general installation instructions -...

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General Installation Instructions

Installation Questions?Call us at 800-549-9680

© 2015 Allied Modular Building Systems 2

RECEIVING FREIGHTWorry Free Freight- (You paid Allied Modular for the freight)When the truck arrives, be sure to check all materials for damage. If some damaged mate-rials are found, you must note it on the receiving paperwork (receiver) and keep a copy. After receiving the freight, contact our office immediately to report the damage. Your request will be processed and replacement materials will be shipped out to your jobsite. Digital pic-tures may be neccessary if you are unsure of the parts damaged.

You provide the freightCustomer assumes all responsibility!When the truck arrives, be sure to check the freight carefully. You are responsible to check all materials and if damage is found, you will need to file a claim with the freight carrier and con-tact us to purchase additional materials. If our installers are in route there may be additional charges for downtime.

DAMAGE CLAIMSIf Allied Modular’s “Worry Free Freight” is provided, we are fully responsible for shipping the materials, all claims and re-manufacturing of materials. However, if you choose your own carrier, ship materials freight collect, or did not accept TanWall’s “Worry Free Freight” option you are responsible for all costs associated with the material loss.

GETTING MATERIAL TO LOCATIONIn most cases, the customer is responsible for getting the materials to the job location. If so, there are a few things to be aware of. When hand loading or unloading any materials, lay panels, doors and other components flat. Ensure that there is foam or other packaging be-tween each door panel to ensure no damage occurs.

Note: Leaning panels against a wall for long period of time will result in damge (bowing) of those panels.

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Installation Questions? 800-549-9680

Safety Glasses 6 ft. Step Ladder Rubber Mallet4 ft. Level12 - 50 ft. Tape Measure(depending on building size)Chalk Line and ChalkCarpenter’s SquareDrill and Masonry Bit (See Detail page for size information)Screw Gun or Variable Speed Drill with No.2 Phillips Tip

and 5/16 in. Nut DriverAppropriate Size Extension Cord 7/8 in. Hole Saw BitPutty KnifeSkill Saw

Hammer

TOOLS REQUIRED

Warning

Follow all tool instructions regarding safety. Eye Protection must be worn while doing any type of installation or use of any tools.

Safety is always the first priority.

Warning

Any electrical work shown in these instructions should always be by a qualified person. Serious injury may occur if not wired properly.


FASTENER & ALUMINUM IDENTIFICATIONScrews, anchors and components will vary depending on application.

Horizontal Channels

Vertical Channels

45° CornerWall Start H-Post Raceway 90° Corner

Floor TrackTop Track

#10 Self Drilling Tek Screw

1/2” Concrete Anchor #8 Drywall ScrewCourse Thread Deck Screw provided for double doors.

#10 x 1” Hex Head with1/4” Plastic Wedge Anchor

Top Track With Fascia

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Existing Wall

AB

C

D

E A B C D

E

RACEWAY CONNECTION

WALL STARTCONNECTION

H-POSTCONNECTION

WALL INTERSECTIONCONNECTION

CORNER POSTCONNECTION

PLAN VIEW

ELEVATION VIEW

EXISTING WALL

G

TOP CAPCONNECTION

G

F

F

45 DEG. POSTCONNECTION

CORNER POSTCONNECTION (TYP)


DEEPSIDED PANEL

H

B

FH

TOP CAPCONNECTION

Existing Wall

AB

C

D

E A B C D

E

RACEWAY CONNECTION

WALL STARTCONNECTION

H-POSTCONNECTION

WALL INTERSECTIONCONNECTION


PLAN VIEW

ELEVATION VIEW

EXISTING WALL

G

TOP CAPCONNECTION

G

F

F

45 DEG. POSTCONNECTION

CORNER POSTCONNECTION (TYP)


DEEPSIDED PANEL

H

B

FH

TOP CAPCONNECTION

CONNECTION OVERVIEWS

ampl

e La

yout

Panels are typically measured to the shortest length of the floor track (and top track) at the the corner post.Deep-sided panels are noted on the floor plan.

FLOOR TRACKTOP TRACK


EXISTING WALLS

CL CL

EX

ISTIN

G W

ALLS

OUTSIDE PERIMETERWALL CHALK LINE

INTERIOR CENTER OFWALL CHALK LINE

SAMPLE

WALL LAYOUTBefore installing the Floor Track to your new wall system, you must create wall guide lines using the provided floor plan drawing and appropriate tools. This step will help you determine the outside wall perimeter and interior wall loca-tions of your new modular wall system. Please read and follow instructions carefully for best results.

