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Standard
"Quick-Ship" Modular Offices
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Installation
Instructions
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Important:
We advise a thorough reading of these instructions before beginning
installation.
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Introduction
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Instructions
should be read thoroughly and cross-referenced with your job drawings
prior to commencing
installation.
Standard "Quick-Ship" Modular Offices are manufactured
from high quality materials with care taken in handling
and packing at the factory. Please inspect your materials and count
them to make sure that damage or loss has not
occurred in transit. Please notify us promptly if you experience
any problems. Review the accompanying Bill of
Materials and parts drawings to familiarize yourself with the components
of the system. Care must be exercised in
handling these materials. The framing parts are made from painted
steel and anodized aluminum. The material,
while strong and durable, will scratch, bend and/or mar. Normal
care in erection will result in a finished product of
which we both will be proud.
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Tool
Suggestions
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•
Hammer
• Rubber Mallet & Wood Block
• Electric Drill
• #30 Drill Bits (3 or 4)
• Phillip's Screwdriver
• 12 Ga. Extension Cord
• Putty Knife or Trowel (4" Blade)
• Level (30"or Longer)
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Plumb Bob
• Chalk Line & Dry Line
• Tape Measure or Ruler
• Tin snips
• Pliers
• Hacksaw
• Pencil
• Ladder |
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Carpenter's Square
• 9/16" Socket w/Ratchet
• 9/16" Wrench
• 5/16" Drive Socket
• 3/8" Drive Socket
• Fiberboard Knife
• Broom |
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Unpacking,
Inspection & Inventory
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The
Modular Office wall system is packaged in the factory in a manner
to protect each part during normal shipping
and handling. It is recommended that the original packaging remain
intact as much as possible until the individual
parts are needed. All extrusion components are typically packaged
in boxes. Panels are shipped with a foam
interleaf between panels.
As the skids are received at the job-site, they should be placed
in a location near the installation area, where they
will not become an obstacle, or require to be moved at a later time.
The skids should then be opened, however
leaving the internal packaging unchanged. Pieces can be removed
on an as needed basis and the packaging
discarded then. At this time the components should be visually inspected
for obvious damage and an inventory
taken to confirm that all parts are received as expected. Notify
us immediately of any discrepancies.
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Fasteners
Not Provided
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The
attachment hardware for the floor track to the flooring and wall
starters to existing structures are not included
due to installer preferences, local codes, and varying flooring
and ceiling systems.
The following are recommendations:
• Concrete floor: powder actuated
fasteners: heavy duty dome head nail – type DS 1-1/4"
long
• Wood floor: 1/4" x 1"
lag bolt
• Steel floor: #14 x 1"
sheet metal screws
• Drywall: 1/4" toggle bolts,
drywall or wood screws
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Installer
Tip!
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To
save time, mark the centerlines of all the studs on the floor in
front of the floor track. This will assist you in
maintaining the centerlines shown on the drawings.
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Floor
Track Installation
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Step
1
Locate the first wall and strike a chalk line
on the floor. This line is the outside edge of your
floor track.
Step 2 Lay out the floor track per floor plan
drawings. Cut floor track length as noted by F.T.
dimensions on the drawing. Use metal snips to cut
the floor track lengths. Note: Use the 3 - 4 - 5
triangle method or a carpenter's square to confirm
90° corners. (Detail A)
Step 3 Mark wiring stud centerlines & door
openings per plans. (Note: It is imperative that
stud centerlines be maintained.)
Step 4 Notch corner locations (Detail B) to allow
ends to lap each other.
Step 5 Refer to (Detail C) when securing floor
track to surface with floor anchors.
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Detail
A - Floor Plan
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Detail
B - Corner Lap Detail
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Detail
C - Floor Track Layout
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Pre-Assemble
Stud Posts
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The
holes of a stud hat have an offset pattern that allows two identical
hats to
be secured together by rotating one of the hat sections. This alignment
will
offset the holes, allowing the standard #10-16 x 3/4" Tek 2
screw to use a pre-punched hole on one hat and to tap through the
opposing hat. (Detail D)
Assemble stud posts. Leave out the cover strips until Step #8 of
Electrical
Section.
Screw the stud sections together leaving the sections loose enough
to install
the panel.
