ROBERTSON "3 + 1" SLAB-ON-GRADE SINGLE LEVEL RACEWAY SYSTEM (Revised July 2000) PART 1 - GENERAL 1.01 SCOPE Furnish complete electrical distribution system including: Cellular deck units, trench headers, junction boxes, preset outlet boxes, grommets, butt joint tape risers, and preset outlet box activation assemblies. 1.02 QUALITY ASSURANCE A. This specification establishes the minimum quality of required function, dimension and appearance to be met by any proposed substitution. B. The manufacturer and erector shall demonstrate a minimum of five years experience with UL 209 electrified floor systems on similar sized projects. 1.03 SUBSTITUTIONS A. The materials, products, and equipment specified in this section establish a minimum standard of quality and required function, dimension, and appearance to be met by any proposed substitution. B. No substitutions will be considered unless written request for approval has been submitted by the bidder and has been received by the Architect at least twenty (20) days prior to the date for receipt of bids. C. Each such request shall include the name of all items to be substituted with appropriate catalogs and a complete description of the proposed substitute including drawings, cross-sections, a full-scale prototype assembly, performance and test data, code compliance data, and other information necessary for a total evaluation. D. All approved substitutes will be named in an addendum issued ten (10) days prior to bid date. E. Systems that have no activated preset adjustment shall have adjustable supports. 1.04 SUBMITTALS AFTER AWARD OF CONTRACT: A. Manufacturer's specifications and installation instructions for each product specified shall be submitted for approval. Included shall be a notarized manufacturer's certification required to show compliance with these specifications. Also prior to product shipment, a copy of each installation instruction shall be distributed to the installer with a copy of transmittal submitted to show compliance. B. Shop Drawings 1. Detailed drawings showing location of feeder and distribution cells, outlet boxes, closers, accessories, and details shall be submitted. 2. Schedule of field welding shall be submitted. C. The following listed samples shall be submitted as applicable: (1) Multi-Service Outlet Box mounted on one foot sample cellular raceway complete with fully grommetted pre-punched holes, illustrating all finish hardware and internal parts. (2) Two foot length of selected width trench header with factory assembled cover, tile stops, side rails, latch clips, adjustable compartment dividers, and fasteners.
OR (3) Complete junction box with factory assembled cover, tile stops, side rails, latch clips and adjustable compartment dividers. PART 2 - PRODUCTS 2.01 CELLULAR FLOOR DISTRIBUTION Material: A. Cellular floor units and trench header shall conform as electrical raceways to the requirements of UL 209. B. Deck unit gauges shall be minimum 20/20 gauge for cellular units. C. Floor unit cells shall have a minimum capacity of 16 in. 2 each for telephone and data and 5.5 in. 2 for the power. D. Cellular units with immediately adjacent cells separated only by steel dividers (no concrete separation between cells) will be acceptable only when provided with cell separators at each butt joint nested within the cells to assure against wire or fish tape crossover. 2.02 TRENCH HEADER (if utilized) A. Trench Header shall be a UL labeled, full bottomless type equal to full slab depth. Note: A concrete sidewalk 8" wider than the trench header is required for support. B. Removable Covers shall conform to UL 209 for minimum thickness of roller leveled steel after shearing for size. C. Covers shall be secured by mechanical latching devices without any exposed surface fasteners. Direct screw fastening of the covers to the side rail is not acceptable. D. Factory Assembled Cover with Side Rails shall be adjustable. E. Five square inches of keying surface of side rail to concrete per lineal inch of side rail shall be provided. Three inch minimum alignment key extrusion with a one and one half inch minimum alignment surface at each side rail shall be provided. F. Covers shall be painted by a dip process to achieve an air dried thickness of 1 Mil. G. Cell Access shall be a minimum of 16 in. 2 for each low voltage service and 5.5 in. 2 for power. H. Power wire compartments shall conform to UL 209, with a minimum steel thickness of 0.054" with vertically adjustable dividers, one each side, provided with a 1/2" wide top flange bearing surface to support the cover plate. A locking nut device for precise height adjustment and readjustment through service life shall be provided (to eliminate rattling). Welded partitions are not acceptable. Manufacturer shall provide test data to show the adequacy of the locking nut device to support a 500# concentrated load without significant vertical slip. Welding of adjustable dividers to provide cover support will not be permitted. I. Cover Plate Load Capacity: Trench cover plate and power compartment/side rail supports must withstand a static concentrated loading of 500# and meet UL 209 requirements.
