INSTALLATION MANUAL KOCH TECHNICAL SYSTEMS GROUP PRE-FAB ACOUSTICAL/THERMAL PANELS AND ENCLOSURES GEORGE KOCH SONS, LLC TECHNICAL SYSTEMS GROUP 10 South Eleventh Avenue Evansville, Indiana 47744 812-465-9600 1-800-264-5624 Revision Date 1/6/99
TABLE OF CONTENTS 1. INTRODUCTION 2. ORIENTATION TO THE KOCH PANELS 3. PREPARATION OF INSTALLATION AREA 4. ENCLOSURE ERECTION PROCEDURES 4.1. INSTALLING FLOOR CHANNEL 4.2. INSTALLING WALL PANELS 4.3. INSTALLING DOORS 4.4. INSTALLING INTERNAL SUPPORT STEEL 4.5. INSTALLING REMOVABLE PANELS 4.6. INSTALLING ROOF SUPPORT BEAM(S) 4.7. INSTALLING ROOF PANELS 4.8. INSTALLING ELECTRICAL WIRING AND CONDUIT 4.9. INSTALLING SLIDING DOORS 4.10. INSTALLING STANDING SEAM ROOF PANELS 5. INSTALLING AIR CONDITIONERS 5.1. WINDOW STYLE UNITS 5.2. SPLIT UNITS 6. INSTALLING AIR INTAKE/EXHAUST SILENCERS 6.1. NON-POWERED UNITS 6.2. POWERED UNITS 7. INSTALLING ACCESSORIES 8. PAINT TOUCH UP
INTRODUCTION SECTION 1.0 This manual along with assembly drawings and/or material list should serve as a guide for quick and easy field erection of KOCH pre-fab acoustical/thermal panels. Should there be a conflict between information in this manual and the data shown on the drawings, the drawings will take precedence. Both the manual and the drawings should be reviewed and understood prior to commencing with installation. When receiving your shipment, please compare what you have received to the bill of material list on the drawing or the shipping list to ensure you have received your complete order. Damaged or missing items should be reported at once to minimize delay of installation. If you should have any questions before or during installation or have any other customer service needs, please call the Panel Products Group at 1-800- 264-5624.
ORIENTATION TO THE KOCH PANELS SECTION 2.0 As you read and familiarize yourself with the following installation instructions you find the term gauge line used frequently. The following will describe and illustrate the term gauge line as it applies to KOCH pre-fab acoustical/thermal panels. From the above illustration, you will see that the gauge line is an imaginary line that is located one-half inch from either edge of the panel. Thus, the total width of any given panel is one inch wider than the designated gauge line. The exposed surface or effective surface when the panel is installed varies for each panel. In the case of a panel having one female edge and one male edge, this surface is equal to the gauge line, while in a double female edge the exposed surface is the full panel width or one inch more than the Gauge Line. The double male edged panels exposed surface is two inches less than the full panel width. Since a corner panel is basically a flat panel with a break, the above descriptions will apply equally for similar edge combinations. Should your enclosure be designed with windows, you will receive your panels already double-glazed with 1/4 thick glass of your specification.
PREPARATION OF INSTALLATION AREA SECTION 3.0 Area should be clean and free of all material that may interfere with the erection team. Check floor for flatness. If flatness in the area where floor channel will be installed is high or low in excess of 1/8, the area should be leveled with grout. If the enclosure is to be erected on a curb, verify curb dimensions with the enclosure drawing. Any irregularities should be corrected. Top of curb should be a minimum of 1/2 wider than the thickness of the panel to be installed. If curb is too narrow, add to the width.
ENCLOSURE ERECTION PROCEDURES SECTION 4.0 INSTALLING FLOOR CHANNEL SECTION 4.1 Layout the floor channel locations on area floor or curb and snap chalk lines for entire length of all walls. Use the overall outside enclosure dimensions located on the drawing. Check to assure that intersecting lines at all corners are square (90 apart). All floor channel corners should be mitered or coped in the field. Locate first length of floor channel along proper chalk line. On all enclosures, the floor channel will be a standard 120 long. Leave an open area in the floor channel for the doorway(s). For a 1 3/4 thk. acoustic door, the floor channel opening = 4 1/2 more than the door clear opening. For a full thickness (4 or 6 thk.) acoustic door, the floor channel opening = 11 1/4 more than the door clear opening. For an oven door, the floor channel opening = 12 1/4 more than the door clear opening. The floor channel has pre-punched holes for floor anchors. Once the floor channel is positioned in the proper place, use the pre-punched holes for templates and drill a 7/16 diameter by 2 long hole in the concrete floor or curb. If a 1/2 diameter anchor bolt is supplied, drill a 9/16 diameter by 2 1/2 long hole in the concrete. Caulk entire length of bottom of floor channel with two heavy beads of the supplied caulking. Make certain the floor channel is properly aligned and anchored securely in place. Using the drawing as a reference, mark the gauge line of the panels on the outside leg of the floor channel to act as a guide during panel installation. This will help to prevent over/under engagement of panels during installation. Caulk both the inside corners of floor channel heavily. Fill the floor channel with pre-cut strip insulation.
