shopfloor cloudwall how to install
ASSEMBLY GUIDE
CloudWall™ Assembly Manual
© 2014 Zahner® — All rights reserved.
General Installation Guidelines • Read all instructions before starting the installation process. • Installers are advised to wear gloves when handling metal. Safety procautions should be taken when installing pieces that require the installer being off level ground. • We do not specify a particular torque for bolts, but each bolt should be “Snug Tight” to ensure that the connections are fully seated and will not loosen due to vibration. “The 2004 RCSC Specification defines a snug-tightened joint as a joint in which the bolts have been installed in accordance with Section 8.1.”
Note that no specific level of installed tension is required to achieve this condition, which is commonly attained after a few impacts of an impact wrench or the full effort of an ironworker with an ordinary spud wrench.
CloudWall Layout • Before assembling the CloudWall it is advisable to layout all of the pieces, checking that all of the parts are present. Layout the pieces in order to have to have a complete understanding of the pieces final locations. The CloudWall should be assembled from left to right if possible, with the boomerangs being attached in a left-to-right and bottomto-top pattern.
Row C
Row B
Row A
• The fins and drop-lock panels will be labeled according to a standardized naming system. All rows will be ordered alphabetically, all columns will be numeric, Figure 3.1. Ex. “Panel 4C” is located in the fourth cloumn and third row.
1
2
3
4
5
Figure 3.1
• The boomerangs will be labeled according to an elaboration of the same system, which is outlined on installing the boomerangs (p.15).
3
COMPONENTS AND FASTENERS
5
CloudWall™ Assembly Manual
Components
*Building not included
COMPONENT C Vertical Wall Mount Extrusion
COMPONENT D Boomerang COMPONENT B Drop-Lock Panel
COMPONENT E Boomerang Lateral Stabilizer
COMPONENT A Fin Assembly © 2014 Zahner® — All rights reserved.
COMPONENT F Boomerang End Connector
Parts & Installation Tools (actual size)
(actual size)
PART G 316 Stainless Steel Round Head Carriage Bolt 5/16”-18 x 3/4” USE: boomerang connections
PART H 316 Stainless Steel Hex Head Cap Screw 5/16”-18 x 3” Partially Threaded (7/8” - 1 3/16”) USE: fin pivot point connection
(actual size)
(actual size)
PART J T-3 Zinc Coated Steel Drilling Screw 12-14 x 3/4” USE: vertical structure and fin attachment
PART K 316 Stainless Steel Hex Nut 5/16”-18 Thread, 1/2” Width USE: boomerang and pivot connections
(actual size)
PART L 316 Stainless Steel Flat Washer 5/16” USE: boomerang and pivot connections
TOOL M Storypole USE: vertical structure allignment 7
ASSEMBLY: STEP BY STEP
9
CloudWall™ Assembly Manual
Preparing Wall for Installation Furring Strips
Non-Furring Strips
Figure 10.1
• There are two primary surfaces that CloudWall can be attached to: framed structures and monolithic structures. In most cases furring strips will be required to securely attach CloudWall to the building. • The second option is to attach the vertical supports (Component C) directly to the monolithic structure.
Alternative Ferring Strips
Figure 10.2
• The installer is responsible for providing the fasteners for attaching the vertical supports to either the furring strips or monolithic wall, unless previous arrangements have been made with Zahner. w • There must be a furring strip at the upper extent of the wall for both furring and non-furring walls, as shown in Figures 10.1 and 10.2. Note that Zahner does not provide furring strips, but requires that they be attached a maximum of 24” O.C. Note that having furring strips enables CloudWall to be attached over preexisting elements see Figure 10.3. • Attach the vertical supports (Component C) to the furring strips (Figure 11.1) or directly to the monolithic wall (Figure 11.2) using either included tek screws (Part J) for the framed wall (Section 11.3) or non-included concrete screws (Section 11.4).
Figure 10.3
CloudWall is able to cover ventilation and various opening that exist on the installation plane. When accommodating existing surface features extra furring strips must be added to provide adequate support, as shown in Figure 10.3. © 2014 Zahner® — All rights reserved.
• The vertical supports should be attached at every furring strip or at a maximum of 24” O.C. if attaching directly to the surface. • Attach the first vertical support, making sure to check for level. Proced to attach the following vertical supports, using the story pole (Tool M) to check for proper allignment between with the first installed support. Repeat this process for the remaining vertical supports.