Note: Where higher concentrated load capacities are required, the manufacturer shall provide test data showing the capability of the cover plates of a trench header to satisfactorily carry a concentrated static load. 2.02 CELL FEED AND JUNCTION BOX (if utilized) A. Junction Box shall be UL labeled, running full slab depth to maximize capacity. B. Removable Covers shall conform to UL 209 for minimum thickness of roller leveled steel after shearing for size. C. Covers shall be secured by mechanical latching devices without any exposed surface fasteners). Direct screw fastening of the cover to the side rails is not acceptable. D. Factory Assembled Cover Assemblies with Side Rails shall be adjustable. E. Five square inches of keying surface of side rail to concrete per lineal inch of side rail shall be provided. Anchoring clips and studs as keying device substitutes are not acceptable. Side rail shall be nominally 1/8" thick and providing 3/8" flat width at the screed level to finish a stop and for seating floor tile respectively. Three inch minimum alignment key extrusion with a one and one half inch minimum alignment surface at each side rail shall be provided. F. Covers shall be painted by a dip process to a minimum dry thickness of 1 mil. G. Distribution Cell Access from the junction box shall be a minimum of 16 in. 2 for each low voltage service and 5.5 in. 2 for power. H. Power wire compartments shall conform to UL 209, with a minimum steel thickness of 0.054" with vertically adjustable dividers, one each side, provided with a 1/2" wide top flange bearing surface to support the cover plate. A locking nut device for precise height adjustment and readjustment through service life shall be provided (to eliminate rattling). Welded partitions are unacceptable. Manufacturer shall provide test data to show the adequacy of the locking nut device to support a 500# concentrated load without significant vertical slip. Welding of adjustable dividers to provide cover support will not be permitted. I. Junction Box interconnections between telephone and data compartments shall be bushed and/or curved edged. Minimum area for interconnection shall be 15 sq. inches. J. Cover Plate Load Capacity: Junction Box cover plate and power compartment/side rail supports must withstand a static concentrated loading of 500# and meet UL 209 requirements. Note: Where higher concentrated load capacities are required, the manufacturer shall provide test data showing the capability of the cover plates of a junction box to satisfactorily carry a concentrated static load. 2.03 PRESET OUTLET BOXES A. Preset outlet box shall be UL labeled and shall be three-service type. B. All openings into the box shall be factory punched. Openings in webs of telephone and 3
special service or data cells shall be 1-1/2" x 3-3/4" obround in each cell (minimum 4.57 square inch area after complete grommetting with snap-in grommet is applied). Opening in top flange of power cell shall be 1-3/4" diameter round (minimum 1.75 square inch area after complete grommetting with snap-in grommet is applied). One-piece, preformed, rigid nylon, snap-in grommets shall be provided and shall firmly fit into wire egress holes and shall completely grommet the opening perimeter. No metal edge shall be exposed at any wire egress opening. Flexible, unformed, stick grommets are not acceptable. No partial grommetting or exposed edges of any kind or to any degree are acceptable. C. Preset outlet box shall be one piece integral formed steel body (sides, ends, and top), 4-1/2" wide by 9-1/8" long with a nominal 4" x 7" (28 sq. inch minimum) top entry opening into box body. Top of box shall include a factory screw attached break out cover (0.027" minimum thick steel) coated with a concrete release agent. The "break out" cover on the box shall be designed to be a maximum depth of 5/8" for ease of concrete removal. D. Box Body shall be one piece construction, minimum 18 gauge, zinc-coated steel, provided with stiffeners to prevent collapse during construction operations. Box shall be field riveted using shop-punched holes in box and cellular deck. Boxes less than 18 gauge thickness must have auxiliary grounding strap screwed or welded to the deck and the outlet box. Preset placement by snap locking shall not in any way incorporate the punched cell openings dedicated to wire egress into the preset. Preset placement by snap locking shall not interfere in any way with low voltage grommets to protect wires. Boxes less than 18 gauge thickness must have auxiliary grounding strap screwed or welded to the deck and the outlet box. E. All preset outlets shall be provided with two 3/4" knock-outs (one in each long side adjacent to power cell) for conduit connection as required. F. Box shall have a minimum interior volume of 109 cu. in. 2.04 PRESET OUTLET BOX ACTIVATION ASSEMBLIES A. Activation assemblies shall consist of cover assembly, electrical brackets and partitions, grommets, and hardware. High and low voltage connectors shall not be part of the activation kit. Box activation shall consist of hardware for either concealed (all connectors and fittings below the finished floor surface) or flush mounted. All removable activation cover plates shall be provided with a locking mechanism. A lab report confirming this performance shall accompany submittal as proof of conformance. Friction fit type latching is expressly prohibited. Activation options shall be provided as follows: (select as required) 1. Easy Access Deluxe - One or two 15 or 20 amp duplex receptacles plus a single duplex modular telephone plate, plus a data interconnect plate. 4