INSTALLING WALL PANELS SECTION 4.2 Start panel installation at a corner. Select the corner panel and caulk the female edge and install strip insulation in the male edge. Stand the panel upright inside the floor channel. Make sure the panel is plumb and secure with a temporary brace.
Should your enclosure be designed with built-up corners instead of corner panels, use the following procedures and illustration. Select the two panels that will form your corner. Caulk and install strip insulation as previously described. Stand one of the two corner panels up right inside the floor channel at the starting corner and secure with a temporary brace. Place the second corner panel inside the floor channel at 90 degrees to the first panel. With both panels now in place, make certain they are plumb and square. Proceed now to secure your corner by installing the inside and outside corner flashings. Prepare the Second wall panel by caulking inside the female edge and placing the pre-cut strip insulation inside the male edge. Stand the second panel upright inside the floor channel, tip it back, engage the bottom male corner then tip the panel forward to engage the panel full length. Following the procedure above, install additional panels. Check gauge line positions during installation. Periodically use a tape measure to check for over/under engagement of panels. Should your measurement indicate the dimension is shorter than specified, you may ease the installed panels apart until the proper dimension is reached or install additional panels with less engagement until the proper dimension is reached. See next page for more detail.
INSTALLING DOORS SECTION 4.3 Special attention should be given so that the frames remain plumb and square. Once the door leaf has been hung in the frame, some adjustment of the latches may be necessary. All acoustic doors should be installed progressively as if they are wall panels. On the 1 3/4 thk. acoustic door, it is best to leave the tie bar at the bottom of the door attached to keep the frame square. The acoustic door leafs can be easily removed from the doorframe to simplify installation. The full thickness acoustic doors (4 & 6 thk.) have a tie bar at the bottom. In most cases this should be removed. These doors have two anchor tabs on the inside bottom of the frame for anchoring to the floor.
The insulated door can be installed progressively during panel installation or after the wall panels are installed. The easiest method would be progressive installation. Should you choose to install last after the wall, the frame will need to be taken apart. See the illustration at the bottom of this page. The insulated door frame should be unbolted and separated into two halves. Each half should be installed respectively from the outside and inside of the already installed panel wall, then bolted back together.
INSTALLING INTERNAL SUPPORT STEEL SECTION 4.4 Internal columns are installed during installation of the panels and are swallowed inside the panel joint. Care must be taken to analyze the sequence of installation of the panel joints prior to beginning installation because the location of the internal steel may dictate which panels must be installed first. Internal columns may extend higher than the wall panels and have beams connected to the top, spanning across the enclosure. INSTALLING REMOVABLE PANELS SECTION 4.5 The removable panel system uses the existing floor channel at the bottom and a cap channel (with 2 1/2 legs) at the top. This cap channel will create a 1 1/2 open space above the removable panel. This will allow the panel to lift up into this space and then to be pulled outward from the bottom. If there is more than one removable panel, the panels will need to be installed in a certain order and removed in the reverse order of installation. These panels are shipped without the pull handles installed to prevent damage during shipping. The screw holes for the handles are pre-drilled in the panel and ready for attachment. See next page for more detail.
INSTALLING ROOF SUPPORT BEAM(S) SECTION 4.6 Place the 10-0 long saddle channel on top of the enclosure wall. The saddle channel will already have the two angle clips welded to it. Place the pre-coped beam between the clips and secure with the provided fasteners. Roof support beam(s) will span across the enclosure and act as a ledge for the roof panels to rest on.
INSTALLING ROOF PANELS SECTION 4.7 Roof panels will rest on the roof support beam or on the enclosure wall. Roof panels must be caulked, stuffed with insulation, and joined just like the wall panels. If the enclosure has an electrical conduit cavity, the 2 x 2 inside corner flashing should be installed prior to installing the roof panels to allow for additional support. After the roof panels are installed, check to make sure the walls are still plumb then secure the remaining flashing with sheet metal screws. All flashing is a standard 120 long. It may require field cutting to fit. As discussed in the next section, all electrical work should be completed prior to installing the outside corner flashing.
INSTALLING ELECTRICAL WIRING AND CONDUIT SECTION 4.8 All electrical conduit is supplied in 10 ft. lengths. All conduit parts necessary for complete installation are supplied by Koch. In most cases, the individual panels will be supplied with conduit and receptacle boxes already installed. The electrical wiring will require being pulled through the conduit by the installer. Use the supplied conduit connector parts to connect all conduit in the conduit cavity as shown in the following illustrations. 14 GA. wiring is the standard size supplied unless otherwise specified by the customer or when wiring for an air-conditioner unit. It is the customer s responsibility to insure all electrical work meets applicable national, state, and local codes.
