duct. The ablation coating cools the cable coat in case of a fire and prevents spreading of fire and a non-permissible temperature rise. On the model photo it can be seen how the white calcium silicate frame reaches into the fire protection duct. From there, the cables are led outward though the mineral fibre mat inside. 6. Accessory/Accessory list Special accessories are available for the FLAMRO FKS fire protection cable ducts. For example, cable clamps, multi-function sheets, separating strips, etc.. More information can be found in the FLAMRO FKS accessory list. We recommend a multi-function sheet, which is available in the respective dimension for all standard sized FLAMRO fire protection cable ducts. These multifunction sheets are bolted directly with the duct to the wall and can also hold separating strips. The separating strips can be stabilised for a higher cable load using support brackets. (see photo) 12

13 7. Two-three-sided ducts On FLAMRO FKS fire protection ducts that are two- or three-sided the installation is done directly at the structure. The attaching holes in the duct are already provided. The use of this design version however, requires a level surface structure, meaning that it might be required prior to the duct installation to prime the wall and ceiling surfaces. Photo: FKS duct, 2-sided, folding design Photo: FKS duct, 3-sided, fitted cover, direct installation to wall, heigh offset and 135 corner FLAMRO FKS fire protection cable ducts can be used for just about any type of installation using the special solutions provided. For example, a cross section reduction in the duct run, as shown in the photo. It is furthermore possible to produce any length, large bending radii of cables can be made with multipart polygon corners (e.g., instead of a 90 corner three corner pieces with 150 ), etc. The range of variation have almost no limits. Since two-and three-sided ducts are not part of the standard program and are always made individually, they provide the widest variations that we can not be displayed here. Dated FLAMRO Brandschutz-Systeme GmbH Am Sportplatz Leiningen Phone: Fax: info@flamro.de 13