Strike a chalk line on the floor locating a starting point of one of the modular wall spans, continue the chalk lines slightly longer than the length of structure to be constructed. This line will act as a guide for the first wall. See Fig. 1 (All dimensions will be outside wall dimensions unless otherwise specified on factory floor plan)

Fig. 1

See “Making a perfect 90 degree angle” on next page for corners or intersecting walls.

Tools Needed For Step• Carpenter’s Square• Chalk Line• Tape Measurer• Pencil

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Chalk Lines

3’-0”4’-0”

5’-0”

Carpenter’s Square

Fig. 2

When To Use:At a point on the line where a cross wall will connect, construct a 90 degree corner using a carpenter’s square or triangle method (See Fig. 2) above.

Strike a chalk line to use as a guide for this wall. Measure from intersecting point to location of other parallel walls from original chalk line. Repeat above steps as required to complete building footprint.

TIP:Making a perfect 90 degree angle.


ANCHORING OF FLOOR TRACK Layout all the pre-cut floor track using the provided floor track plan and guide lines (See Fig. 3). With the tape measure and a black marker, mark out in the floor track where each panel, vertical aluminum channels and door cut-outs are located. This step is important in order to prevent you from accidentally placing an anchor in the middle of a door cut-out.

Butt straight edges in place and anchor at each end with anchors provided to keep track in place (See Fig. 5, page 9). Fasten the rest of the floor track approximately 48” on- center. (See Fig 4. page 9). See “D” page for actual measurements.

FLOOR TRACK SCHEDULETRACKLETTER LENGTH QTY. PROFILE

A 106" 1B 120" 1C 72" 1D 119" 1E 103-3/4 2

Your drawings will show a “Floor Track Schedule,” with corresponding parts and lengths. Please measure carefully!

Tools Needed For Step• Screw Gun or Drill• Skill Saw• Measuring Tape

Note: For Concrete Floors use 1/4” Wedge.

For Wood Floors use #10 x 1” Hex Head Screw.

Do not place anchors in the shaded areas of the drawings. You will be cutting out the track where the doors are located.

Fig. 3

EXISTING WALLS

A

BB CC DD

E

FIELD CUTFLOOR TRACK

FOR 2668 DOOR


FOR 2668 DOOR


FOR 2668 DOOR

61" 31" 31"

106"

103

3/4"

103

3/4"

120" 72" 119"

E

EX

ISTIN

G W

ALLS

INCLUDED ONYOUR FLOORTRACK PLAN

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ANCHORING OF FLOOR TRACK

FLOOR TRACK

BUTTED

ANCHOR

SEAM

Door Cut-Out

Fig. 4 Fig. 5

Use an anchor about two inches from the door cut-out for stability.

See “T” page for more information on Track Layout and Door Cut location.

Illustrations above show a 4” Floor Track, but many of our walls use a 2” Floor Track. Consult your plans for specific details about your project.


Wall Start Installation

Installation of Wall Start should not be done until Floor Track is in place and anchored to the floor.

Start by predrilling three holes in the Wall Start: one at the top, middle and bottom. Holes should accommodate the type of anchor being used determined by wall con-struction. (See Fig. 6)

Insert Wall Start into Floor Track and up against the wall; level and mark existing wall with pencil through predrilled holes. Depending on wall construction, drill and install plastic wedge anchors. Finish by inserting Wall Start back into Floor Track and fasten-ing.

Plastic WedgeAnchor

Fig. 6

Anchor to Concrete, Brick Construction, or Drywall

Top Down View

Tools Needed For Step• Screw Gun• See Fig. 6 for Screw Tip Type• Variable Speed Drill• 4 ft. Level• Pencil

Use Drill, 1/4” Masonry Bitand 5/16” Nut Driver

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Working in one direction, install the appropriate vertical channels and panels per the factory floor plan provided (no screws are necessary during this step other than attaching first Corner Post or Wall Start). Continue until you have reached the last panel on the wall span (see next page).

PANEL INSTALLATIONAssuming Floor Track and Wall Starts are in place and anchored, place appropriate panels according to your floor plan beginning at the existing wall (or start at one corner of floor track, install a corner post & appropriate panels on both sides of corner post). See your provided floor plan for appropriate panel locations.