2. Concealed Sloped - One or two 15 or 20 amp duplex receptacles, plus a single duplex modular telephone plate, plus a data interconnect plate. 3. Easy Access Standard - One flush surface mounted plus one or two in-cavity 15 or 20 amp duplex receptacle plus a single duplex modular telephone plate, plus a data interconnect plate. Other options include one 250 volt, or one 30 amp, or one twist-lock surface mounted receptacle. 4. Wired Partition Interface - a. High Voltage - Cover plate shall accept a conduit pass through. The preset outlet box shall contain a power connect/work box which accepts a partition flexible power whip, a flexible conduit, or hard wiring. b. Low Voltage - Cover shall be removable and separate from high voltage cover plate. Furnish single modular duplex telephone plate, plus a data interconnect plate. Complete separation of power and low voltage wires shall be maintained. 5. Above the Floor Multi-Service Outlet - One 15 or 20 amp duplex receptacle, plus one low voltage outlet above the floor; plus another low voltage outlet in the box cavity. B. Activations shall be available and be interchangeable within all the preset outlet boxes. All multiple duplex power activations shall incorporate receptacle placement immediately adjacent to one another (be ganged together) within the preset outlet box. C. Activation Cover Assemblies 1. Easy Access Deluxe - Lexan (KED-NAC) shall consist of a flange ring and cover with egress shield. This shield shall be designed to contain multiple grommetted individual ports to separate, shield, and protect wires against crimping and damage. This shield shall be totally self abandoning and permanently attached to the activation cover so it cannot be lost. Detachable wire egress blocks are not acceptable. Flange and cover shall be available in any color to blend aesthetically with surroundings. Flange and cover shall be manufactured from structural Lexan and shall be capable of sustaining an ultimate static point load of 800 pounds through a one inch mandrel. The test assembly shall simulate the activated flange and cover to check for flexural and shear loading. A lab report confirming this performance shall accompany submittal as proof of conformance. Cover shall be designed with a recessed area to accept a carpet insert. Cover shall be detachable and re-attachable in either direction on the flange ring. Field notched wire egress holes in the cover or on the flange ring are expressly prohibited. Lexan cover shall accommodate Easy Access Deluxe or Concealed Sloped Activation Assemblies. 2. Easy Access Deluxe - Aluminum (KED-MC) shall consist of a flange ring and cover with wire egress ports. Cover shall be totally self abandoning with aluminum blocks stored on the underside of the activation lid with velcro tabs during 5
activation. Aluminum finish shall be available in factory brushed and anodized finish. Aluminum flange ring and cover shall be made of machined plate. Cast aluminum parts shall not be used to insure adequate structural capacity. Flange and cover shall be capable of sustaining an ultimate static point load of 1500 pounds through a one inch mandrel. The test assembly shall simulate the activated flange and cover to check for flexural and shear loading. A lab report confirming this performance shall accompany submittal as proof of conformance. Cover shall be designed with a recessed area to accept a carpet insert so that fraying of carpet edges is eliminated and visual impact is minimized. Cover shall be detachable and re-attachable in either direction on the support ring. Field notched wire egress holes in the cover or on the flange ring are expressly prohibited. Aluminum cover shall accommodate Easy Access Deluxe and Concealed Sloped Activation Assemblies. 3. Concealed - Valox (KEC-PC-3, 4, 5) shall consist of a three-piece assembly consisting of a screw attached center, a hinged power and telephone cover, and a removable data cover. Wires shall exit from connections recessed below the carpet through field notched openings in the cover and through carpet cuts as required. 4. Easy Access Standard - Valox (KEC-PC-5, 7, 8, 12) shall consist of a multiple piece cover assembly comprising of a screw attached center frame with two removable doors to accommodate a flush receptacle, and two removable under the carpet telephone and data covers. Wires shall exit from connections recessed below the carpet through field notched openings in the covers and through carpet cuts as required. 5. Wired Partition Interface - Valox (KEC-PC-5, 6) shall consist of a screw attached center power cover, plus two removable telephone and data covers. The cover assembly shall be concealed by the carpet to blend aesthetically with surroundings; only the fittings and conduit shall be exposed. 6. Above The Floor Multi-Service Outlet shall consist of a two piece extruded brushed aluminum head, plus one removable Valox cover for either telephone or data. D. Activation Assembly Selection The quantity of initial activations during fit-out to be installed at "move in" shall be: Activation Option (select as required): ( ) Easy Access Deluxe Lexan Cover With Concealed Sloped Activation ( ) Easy Access Deluxe Aluminum Cover With Concealed Sloped Activation ( ) Concealed Valox Cover With Concealed Sloped Activation ( ) Easy Access Standard - Valox ( ) Easy Access Standard Activation ( ) 250 Volt Simplex/Duplex 6