Attaching Vertical Extrusions Furring Strips
Non-Furring Strips
C
C
Figure 11.1
Figure 11.2
3
1 4 2
J
5
C Section 11.3
J C 1 2 3
C Section 11.4
tek screw (Part J) - included
C vertical support (Component C) - included
vertical support (Component C) - included
4 monolithic wall - building not included 5 concrete screw - not included
substrate - building not included furring - not included stud framing - building not included
11
CloudWall™ Assembly Manual
Installing Fins
C
L K A
J A Figure 12.2
C
• If there is a tolerance of at least 3”, then the fin assemblies (Component A) can be bolted on at the bottom of the vertical support (Component C). This allows the fins to be correctly aligned and rotated into place, as seen in Figure 12.1. • Use the following components to create the pivot point, as illustrated in Figure 12.2: •3” hex head cap screw (Component H) • washer (Component L) • hex nut (Component K) Note that the tolerance is necessary to accommodate the turning radius of the fin assembly.
• Install the fin assemblies (Component A) to the previously installed vertical supports. Install the fins from left to right, completely finishing one fin before moving to the next.
© 2014 Zahner® — All rights reserved.
Figure 12.1
A
Figure 13.2
J
Figure 13.3 Figure 13.1
• After rotating the fin assembly into position, attach the fin to the vertical support with Tek Screws (Part J) at 12” O.C. as shown in Figure 13.1. • The fin assemblies have pilot holes at drill points on both sides of the fin as shown in Figure 13.3. Repeat process until all fin assemblies are installed, Figure 13.2.
13
CloudWall™ Assembly Manual
Installing Drop-Lock Panels Drop ‘n’ Lock
B
Figure 14.2
B
B
Figure 14.3
•To install the drop-lock panels, first allign all lock tabs with their associated slots in the fin assemblies (Component A). Making sure that all tabs are fully within the slot, Figure 14.2. Secondly, allow the panels to slide down in the slot; gravity locking the tabs in place, Figure 14.3.
B
Figure 14.1
• Once all of the fins have been installed, begin infilling with drop-lock panels (Component B). The panels should be installed by column, starting with Column 1 and moving to the right. The drop-lock range of motion requires that the panel be installed from bottom to top, as illustrated in Figure 14.1. © 2014 Zahner® — All rights reserved.
Lateral ‘Boomerang’ Supports Information The lateral ‘boomerang’ supports provide a dynamic solution for transferring lateral loads through the CloudWall, such as wind loads. • Before attaching the boomerangs (Component D) to the fins, first layout all of the boomerangs. Each boomerang is a custom shape, and has a specific placement within the CloudWall. Therefore, each boomerang is labeled with its position according to the naming system outline on (p.1):
1A - L
D
COLUMN
ROW
SIDE (L) Left or (R) Right
• The naming system is intended to be hidden on the inside (touching) faces of the two boomerangs that make up a pair. The name of the left boomerang will be upward facing, and the name of the right boomerang will be downward facing as shown in Figure 15.1. Figure 15.1
Fastener Set
Secure boomerang connections using: • 3/4” carriage bolt (Component G) • washer (Component L) • hex nut (Component K)
G
L K Figure 15.2
15
CloudWall™ Assembly Manual
Installing Lateral ‘Boomerang’ Supports
D
E D Figure 16.1
Figure 16.2
Step 1 Step 2 Insert the left boomerang (Component D) into the slots To attach the first boomerang to the fin, thread in the left fin of the column the boomerang is located in, a stabilizer (Component E) to the top face of the boomerang legs that stick through the fin using the as shown in Figure 16.1. The boomerang name will be standard fastener set. facing upwards.
D D
Figure 16.3
Step 3 Attach the right boomerang of the set to the left boomerang. The boomerang name will be facing downwards, subsequently hiding it from view when attached, as shown in Figure 16.3.
D
Figure 16.5
Step 5 Connect the internal boomerangs using the standard fastener set. Continue this process for the entire row before moving to the next row. © 2014 Zahner® — All rights reserved.
Figure 16.4
Step 4 Insert the left boomerang for the second bay, continuing the attachment pattern of Left-Right-Left etc. Note that the left boomerang will always sit below the right boomerang.
F
Figure 16.6
End Connection Use the end connectors (Component F) to connect the right-most boomerang to the last fin, using the standard fastener set. Note that the end connectors will sit below the right boomerang.