BEFORE YOU START INSTALLING PANELS AND ALUMINUMPlease familiarize yourself with the “Fastener & Aluminum Identification” sheet and locations of doors, double doors, outlets, switches and other infor-mation before proceeding with the following steps. Ensure that all parts are securely fastened prior to installing any panels.

VERTICAL CHANNELS AND PANEL INSTALLATION


Fasten with #10 Tek Screws at Corner Post and Floor Track intersection, on both sides (see below).

Top Down View of Panels and Vertical Posts

#10 Tek ScrewTop Cap

Vertical H-Post or Raceway

Wall Panel

Tools Needed For Step• Screw Gun and #2 Phillips Tip• 4 ft. Level

See page 5 for special note

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WINDOW PANEL INSTALLATIONThe window panel section is split into 3 separate components: the Kick (or bottom), the window frame, and the top (or header). Begin by installing the kick panel into the vertical channel and Floor Track. Insert the window frame into the vertical channel and slide over the kick panel (if difficulty arises, use a putty knife to aid in installation). Then proceed to install the window panel header into the top of the window frame by using the same method. Then proceed to the appropriate vertical channel.


REMOVE WOOD BRACINGBY UNSCREWING

REMOVE PINS FROM ALLHINGES AND REMOVEDOOR BEFORE PANELINSTALLATION

The door panel is shipped completely assembled. Remove door from the panel by removing the wood bracing and the hinge pins from the hinges.

Be careful moving the door panel into position; this component can break or wishbone easily.

DOOR PANEL INSTALLATION

DOOR PANEL INSTALLATION- 3068 or 3’- 0” x 6’- 8”Starting from a previously installed panel, place a mark on the floor channel at 5-1/2” and 42” making a 37” opening as per (this is example is specifically for a 36” door). Cut the Floor Track, preferrably using a skill saw, and remove the aluminum that will serve as your door opening. Make sure the Floor Track is anchored 3” from the door cut-out and Plastic Wedge Anchors, near the cut out.

37 1/2"

31 1/2"

31 1/2"5 1/4" 11 1/4"

8 1/4"8 1/4"

5 1/4" 5 1/4"

DOOR CUT OUT

DOOR CUT OUT

DOOR CUT OUTFLOOR TRACK

FLOOR TRACK

FLOOR TRACK

ANCHOR (TYP)

ANCHOR (TYP)

ANCHOR (TYP)

ADJACENT WALLPANEL

ADJACENT WALLPANEL

ADJACENT WALLPANEL

USE FOR 30" DOOR CENTERED IN PANEL

USE FOR 30" DOOR OFFSET IN PANEL

USE FOR 36" DOOR CENTERED IN PANEL

Fig . 7

See “T” page for more information about your specific door cut outs.

Tools Needed For Step• Screw Gun and #2 Phillips Tip• Skill Saw• Measuring Tape

Save screws. These will be used later for door lever installation.

PLASTIC ANCHOR

CONCRETE ANCHORCONCRETE ANCHOR

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Insert the side of the door panel into the vertical channel and slide panel into the floor track (See Fig. 11). Shims may be required to plumb and level the door and frame. Using a 4 ft. level on the hinge side, level the frame and reinstall the door by inserting the hinge pins. Close the door and place a 1/8” shim on the top and the level side between the door and frame. This is to make sure there is an even gap, or reveal, between the door and the frame before fastening frame to floor track.

Note: If the door won’t close you need to raise the frame leg off the Floor Track with a shim.

PLUM DOOR BYADJUSTING DOOR JAMBUP OR DOWN WITHPRY BAR THEN SECUREWITH PROVIDE #8 TEKSCREW.

SECURE WITH PROVIDE #8TEK SCREW.

For door knob or lever installation, see page 22

Fig. 8

Plumb door by adjusting Door Jamb up or down with pry bar, then secure with provided #10 Tek Screws.

Secure with #10 Tek Screw

Tools Needed For Step• Screw Gun and #2 Phillips Tip• Pry Bar• 4 ft. Level


Tools Needed For Step• Screw Gun • 5/16 Nut Driver• Pry Bar• 4 ft. LevelRivet Gun

DOUBLE DOOR PANEL INSTALLATIONInstall one side of the panel in the vertical aluminum and the Floor Track. Then insert the assembled door frame in the opening. Put the small H-post over the header to accept the next panel. The notched side will go into the door header. Install the other side of the double door panel. (See Fig. 9)

Screw in the hinges with the hinge screws provided. Make sure you use the hinge with 2 knuckles and the hinge with 3 knuckles will be installed on the door. This will secure the frame to the panel. Next, put the hinge pins in the door and level. After the frame is leveled, install the “T” astrigal between the doors.