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Detail
D
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The
holes of a Series 300 stud hat are prepunched on both sides of the
raceway at 12" o.c. Assemble stud assembly by inserting Part
A into Part B. Using a #10-16 x 3/4" Tek 2 screw fasten the two
parts together using a prepunched hole on Part A to tap through the
opposing Part B. |
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Wall
Erection
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Wall
panels are fabricated and ready to install. Standard wall panels
are 44-7/8" wide and are interchangeable with
other full panels, windows and door panels. Special width filler
panels (F.P.) are labeled on floor plan.
Step 6 Check the floor for level. In extreme cases (out of
level by 1/2" or more) select the high corner as your
starting point. If possible, leave the door panel to be installed
last. Shimming may be necessary if floor surface is
not very level.
Step 7 Begin wall installation by inserting a corner post
into the floor track (Detail E). Note: the corner
post is
inside both the vertical legs of the floor track. The corner post
should be loosely assembled using Phillip's flat head
1/4"-14 x 3/4" screws to allow install of panel.
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Detail
G
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Installer
Tip!
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When
installing the panels into the stud, pull the panel back on one corner
and slide the other
corner into the stud or corner. |
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Detail
E
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Detail
F
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Step
8 Install
the two adjacent corner wall panels into the floor
track and slide gently into corner post (Detail F). Tighten
the
corner post screws and install vinyl corner inserts (Detail G). |
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Installation
Note
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Do
NOT push panel all the way into the stud. Hold centerline dimension. |
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Step
9 Install
pre-assembled studs next to each panel.
Check centerline dimension of stud to corner post from your floor
plan.
Tighten screws after panel is in place (Detail H). Refer
to the fastener guide for screws required. Do not over
tighten screws.
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Detail
H
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Load-Bearing
Office
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Install
a 10 gauge bearing plate inside the floor track below
each stud and corner. Use 3-3/16" x 5" plate for studs and
4-1/2" x 4-1/2" notched plate for corners. |
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Step
10
Assemble mitered
cornice mold corner assembly
(Detail I). Each standard corner includes two short pieces
of
cornice mold with one end
mitered. These special pieces
will be used to make your
cornice mold corners. If corner
to stud dimensions is less than
50-1/4", field cut the cornice
mold so that the end not mitered falls on the centerline of the
stud. Secure cornice mold
corners to the interior side of
the corner post w/ #10-16 x 3/4"
Tek 3 screws.
Step 11 Insert next panel into
floor track; slide into stud and
tighten screw. (Note: Do not
over tighten screws). Continue toward next corner. Check each panel
for plumb (Detail J). |
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Detail
J
1. Check stud
for plumb.
2. Check wall
for plumb.
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Detail
I
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Step
12
Check the centerline dimension of each stud with the dimensions
on your floor plan. This will eliminate any growth or shrinkage
of the overall dimension.
Step 13 Set cornice mold in place. If necessary, cut the
cornice mold so that it fits between the two cornice mold corners
you have assembled.
Step 14 Recheck the wall and corners for plumb. Secure the
stud through the cornice mold and floor track on the interior side
of wall at each stud location with #10-16 x 3/4" Tek 3 screws
(Detail K).
Step 15
Install the remaining walls in the same manner.
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Detail
K
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Window
Panels
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Window
panels install into the stud in the same manner as the wall panels.
Step 16 Insert the lower window panel in the adjacent stud. (Detail
L)
Step 17 Install the window onto the lower window panel with
the gasket to
the inside of the room. (Detail M) Handle with care. |
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Detail
L
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Detail
M
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Step
18
Insert the upper window panel. (Detail L)
Step 19 Slide on the adjacent stud and proceed with the next
panel.
Note: To prevent breakage, we recommend the window be moved
only in an upright position with the bottom
supported.
For a neat job, make certain that the window frames are inserted completely
into the studs and the sill heights
align. If the wall consists of many window units it is imperative
the windows be inserted all the way into the studs
and you check your centerline dimension of your studs to make sure
they match the drawing; otherwise the wall
will grow in length and the last unit will not fit into the corner. |
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Vinyl
Base
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Step
20 The screw on vinyl base should be cut to fit for the interior
and exterior of the room. Lift cover flap and
secure to wall with #10-16 x 5/8" pan head screws at 24"
centers. Push the cover strip in, to lock in place, and
cover screw heads. Pre-formed exterior corners are supplied for
the outside corners only. (Detail N)
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Detail
N
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Single
Door Installation
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The
door and frame come pre-installed in a full size wall panel. Handle
door assembly panel with care and lift the
panel from the sides, not the ends. |
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Step
1 For handling purposes, the bottom of the door is fastened
to the
door frame. This must be removed before installing the door assembly
panel. Also verify at this point that the floor track opening is
37-3/8".
