CELLCAST SYSTEM March 2008
PART 1: GENERAL
1.01SCOPE
Furnish the complete structural/electrical steel floor system. Work includes, but is not necessarily limited to, the following principal items:
A.Composite cellular and non-cellular steel deck units and cell end closers.
B.All factory punched cell access holes at trench header and outlet box locations.
C.Trench headers, flute closures, preset outlet boxes, grommets, butt joint tape and risers.
D.Preset outlet box activation assemblies.
1.02RELATED WORK SPECIFIED IN OTHER SECTIONS (CSI Master Format)
A.Concrete, welded wire fabric, or reinforcing fibers; Section 03 33 00
B.Fireproofing; Section 07 81 00
C.Decking; Section 05 31 00
D.Electrical; Section 26 27 00 & 26 05 33
1.03QUALITY ASSURANCE
A.Standards
1.This specification establishes the minimum quality of required function, dimension and appearance to be met by any proposed substitution.
2.The manufacturer and erector shall demonstrate a minimum of five years experience with this type of electrified floor system on similar sized projects.
B.Codes and Approvals (latest editions)
The project design and material furnished shall be in strict compliance with the following codes and approvals:
1.Steel deck section properties shall be calculated in strict accordance with the procedures outlined in the American Iron and Steel Institutes (AISI) "Specification for the Design of Cold Formed Steel Structural Members," latest edition.
2.American Welding Society Structural Welding Code with reference to applicable AISC and AISI provisions.
3.Complete UL listing in the Electrical Construction Materials Directory and per UL 209.
4.Installation shall comply with the National Electrical Code.
5.Provide trench header, cellular floor deck units, and activations classified and listed in Underwriters Laboratories Fire Resistance Directory. Each metal floor unit shall bear the UL label and marking. Activations shall be listed in UL Fire Resistance under "Outlets and Fittings Classified for Fire Resistance." UL rating shall be based on one UL Design Number covering all components of floor assembly, i.e., cellular and non- cellular floor decking, bottomless trench header, preset outlet boxes, activatingassemblies,concrete type and thickness, composite beam and applicable spray fireproofing.
1.04SUBSTITUTIONS
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, compliance with codes and approvals, 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.
1.05SUBMITTALS AFTER AWARD OF CONTRACT:
A.Manufacturer's specifications and installation instructions for each product specified shall be submitted for approval. Included shall be manufacturer's certification required to show compliance with these specifications. Also prior to product shipment, a copy of each instruction shall be distributed to the installer with a copy of transmittal submitted to show compliance.
B.Shop Drawings
1.Detailed drawings showing layout and types of deck units, shape, gauge, dimensions, perimeter pour stop, and end closers, supplementary framing, cut openings, special jointing or other accessories shall be submitted.
2.Schedule of field welding shall be submitted.
3.Trench header, outlet box and riser locations and details, trench header expansion joints, typical expansion joint through floor, if required, shall be submitted.
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CELLCAST SYSTEM March 2008
C.The following listed samples shall be submitted: (1) Multi-Service Outlet Box mounted on one foot sample cellular floor 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, screed bars, side rails, latch clips, adjustable compartment dividers, and fasteners.
PART 2 - PRODUCTS
2.013" DEEP STEEL FLOOR UNITS
A.Material: The steel floor units and associated accessories shall be fabricated from sheets conforming to ASTM A446, Grade A or ASTM A653-94 with a minimum yield strength of 33 KSI.
B.Fabrication
1.Steel floor units shall be fabricated in lengths to span a minimum of four structural supports (three spans) except where precluded by the building layout. The minimum depth of the units shall be 3" and each unit shall contain 2 separate cells.
2.Protective Coating shall conform to ASTM A525 G-60 or to ASTM A924-94 minimum and Federal Specification QQ-S-775E, Type 1, Class E, conforming to G-60 minimum coating class and complying with UL 209.
3.Cellular floor units and trench header shall conform as electrical raceways to the requirements of UL 209.
4.Deck unit gauges shall be minimum 20 gauge for non-cellular and 20/20 gauge for cellular units and designed to meet span, load, and deflection criteria.
5.Cellular floor shall be roll-formed to assure dimensional uniformity and strength. Sufficient embossments shall provide the horizontal shear design loading based on a minimum factor of safety of 2.0 on ultimate load. Minimum depth of embossments or indents shall be 0.060".
6.Shear devices rolled into deck webs or flanges shall be spaced at 3" maximum centers along the length of the deck or floor unit and at 12" maximum spaces in the transverse direction.
7.Flat compression elements shall be considered as "stiffened" by other elements only if such elements are connected or are welded together at 6" maximum spaces in the direction of deck span. Such connections or welding shall be adequate to develop the full shear which could occur at the weld interface with a safety factor of 2.0.