Note: If the door won’t close you need to raise the frame leg off the Floor Track with a shim, then repeat the previous step. (See previous 3068 door installation diagrams)

(1ST STEP)1ST HALF DOOR PANEL

(3RD STEP)H-POST CONNECTOR

(4TH STEP)2ND HALF DOOR PANEL

(2ND STEP)ASSEMBLED DOORFRAME

INSTALLEDFLOOR TRACK

VERTICALCONNECTOR(H-POST, RACEWAYOR CORNERPOST)

Fig. 9

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INTERIOR PANEL INSTALLATION

When you are working with a wall between two other walls, the panels are 1” shorter than the over all aluminum length. This provides enough room to in-stall both the Wall Starts, panels and vertical aluminum to slide over and hide the gaps. See below:

Above diagram show all panels and aluminum extrusions pushed over to the left side making room for the last panel to be installed. Once panel is installed, slide panels and extru-sions to right covering gaps.

Screw down all vertical extrusions to floor track with #10 Tek screws provided as shown below.

#10 TEK SCREW (TYPICAL)

Tools Needed For Step• Screw Gun and #2 Phillips Tip• Putty Knife• 4 ft. Level

FLOOR TRACKVERTICAL ALUMINUMH-POST OR RACEWAY

WALL PANEL

2 Part Wall Start


INSTALLING THE TOP TRACK Using the drawings provided for your project, determine correct length Top Track piece, place Top Track over the installed panels and vertical channels (see next page).

Note: The Top Track will be one of two types. If your plan includes electrical raceways it will require Top Track with Electrical Wire Tray around the perim-eter walls of the structure, otherwise it will require only the standard Top Track (refer to page 4 for profiles).

EXISTING WALLS

A1

BB1 CC1 DD1

EE1

TOP TRACK SPLICE TOP TRACK SPLICE

106"

103

3/4"

120" 72" 119"

EE1

EX

ISTIN

G W

ALLS

Your drawings will show a “Top Track Schedule,” corresponding parts and lengths. Please measure carefully!


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INSTALLING THE TOP CAP Determine correct length of Top Cap (provided on “T” pages labeled “top cap”)and, place top cap over the installed panels and vertical channels. Install the provided #10 Teks Screws on the inside and outside of intersecting points.

Note: The Top Cap will be one of two types. If your plan includes Roof Deck, it will require Top Cap / Fascia combo around the perimeter walls of the structure as seen in above illustrations. Otherwise it will require only the Top Cap.

Top Down View of Panels and Vertical Posts

#10 Tek ScrewTop Cap


Wall Panel


INSTALLING THE TOP TRACK The Top Track slides over all the vertical aluminum channels and panels. After installing all Top Track, level the walls and anchor (as shown below).Use provided #10 Tek Screws on the inside and outside of intersecting points .

Note: Where two pieces of Top Track come together, use the provided 6” Splice. The Splice sits inside the Top Track and is screwed using a #10 Tek Screw.

Fig. 10#10 Tek Screw

Top Track


Wall Panel


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PLUM DOOR BYADJUSTING DOOR JAMBUP OR DOWN WITHPRY BAR THEN SECUREWITH PROVIDE #8 TEKSCREW.

SECURE WITH PROVIDE #8TEK SCREW.

Leveling and Installing the Door LeversInstall door back into the frame and replace the hinge pins. Level up the for an even gap around the doors & frame. If the floor is un-level, you can adjust the doorframe to straighten out the header. Secure with #10 Tek Screws.

Prior to installing the door Levers, close the door and through the door latch hole trace an outline of the hole with a pencil. Use a 7/8” Bi-Metal hole saw and make the hole for the strike plate. Predrill holes for the catch plate screws using Tek Screw as a drill bit. Remove the Tek Screws and replace it with the screws that came in the bottom of the door. Lastly, attach the catch plate.

Fig. 11

Fig. 12

Plumb door by adjusting Door Jamb up or down with pry bar, then secure with provided #10 Tek Screws.