Notes
17
CloudWall™ Assembly Manual
© 2014 Zahner® — All rights reserved.
General Installation Guidelines • Read all instructions before starting the installation process. • Installers are advised to wear gloves when handling metal. Safety procautions should be taken when installing pieces that require the installer being off level ground. • We do not specify a particular torque for bolts, but each bolt should be “Snug Tight” to ensure that the connections are fully seated and will not loosen due to vibration. “The 2004 RCSC Specification defines a snug-tightened joint as a joint in which the bolts have been installed in accordance with Section 8.1.”
Note that no specific level of installed tension is required to achieve this condition, which is commonly attained after a few impacts of an impact wrench or the full effort of an ironworker with an ordinary spud wrench.
CloudWall Layout • Before assembling the CloudWall it is advisable to layout all of the pieces, checking that all of the parts are present. Layout the pieces in order to have to have a complete understanding of the pieces final locations. The CloudWall should be assembled from left to right if possible, with the boomerangs being attached in a left-to-right and bottomto-top pattern.
Row C
Row B
Row A
• The fins and drop-lock panels will be labeled according to a standardized naming system. All rows will be ordered alphabetically, all columns will be numeric, Figure 3.1. Ex. “Panel 4C” is located in the fourth cloumn and third row.
1
2
3
4
5
Figure 3.1
• The boomerangs will be labeled according to an elaboration of the same system, which is outlined on installing the boomerangs (p.15).
3
COMPONENTS AND FASTENERS
5
CloudWall™ Assembly Manual
Components
*Building not included
COMPONENT C Vertical Wall Mount Extrusion
COMPONENT D Boomerang COMPONENT B Drop-Lock Panel
COMPONENT E Boomerang Lateral Stabilizer
COMPONENT A Fin Assembly © 2014 Zahner® — All rights reserved.
COMPONENT F Boomerang End Connector
Parts & Installation Tools (actual size)
(actual size)
PART G 316 Stainless Steel Round Head Carriage Bolt 5/16”-18 x 3/4” USE: boomerang connections
PART H 316 Stainless Steel Hex Head Cap Screw 5/16”-18 x 3” Partially Threaded (7/8” - 1 3/16”) USE: fin pivot point connection
(actual size)
(actual size)
PART J T-3 Zinc Coated Steel Drilling Screw 12-14 x 3/4” USE: vertical structure and fin attachment
PART K 316 Stainless Steel Hex Nut 5/16”-18 Thread, 1/2” Width USE: boomerang and pivot connections
(actual size)
PART L 316 Stainless Steel Flat Washer 5/16” USE: boomerang and pivot connections
TOOL M Storypole USE: vertical structure allignment 7
ASSEMBLY: STEP BY STEP
9
CloudWall™ Assembly Manual
Preparing Wall for Installation Furring Strips
Non-Furring Strips
Figure 10.1
• There are two primary surfaces that CloudWall can be attached to: framed structures and monolithic structures. In most cases furring strips will be required to securely attach CloudWall to the building. • The second option is to attach the vertical supports (Component C) directly to the monolithic structure.
Alternative Ferring Strips
Figure 10.2
• The installer is responsible for providing the fasteners for attaching the vertical supports to either the furring strips or monolithic wall, unless previous arrangements have been made with Zahner. w • There must be a furring strip at the upper extent of the wall for both furring and non-furring walls, as shown in Figures 10.1 and 10.2. Note that Zahner does not provide furring strips, but requires that they be attached a maximum of 24” O.C. Note that having furring strips enables CloudWall to be attached over preexisting elements see Figure 10.3. • Attach the vertical supports (Component C) to the furring strips (Figure 11.1) or directly to the monolithic wall (Figure 11.2) using either included tek screws (Part J) for the framed wall (Section 11.3) or non-included concrete screws (Section 11.4).
Figure 10.3
CloudWall is able to cover ventilation and various opening that exist on the installation plane. When accommodating existing surface features extra furring strips must be added to provide adequate support, as shown in Figure 10.3. © 2014 Zahner® — All rights reserved.
• The vertical supports should be attached at every furring strip or at a maximum of 24” O.C. if attaching directly to the surface. • Attach the first vertical support, making sure to check for level. Proced to attach the following vertical supports, using the story pole (Tool M) to check for proper allignment between with the first installed support. Repeat this process for the remaining vertical supports.