(Detail O)
Install the door assembly panel into the floor track. The floor
track will fit between the door frame and the panel. Be sure the
wall with the door is
installed with cornice mold attached to studs before adjusting door.
Step 2 Remove hinge bolts and door prior to squaring/leveling
door
frame. (Detail Q)
Step 3 Verify there is equal spacing between both jambs by
measuring or
by using a temporary wooden spreader. (Detail P)
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Detail
O
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Detail
P
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Detail
Q
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Step
4
Level door header and shim jambs as required. (Detail R)
Step 5 Use the sill anchor brackets to anchor jambs to the
floor track.
(Detail S)
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Installation
Note
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Make
sure that the frame is plumb. |
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Step
6 Turn
adjustment screw counterclockwise to secure frame.
Do not use these screws to plumb the frame. (Detail T) |
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Detail
S
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Detail
R
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Detail
U
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Step
7 If
the frame is installed properly, there will be an equal gap between
the door and the frame. (Detail U) |
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Detail
T
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Double
Door Installation
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Walls
should be secure at this point. Check on this before installing door.
The double door assembly is shipped knocked down and is not pre-hung
in a panel. Framing for the door opening
includes steel tubes for 3" walls and steel channels for 1-9/16",
4-5/8" and 6" walls. The door should be installed
during the wall installation. The steel assembly framing should be
in place with the remainder of the wall. All studs
should be secured to the cornice mold before adjusting the frame.
Note: The material sizes indicated in the
following steps are for a 6'-0" x 7'-0" double door in an
8'-0" wall system. Sizes will vary for other door sizes and
wall heights. Refer to drawings.
Assure that studs on each side of the door are plumb and located properly
according to the layout. The distance
between studs should be 76". (Detail V)
Install 84-7/8" vertical tubes or channels into each stud. (Detail
X) Note: Channels are installed with the open side towards
the stud. |
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Detail
W
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Detail
V
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Set
77 1/4" tube or channel across opening to rest on vertical supports.
(Detail W) Place 76" H-stud on horizontal
tube or channel.
Install 37 1/8" x 12 7/8" header panels along with the 12
1/8" header stud. Note that header stud will rest on h-stud.
(Detail Y) |
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Detail
X
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Detail
Y
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1)
Install cornice mold on top of wall, plumb studs and secure studs
to cornice mold.
2) Locate all frame parts before installing frame. Included with
the three (3) framing parts will be the following:
four (4) sill anchor brackets to be installed
at the bottom of the hinge jamb to secure the frame. Six (6) 4-1/2"
x
4-1/2" hinges, six (6) hinge back-up
plates to place between the hinge and door and four (4) #8x1/2"
pan head
screws to secure frame header to jambs.
3) Install sill anchor brackets into the bottom of the hinge jambs.
4) Install three (3) door frame parts into opening making sure that
the mitered joint connects properly.
(Detail 4 & 5) Plumb each jamb
and level header. Secure jambs at floor using sill anchor brackets.
(Detail 1)
Tighten adjustment screw to hold door frame
plumb. Install door frame header screws in top of frame using
#8x1/2" pan head screws. (Detail
2)
5) Secure studs to tubes by fastening through the leg of the studs
and h-stud with #12-14 x 1-1/4" Tek 3 screws.
This must be done at the corners of the
frame and at 18" o.c. on both sides of the door. (Detail
3)
6) Install hinge butts: one-half mounts to frame and the other half
to the door. Make sure the hinge back-up plates
are installed between the hinges and the
door.
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7)
Once the wall is rigid, hang the door onto the frame by meeting
hinge butts together and replacing hinge pins.
8) Operate door to check fit. Doors should swing easily.
9) Install head and foot bolts on inactive door |
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Detail
1
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Detail
2
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Detail
3
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Detail
4
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Detail
5
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Dust
Cover Installation
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The
dust cover consists of metal decking and support beams, as required.
The standard decking is 22 gauge, 1-1/2"
type "B" deck, and is required to make the office walls
free-standing. The decking has a modified "V" roll form
design. As such, it will grow or shrink in width during installation.