Secure with #10 Tek Screw

Tools Needed For Step• 7/8 Hole Saw and Drill• Screw Gun• #2 Phillips Tip


ROOF DECK / DUST COVEROur roof deck is shipped and cut to the appropriate lengths (spans) of the structure. This galvanized steel corrugated deck sits on top of the complet-ed wall sections. Placing the first piece (#1) of deck onto of the wall with the turned up lip facing the starting point. The second piece (#2) interlocks with the previous piece and so on. Screws should be fastened every 1’ O.C. using #12 Tek Screws provided. These roof deck sections are shipped in 3’ widths and can be overlapped if excess width is provided. This deck provides a max-imum live load of only 10lbs PSF unless otherwise indicated and should not be used for storage.

1stsection

2ndsection

Roof Deck & Wall Connection

Roof Deck to Roof Deck Connection

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1. Choose the ceiling heightInstall your ceiling at any level, as long as you maintain 6” min. clearance be-low the roof deck. If roof deck is not being installed, choose a height which maintains a 3” min. clearance below the lowest air duct, pipe or beam for installing ceiling tiles. Measure and mark the desired height at each room corner.

2. Mark a perimeter chalk lineSnap a chalk line around the entire room perimeter, 3/4 in. above your desired ceiling height. Check it with a carpenter’s level to be sure the ceiling will be level all around. Mea-suring down from the joists, or up from the floor, is not recommended since either might not be level.

T-BAR GRID CEILING

3. Install wall anglesWith the top of the wall angle along the chalk line, nail wall angles around the entire room. Space nails 2 ft. o.c. or closer.

3. Install wall anglesWith the top of the wall angle along the chalk line, nail wall angles around the entire room. Space nails 2 ft. o.c.


5. Locate Main TeesStretch a string across the room at ceiling height to locate each main tee. To do this, pull the string taut around nails which you inserted between the wall and the wall angle on opposite wall locations. You can use ceiling grid clamps to anchor the string.

6. Locate Cross TeesStretch a string perpendicular to the main tee strings, locating the first row of cross tees. Do this just once, since prepunched slots in the main tees space out subsequent rows of cross tees. Make sure the cross tee string is at a 90 angle to the main tee string.

7. Install Hanger Wires Install clip or screw eyes at 4-ft. intervals along the main tee string lines, then attach the hanger wires. The wires should extend 6 in. be-low the string line. Twist screw eyes tightly into substrate.

8. Bend Hanger Wires Use pliers to bend each hanger wire at a 90 angle 3/4 in. above the string line.

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9. Align main tee lines In each row, trim the main tee at the wall so that the slot for the first row of cross tees lines up at the string. Rest the cut end of the main tee on the wall angle.

10. Hang main teesPull each hanger wire through the round hanger hole in the main tee. After checking the string line to be sure the tee is level, bend the wire up and around, twisting the ends to secure it. Twist wire tightly (3 1/2 full turns). If the nearest hanger hole is not directly below the screw eye, adjust the hanger length accordingly.

11. Install cross tees After main tees are hung, install cross tees. Push cross tee end through main tee slot until you hear a “click.” Where two cross tees intersect in the same slot, be sure to insert the second tee to the left of the first cross tee end.

12. Lay in the ceiling panels It’s easiest to begin in one corner of the room and install panels one row at a time. Tilt each panel up through the opening and lower it to rest squarely on all four tees.


RACEWAY / ELECTRICAL

ELECTRICALIf you are a qualified person, please review the diagrams below to aid in completing the electrical portion of your project.

Tools Needed For Step• Screw Gun • 7/8” Hole Saw• Wire Strippers• Lineman’s Pliers

TOP TRACK

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The installation of all electrical devices should be performed by a qualified person and must meet all national, local codes and ordinances.

Review provided floor plan drawing and note where light fixtures will be installed in grid ceiling. The fluorescent lighting fixtures will drop into a 2’ x 4’ ceiling tile opening and attached to roof deck using ceiling wires.

Using 12 gauge grid wires (2 wires per light fixture), attach two wires to the bot-tom side of the roof deck so that they may attach to opposite ends of the light fix-ture. This is to help support the weight load on the ceiling and is very important.

2’ X 4’ INLAY LIGHTING INSTALLATION

12 Gauge WireAttached to Roof Deck

2’x 4’ Light Fixture

T-bar Ceiling Grid

12 Gauge WireAttached to Roof Deck


Technical AssistanceIf further assistance is needed, please call our office.

Office hours: Monday - Friday, 7:00am - 5:00 PM Pacific TimePhone 800-549-9680 Fax 800-588-6792

Allied Modular Building Systems, Inc. 642 W. Nicolas AveOrange, CA 92868

Ph 800-549-9680 Fax 800-588-6792

Allied Modular has three United States pro-duction facilities to quickly ship across the

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