C.Design
1.Calculate section properties of the steel floor units according to the latest AISI procedures. Section properties shall be reduced accordingly where electrical access holes are provided in the effective areas (such as flanges) of the floor unit profile. The floor deck shall be designed non-compositely to carry all dead and live loads at all trench header spans.
2.In cases where multi-span floor units are used, base non-composite and composite design upon uniform load placed on all spans simultaneously.
3.Maximum allowable bending stress in the steel floor is 0.6 Fy for non-composite design in trench header spans.
4.Steel deck deflection shall not exceed 1/180th of the clear span or 3/4" maximum, relative to the supports, under the uniformly distributed concrete dead load (all spans loaded).
2.02TRENCH HEADER
A.Trench Header shall be a UL labeled, full bottomless type.
B.Removable Covers shall conform to UL 209 for minimum thickness of roller leveled steel after shearing for size. Covers shall be secured by mechanical latching devices without any exposed surface fasteners.
C.Factory Assembled Cover Assemblies with Side Rails shall be adjustable from
2-3/8" (min.) to 3-5/16" (max.) over top of cells for 2-1/2" nominal concrete fill, from
3-1/8" (min.) to 4-1/16" (max.) over top of cells for 3-1/4" nominal concrete fill, and from 1-7/8" (min.) to 2-1/2" (max.) over top of cells for 2" nominal concrete fill.
D.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.
E.Covers shall be painted by a dip process with an air-dried, primer coat.
F.Longitudinal Cover Seating Gaskets shall be provided as a nominal 1/4" width, integral with vinyl tile stop securely anchored to trench side rail units.
G.Edging for Finished Floor Tile shall be vinyl composition with integral cover gaskets, 1/8" width on top, with top edging to match floor tile color.
H.Cell Access Holes: A total of nine (9) holes at each cell/trench intersection shall be provided as follows:
(1)Four 1-1/2" x 7" (obround) factory punched holes into webs of each telephone and each special service or data cell. Snap-in grommets shall be provided for all web holes which completely grommet the opening perimeter.
(2)One 2-1/4" round, factory punched hole into top of each power cell with a snap-in grommet to completely grommet the opening perimeter.
I.Maximum usable width of trenches shall be 1-3/4" less than cover width.
J.Cell closers at cell ends shall be made from minimum 22 gauge steel angles with protective coating conforming to UL 209.
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CELLCAST SYSTEM March 2008
K.Power wire compartments shall conform to UL 209, with a minimum steel thickness of 0.054" in 3-1/2", 4-1/2" or 5-1/2" widths with a 3-1/4" diameter opening in base to align with self-grommetted 2-1/4" round adapter to power cell opening. Vertically adjustable dividers, one each side, shall be provided with a 1/2" wide top flange bearing surface to support the cover plate. A locking nut device for precise height setting shall be provided. 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.
L.Trench/raceway interconnections between telephone and data compartments shall occur at 12" intervals without reducing effective cross section of compartments. All access openings shall be bushed and/or curved edged. Minimum area for interconnection shall be 15 sq. inches.
M.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.
2.03PRESET OUTLET BOXES
A.Preset outlet box shall be UL labeled and shall be three-service type.
B.Openings in webs of telephone and 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 (min. 1.75 square inch area after complete grommetting with snap-in grommet is applied).
C.Boxes 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 teflon to act as a concrete release agent. Depth of "break out" concrete cover shall not be greater than 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. Boxes for 2-1/2" and 2-1/4" concrete fills shall have locking/grounding latches for one-step, snap-in installation in the field. Box for 1" fill 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.
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CELLCAST SYSTEM March 2008
E.Box Capacity (activated):
Floor DepthConcrete FillVolume
3"2-1/2"169 cu. in.
3"3-1/4"199 cu. in.
F.Box Activation shall consist of hardware for either concealed (all fittings below the finished floor surface) or flush mounted. Activation options shall be provided as follows: (select as required)
1.Concealed horizontal, two 15 or 20 amp duplex receptacles, a double duplex modular telephone plate and a data interconnect plate, or
2.Concealed sloped, two 15 or 20 amp duplex receptacles, a double duplex modular telephone plate and a data interconnect plate, or
3.Flush, one surface-mounted and one in-cavity duplex receptacle of 15 or 20 amp. Also provide one data interconnect plate to be activated on either side of the preset outlet. Access to both voice and data cells shall be provided at all times, or
4.Flush with carpet flange, two 15 or 20 amp duplex receptacles, a double duplex modular telephone plate and a date interconnect plate. Activation to include cover assembly with carpet flange ring and retractable cable exit port. Cover assembly to receive carpet or tile, or
5.Multiple wiring device activation, four 20 amp specification grade or isolation grade duplex receptacles (total of eight plug-in capability) with a duplex modular telephone plate. Access to data cell shall be provided. Activation to include cover assembly with carpet flange ring and retractable cable exit port. Cover assembly to receive carpet or tile, or
6.Special options, 250 volt, flat conductor cable, hard wired or fiber optic interconnects.