Care should be exercised to control the
dimensions while installing. All Fire & Sound buildings come with
a rubber deck closure to fill the corrugation
openings between deck and building. |
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Note:
Unless the office has been specifically designed to have a storage
roof, it is not intended to hold the weight of a person or storage. |
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Detail
7
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Detail
9
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Detail
6
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1)
Install the dust cover by placing the first piece of deck at one end
of the office, resting on the cornice mold.
Follow dust cover layout on building plans.
The edge without a return lip should be next to the outside of the
building. (Detail 6)
2) Prior to screwing the dust cover down, insert the rubber deck closure
by tacking it between the dust cover and |
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the
top of the cornice mold. (Detail 7) |
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Detail
8
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3)
Secure decking to the cornice mold with #10-16 x
3/4" Tek 3 screws at 18" o.c. along
the seams and
with #12-24 x 1-1/4" Tek 5 screws in
every other
valley. (Detail 6)
4) Make a mark on the cornice mold to locate the
placement of the next section of the decking.
This
dimension will vary between 35-3/8" and
36-1/4".
5) Place the second piece of decking next to the first
piece with the edge overlapping the return
lip of the
first piece. Note: Be sure to secure
each piece.
6) Continue installing decking across the room as
instructed above to complete. (Detail 8)
Overlapping
dust cover sections may be necessary. (Detail
9)
Please refer to job drawings sent with project. |
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Non-Load
Bearing Beams
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Place
support beams above the walls. Beams must be supported by wall studs
or steel columns at ends. Follow layout drawing for proper beam
placement.
Step 1 Secure ends of beam with #10-16 x 1-1/2" Tek
3 screws into cornice mold at wall. (Detail 10)
Step 2 Fasten roof deck to the beam with #12-14 x 1-1/4"
Tek 5 screws at 12" o.c. To complete the deck installation,
refer to dust cover installation on previous page.
Step 3 Attach conduit beam braces to the beam top flange
and dust cover.
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Detail
11
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Installation
Note
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Detail
10
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Electrical
wiring should be done by a qualified electrician. |
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Electrical
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1)
Install handy boxes into studs at desired locations with a #10-16
x 3/4"
Tek 3 screw. Fasten through the back of
the box (Detail 12) Typical
locations are 12"-18" above the
floor for duplex outlets and 48" to 54"
AFF for switches and single outlets.
2) Cut conduit as needed. Conduit should terminate just above ceiling
level.
3) Install stud cover plates by cutting to size above and below
each handy
box location. Cover plates should also terminate
just above the ceiling
to allow for wiring across the ceiling.
4) If installing a bean onto a column, follow steps 1-3 when securing
top
plate of columns. (Detail 11)
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Detail
12
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Acoustical
Ceiling Installation
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Determine
the required finished ceiling height for the room. For ease of installation
and proper light fixture
clearance, the ceiling should be a minimum of 6" below the
underside of the deck (6-1/2" if an exhaust fan will be
installed). Most building codes require a minimum clearance of 7'-6"
from the floor to ceiling.
1) Snap a chalk line 1" above the required ceiling height around
the perimeter of the room. This line should be
checked for level before snapping the string.
(Detail 14).
2) Cut wall mold as required and position so that top of angle is
even with the chalk line. Secure the wall angle to
studs and corners with #10-16x3/4"
tek 3 screws. Proceed around the room. Wall mold may be overlapped
or
miter cut at corner joints.
3) Mark the location of main runners by putting marks above the
wall mold. Tie a string around the wall mold and
stretch it across the room near the position
of the main runner. This will provide a reference line to install
hanger
straps and wires.
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4) Attach wire hanger straps to the bottom of the dust
cover at 4' o.c. Along each main runner. (Detail
15)
Make certain that a hanger wire is located
at each
corner where a lay-in light fixture will be.
Cut hanger
wire as needed, usually allowing an additional
6" at
each end to twist in place. Install wire through
the
hanger strap; bending wire back down and wrapping
tightly 3-4 twists. (Detail 16) |
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Detail
16
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Detail
15
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Detail
14
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The
ceiling grid consists of two major components, 12' main runners and
4' cross tees. (Detail 17) The main
runners typically run the longer length of the room. Closely follow
the layout drawing provided to assure easy
installation and proper material quantities.
5) Install 12' main runners at locations shown on drawing using hanger
wire provided. Be certain that 4' cross tee
anchor points correspond to the ceiling plan.
Allow the main runner to fully rest on the wall mold.