( ) 30 Amp Simplex/Duplex ( ) Twist Lock Receptacle ( ) Wired Partition Interface - Valox ( ) Above The Floor Multi-Service Outlet PART 3: INSTALLATION 3.01 CELLULAR FLOOR UNITS Install steel floor units and accessories in accordance with the manufacturer's final approved erection drawings and the manufacturer's floor deck installation manual. A. Installing Cellular Units Cellular units shall be placed and adjusted to final position with accurate alignment at the butt joint before permanent fastening. Cellular units shall be laid out and fastened in strict accordance with the erection drawings. Weld cellular units to grounding plates at each butt joint. Avoid excessive damage to cellular units prior to or during the construction phrase can significantly reduce capacity and create a hazardous condition for workers. B. All deck cells shall be kept clear and free of debris to ensure proper wire passage. C. Concrete containing chlorides from any source shall not be placed on galvanized deck, trench, or activation units. 3.02 TRENCH HEADER OR JUNCTION INSTALLATION Trench header or junction boxes (if utilized) shall be installed in accordance with the manufacturer's approved electrical installation drawings and the manufacturer's electrical components installation manual. A. Bottomless Trench Header/Junction Box Header 1. All factory punched openings shall be completely bushed with snap-in grommets. 2. Trench header assembly or junction box and side flute closures shall be fastened to intersecting cells per manufacturer's standards and installation instructions. 3. Cover assembly shall be leveled using screw adjustment prior to concrete placement. Leveling after concrete pour is not required. 4. Trench header or junction box shall be set at screed height. Contractor placing the floor fill shall carefully hand finish a minimum of 24" adjacent to trench header or junction box, so that top of fill and trench header are flush after concrete has set. 5. Vinyl edging shall be flush with adjacent screed strip and cover during installation. Where floor finish is carpet, the edging strip shall remain in the flush position. 6. After concrete pour and prior to wiring, adjustable dividers shall be raised to correct level and secured with lock washer and bolt and nut assembly to provide positive support for the header cover. Welding of adjustable dividers is not permitted. 7. Latch clips shall be used to detach and reattach cover plates to side rail assembly for ease of access. Direct attachment of cover plates to side rail assembly with screws or other devices is prohibited. 7
8. Two cover lifting devices shall be delivered to owner for maintenance. 3.03 PRESET OUTLET BOX INSTALLATION 1. Permanent concrete release agent shall be applied both to the inside and outside of entry cap, if not already shop applied. Install outlet boxes to cover all factory punched holes using pop rivets. 2. Preset placement shall not in any way incorporate the punched cell openings dedicated to wire egress into the presets. Preset placement by snap locking shall not interfere in any way with low voltage grommets to protect wires. 3. An electronic multi-service box locator shall be supplied to the owner for maintenance purposes. 3.04 ACTIVATION ASSEMBLIES Installation shall be in accordance with manufacturer's installation instructions and shop drawings. Miscellaneous 1. Self-adhesive tape shall be applied over all butt joints of cellular units. 2. All connections shall be completed using components of the system as indicated on drawings including, but not limited to, cell feeds and pull boxes. Openings for cell feeds and pull boxes shall be field cut in closet areas as required. 3. Risers are installed under the electrical section of these specifications. NOTE: These items should be included under the general or special conditions and are to be the responsibility of the General Contractor. They should be cross referenced in this specification. 1. "Protection of Electrical Floor System Trench Header: Equipment and heavy traffic shall not be allowed over trench headers during the entire construction period without first installing ramps over the trench headers. Project shall be constructed to accommodate imposed loads without transferring the loads to the trench headers. Bent, warped, or damaged cover plates or other components of the trench header system shall be replaced at no expense to the owner or Robertson." 2. "Concrete used over galvanized steel components of the cellular floor system shall not under any circumstances contain chlorides from any source." 8
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"3 + 1" INSTALLATION INSTRUCTIONS * Layout trench units or feeder cells with junction boxes per the approved electrical installation drawings and manufacturer's electrical components manual. * Layout cells per the approved electrical installation drawings and manufacturer's electrical components manual. * Adjust units for final alignment from the trench duct or junction boxes and fasten to mud slab or other construction surface with straps supplied by others as required. * Trench or junction box adjustment shall be completed so that cover plate assembly is at slab screed line. Hand finish concrete adjacent to trench duct sides or junction boxes side rails to ensure flush finish. * Keep all deck cells clear and free of debris to ensure proper wire passage. * Secure preset outlet boxes with two pop rivets at the holes provided through the box into the cell. * Apply self-adhesive tape over all abutting end joints of cellular units. * Risers are installed under the electrical section of these specifications. * Concrete containing chlorides from any source shall not be placed on galvanized deck, trench, or activation units. * After concrete pour and prior to wiring, raise the adjustable dividers of the power tray to correct level and secure with lock washer and bolt and nut assembly to provide positive support for the trench header or junction box cover. 10