All activation options shall be available and be interchangeable within all the preset and afterset outlets on the project. All power activation options shall incorporate duplex receptacle placement immediately adjacent to one another within the outlet box, to facilitate ease of wiring.
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CELLCAST SYSTEM March 2008
G.Activation lid and support ring shall consist of the following:
1.Structural Lexan available in any color to blend with surroundings. Wire egress port assembly shall be designed to contain multiple grommetted individual ports to accommodate and protect wires against crimping. Wire egress port assembly shall be permanently attached to lid.
2.Structural aluminum available in any color to blend with surroundings. Wire egress through the lid shall occur at a designed port assembly to maintain wire integrity.
H.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.
I.A UL approved multi-service afterset outlet box capable of using the same activation hardware, support ring, and lid as the preset outlet box shall be available.
J.Metal activation hardware shall be made of aluminum extrusions and plate aluminum. Cast aluminum parts shall not be used.
K.Outlet box activation cover plates shall be provided with a positive finger-type latching mechanism capable of resisting a 10# opening force. Friction fit type latching is not acceptable.
L.Activation ring and lid shall be capable of sustaining a load of 800 pounds through a one inch mandrel without a permanent set exceeding 1/8 inch.
M.Activation lid shall be designed with a lip or flange around its perimeter so that it accepts a carpet insert which is recessed so that fraying of its edges is eliminated.
N.Activation lid shall be detachable and re-attachable in either direction on the support ring. Support ring shall be designed to accommodate this requirement.
O.Detachable wire egress blocks are not acceptable; self abandoning assembly shall be permanently attached to lid or to ring. Field notched holes on the lid or the ring are expressly prohibited.
2.04PRESET OUTLET ACTIVATION ASSEMBLIES
Activation Assemblies shall consist of snap-in grommets, partitions brackets, adjusting ring, and cover assembly at locations directed by Architect. The initial activation shall utilize the ______option, provide a total of ______activation assemblies.
3.01STEEL FLOOR UNITS
Install steel floor units and accessories in accordance with the manufacturer's final approved erection drawings. Installed by others.
A.Installing Floor Units
1.Floor units shall be placed on the supporting framework and adjusted to final lateral position with proper end bearing and accurate alignment at the butt joint before fastening. Units shall not be stretched or contracted in the transverse direction. Cellular units shall be laid out on the framework in each bay and located in strict accordance with the deck erection drawings in order to maintain the transverse module as dimensioned.
2.Steel floor shall not be used for storage or working platforms until it has been permanently fastened. Heavy storage loads shall be supported on wood blocking in the flutes of the deck.
3.Excessive damage to floor units prior to or during the construction phrase can significantly reduce steel deck load-carrying capacity and create a hazardous condition for workers. Appropriate care and judgment shall be exercised to insure that any excessively damaged floor unit is suitably strengthened, shored, or replaced. Shoring of deck in trench span is prohibited since these spans are designed non-compositely.
B.Closures shall be fastened in place at beams and perimeter ends of cells or where cells change direction as shown on the deck erection drawings.
C.The floor deck supplier shall supply those framed floor openings shown on the structural drawings. Smaller openings shall be field cut by the trade requiring the opening. Where possible, holes shall be blocked out to eliminate concrete. Cutting of the metal deck shall be done only after the concrete has cured. The structural engineer shall be consulted before any hole is cut. Reinforcement, if required, at all openings shall be supplied by the general contractor.
D.Field welds or abrasions on floor units or flashings shall be field painted only when the finished installation is permanently exposed to the weather.
E.Concrete containing chlorides from any source shall not be placed on galvanized deck, trench, or activation units.
3.02CELLULAR FLOOR SYSTEM INSTALLATION
Cellular floor system including bottomless trench header and preset electrical outlets shall be installed in accordance with the manufacturer's approved electrical installation drawings and the manufacturer's electrical components installation manual, and this specification.
A.Bottomless Trench Header
1.All openings shall be completely bushed with snap-in grommets.
2.Trench header assembly and side flute closures shall be fastened to top of cells per manufacturer's standards and installation instructions.
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CELLCAST SYSTEM March 2008
3.Cover assembly shall be leveled using screw adjustment prior to concrete placement.