6) The ceiling wire may then be attached to the main runner. Be sure
to wrap the wire around itself at least 3 times.
(Detail 16) Care should be taken to
install the main runner straight and level. Continue until all main
runners are
installed.
7) Install cross tees at points indicated on the drawings by inserting
tabs into anchor points. Trim pieces at wall, as
required, for tee to rest fully on wall mold.
To strengthen the grid the tees may be secured to the wall mold with
pop-rivets (not supplied). Intersections
of cross tees and main runner must form a 90-degree corner. (Detail
18)
8) Place light fixtures into grid at locations indicated on drawing.
Make certain that a hanger wire is located at each
corner where a lay-in light fixture will be.
9) Cutting ceiling panels may be accomplished with the panels facing
up using a saw or a very sharp fiberboard
knife. Measure and cut each of the border
panels individually.
10) Lay-in panels are installed by carefully tilting the panel to
fit through grid opening then resting the panel on
cross tee and main runner flanges. Exercise
care when handling ceiling panels to avoid marring the surface.
Handle edges of panels, keeping fingers off
the finished side of the panel as much as possible. Clean hands are
necessary for a clean job. It may be necessary
to use the left over portion of the tile for other cut pieces. |
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Detail
17
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Detail
18
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In-Plant
Office Fastener Guide
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Part
No.
Size
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Sample
Image
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Description,
Uses & Quantities
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FAS87630
#10-16x3/4"
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Hex
Washer Head Tek 3
• Assemble studs (8 per 8', 10 per 9', 12 per
10', etc.)
• Secure studs, corners and wall starter to
floor track and cornice mold (3 per stud)
• Fasten roof deck at seams (18" o/c at
seams)
• Fasten beam braces to deck (2 per brace)
• Fasten ceiling hanger straps to deck (1 per
strap) |
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FAS35790
1/4"-20x7/8"
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Phillips
Flat Head
• Assemble 3" corner post (4 for 8', 5 for 9',
6 for 10', etc.) |
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FAS10-16CRIMP
#10-16x3/4"
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Hex
Head Type 1 Crimptite Tek 2
• Assemble studs (8 per 8', 9 per 9', etc.) |
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FAS87780
#10-16x1 1/2"
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Hex
Washer Head Tek 3
• Fasten beams to cornice mold (4 per recessed
beam plate, 2 per beam saddle,
4 per non-load bearing beam) |
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FAS87845
#12-24x1 1/4"
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Hex
Washer Head Tek 5
• Fasten roof deck to beams (12" o/c at
beam)
• Fasten beam braces to beams (2 per brace)
• Fasten roof deck to cornice mold (12" o/c
at deck ends) |
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FAS87849
#12-24x2 1/2"
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Phillips
Flat Head Tek 3
• Fasten wood support boards to cornice
mold (2 per board) |
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FAS87840
#12-14x1 1/4"
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Hex
Washer Head Tek 3
• Fasten shear panels (12" o/c all around
shear panel and 8 per bracket)
• Fasten studs to double door tubes (30 per
door) |
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FASDWS08108
#8 x 1 1/2"
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Phillips
Bugle Head Drywall Screw
• Fasten 3/4" plywood/OSB to roof deck
(45 per sheet) |
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FAS87580
#10-16x5/8"
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Phillips
Pan Head Tek 3
• Fasten vinyl base to wall (7 per pc. of
vinyl base and 2 per corner) |
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FAS166310
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HVAC
Screw Packet
• 1 Pkg/per Unit |
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Cleaning
& Maintenance Protocol: Modular Wall Systems
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Wipe
the panels, studs and extrusions with an owner approved alcohol
wipe or mild soap and water with a damp
sponge or rag. If any chemicals are to be utilized, spot check with
extra materials or in an inconspicuous place
prior to use to insure that the finish of the wall system is not
damaged.
Upon request, we can provide touch-up paint, vinyl facings and replacement
material based on your requirements.
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Aluminum
Wall System
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The
aluminum version installs in the same manner as the modular office
system.
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Standard Quick-Ship
Modular Offices, Modular Offices, Inplant Building, Inplant Buildings,
Inplant Modular Office, Inplant
Modular Offices, Inplant Office, Inplant Offices, Partition Wall
Systems, Prefab Office, Prefab Offices, Inplant Modular Offices,
and Prefabricated Offices from your complete source for material
handling equipment.
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