INSTALLING SLIDING DOORS SECTION 4.9 The sliding doors can be installed after the enclosure walls and roof are complete. All the hardware needed to complete this installation is supplied by Koch. Before installing any sliding door hardware, the door opening in the enclosure should be finished with the supplied cap channel. You are now ready to install the structural angle to support the sliding door track. This angle should be located above the opening as shown on the drawing with the pre-drilled holes straddling the panel gauge line dimension locations. Mark the holes using the structural angle as a template. Drill 11/16 diameter holes completely through the thickness of the panel. Mount the structural angle on the exterior side of the wall. Mount the 1/4 thick back-up plate with pre-drilled holes on the interior side of the enclosure and secure with the provided fasteners. Next, mount the sliding door track brackets to the structural angle in the prepunched slots. Install the track into the track brackets. The sliding door leafs have pre-drilled and tapped holes ready for attaching the trolley trucks. Slide the door (trolley trucks) onto the sliding door track. Install the end caps onto the ends of the track to prevent the door from sliding off the track. Attach the stay roller to the floor as shown in the following illustrations or as shown on the drawings. Install the brush seals around the door opening, as noted on the drawing. Adjust doors as needed via the slot in the structural angle for horizontal adjustment or the jamb nut on the trolley truck for vertical adjustment.
INSTALLING STANDING SEAM ROOF PANELS SECTION 4.10 Install first standing seam panel at right edge of enclosure. The first standing seam panel may require trimming off the right side roll formed edge. Place the clip over the left side of the standing seam panel. Attach to the structure by either plug welding or with sheet metal screws. Place clips on approx. 4-0 centers. Place the next panel with the right side roll formed ridge over the top of the clip and previous standing seam panel. Continue this process until reaching the left side of the enclosure. The left edge of the last standing seam panel may need trimming off. Dimple each ridge every 24 with a button punch for a watertight seal.
INSTALLING AIR CONDITIONERS SECTION 5.0 WINDOW UNITS SECTION 5.1 Most window style units installed in Koch enclosures are installed in cutouts in the wall, not in a window opening. The wall cutout in most cases is pre-finished and ready for the A/C unit to be installed. Line the opening with some soft foam commonly used for window units prior to inserting the unit. Attach the supplied A/C support stand to the exterior side of the wall. Insert A/C unit. SPLIT DUCTLESS UNITS SECTION 5.2 The split style units consist of a fan coil unit and a condensing unit. The fan coil unit is installed on the inside of the enclosure on a specified panel, which has internal back-up steel for attaching the unit. Included in the packing box of this unit is a paper pattern used as a template and instructions for mounting this unit to the wall. A hole should be drilled or cut out for the hose connecting the fan coil and condensing units. The hole size and location are also specified on the paper pattern and instructions. The condensing unit is located on the exterior of the enclosure. It can be located on the floor, or if properly supported, on the enclosure roof. This cannot be done unless the roof is designed to withstand the load of the unit. INSTALLING AIR INTAKE/EXHAUST SILENCERS SECTION 6.0 NON-POWERED UNITS SECTION 6.1 This unit has a shoe box style lid that is attached with Tek screws. Remove this lid and attach the remaining unit in place over the supplied cutouts in the enclosure wall. Use the supplied Tek screws for attaching. Glue the supplied duct board in place to the enclosure wall. Cut out an opening in the duct board using the existing wall cutout as a template. Screw the silencer lid back on the silencer. Attach the supplied air vent grilles or bird screen covers to the openings.
POWERED UNITS SECTION 6.2 This unit is most commonly installed on the roof of the enclosure. Place the unit over the existing roof cutout. Secure the unit with the supplied 2 x 2 inside corner flashing. Connect the electrical wires to the enclosure electrical system.
INSTALLING ACCESSORIES SECTION 7.0
All supplied accessories (louvered vent covers, lights, receptacles, switches, etc.) are all standard type parts and are easily installed using standard construction methods. PAINT TOUCH UP SECTION 8.0 If your enclosure is painted Precision Tan, a Precision Tan Aerosol Can will be supplied for easy touch ups. If your enclosure is painted any color other than Precision Tan, a Preval Power Spray Unit and three different 1 QT. cans of Sherwin Williams Polane- T paint, catalyst, and reducer will be supplied. The paint, catalyst and reducer should be mixed together with a mix ratio of 64% paint, 11% catalyst, and 25% reducer. Pour the mixture into the Spray Unit bottle for paint touch ups.