Attaching Vertical Extrusions Furring Strips
Non-Furring Strips
C
C
Figure 11.1
Figure 11.2
3
1 4 2
J
5
C Section 11.3
J C 1 2 3
C Section 11.4
tek screw (Part J) - included
C vertical support (Component C) - included
vertical support (Component C) - included
4 monolithic wall - building not included 5 concrete screw - not included
substrate - building not included furring - not included stud framing - building not included
11
CloudWall™ Assembly Manual
Installing Fins
C
L K A
J A Figure 12.2
C
• If there is a tolerance of at least 3”, then the fin assemblies (Component A) can be bolted on at the bottom of the vertical support (Component C). This allows the fins to be correctly aligned and rotated into place, as seen in Figure 12.1. • Use the following components to create the pivot point, as illustrated in Figure 12.2: •3” hex head cap screw (Component H) • washer (Component L) • hex nut (Component K) Note that the tolerance is necessary to accommodate the turning radius of the fin assembly.
• Install the fin assemblies (Component A) to the previously installed vertical supports. Install the fins from left to right, completely finishing one fin before moving to the next.
© 2014 Zahner® — All rights reserved.
Figure 12.1
A
Figure 13.2
J
Figure 13.3 Figure 13.1
• After rotating the fin assembly into position, attach the fin to the vertical support with Tek Screws (Part J) at 12” O.C. as shown in Figure 13.1. • The fin assemblies have pilot holes at drill points on both sides of the fin as shown in Figure 13.3. Repeat process until all fin assemblies are installed, Figure 13.2.
13
CloudWall™ Assembly Manual
Installing Drop-Lock Panels Drop ‘n’ Lock
B
Figure 14.2
B
B
Figure 14.3
•To install the drop-lock panels, first allign all lock tabs with their associated slots in the fin assemblies (Component A). Making sure that all tabs are fully within the slot, Figure 14.2. Secondly, allow the panels to slide down in the slot; gravity locking the tabs in place, Figure 14.3.
B
Figure 14.1
• Once all of the fins have been installed, begin infilling with drop-lock panels (Component B). The panels should be installed by column, starting with Column 1 and moving to the right. The drop-lock range of motion requires that the panel be installed from bottom to top, as illustrated in Figure 14.1. © 2014 Zahner® — All rights reserved.
Lateral ‘Boomerang’ Supports Information The lateral ‘boomerang’ supports provide a dynamic solution for transferring lateral loads through the CloudWall, such as wind loads. • Before attaching the boomerangs (Component D) to the fins, first layout all of the boomerangs. Each boomerang is a custom shape, and has a specific placement within the CloudWall. Therefore, each boomerang is labeled with its position according to the naming system outline on (p.1):
1A - L
D
COLUMN
ROW
SIDE (L) Left or (R) Right
• The naming system is intended to be hidden on the inside (touching) faces of the two boomerangs that make up a pair. The name of the left boomerang will be upward facing, and the name of the right boomerang will be downward facing as shown in Figure 15.1. Figure 15.1
Fastener Set
Secure boomerang connections using: • 3/4” carriage bolt (Component G) • washer (Component L) • hex nut (Component K)
G
L K Figure 15.2
15
CloudWall™ Assembly Manual
Installing Lateral ‘Boomerang’ Supports
D
E D Figure 16.1
Figure 16.2
Step 1 Step 2 Insert the left boomerang (Component D) into the slots To attach the first boomerang to the fin, thread in the left fin of the column the boomerang is located in, a stabilizer (Component E) to the top face of the boomerang legs that stick through the fin using the as shown in Figure 16.1. The boomerang name will be standard fastener set. facing upwards.
D D
Figure 16.3
Step 3 Attach the right boomerang of the set to the left boomerang. The boomerang name will be facing downwards, subsequently hiding it from view when attached, as shown in Figure 16.3.
D
Figure 16.5
Step 5 Connect the internal boomerangs using the standard fastener set. Continue this process for the entire row before moving to the next row. © 2014 Zahner® — All rights reserved.
Figure 16.4
Step 4 Insert the left boomerang for the second bay, continuing the attachment pattern of Left-Right-Left etc. Note that the left boomerang will always sit below the right boomerang.
F
Figure 16.6
End Connection Use the end connectors (Component F) to connect the right-most boomerang to the last fin, using the standard fastener set. Note that the end connectors will sit below the right boomerang.
Notes
17
