FLOOR AND ROOF PANEL INSTALLATION

This Installation Guide helps owners, design professionals, construction managers and installers install Eastland Autoclaved Aerated Concrete (AAC) Floor and Roof Panels. It is especially for the installer who may not be familiar with AAC floor and roof construction.

We have attempted to provide some general information regarding various areas of construction and details. However, since we cannot cover all areas or possibilities, we encourage and trust that you will ask for additional information regarding specific areas or possibilities, or when you have questions or need additional information.


General Installation Guidelines
1.Unload panels using pallet forks(nylon straps, slings or pallet fork on a crane cable). Consult an appropriate safety consultant or knowledgeable OSHA trainer for "rigging" or other safety considerations.

2.Insure adherence to Leading Edge Support OSHA Guidelines.

3.Stored areas should be accessible to delivery trucks and convenient to material staging areas. If possible, drop-deliver the material right to the material staging areas.

4.Storage material should always be stored away from other construction activities on a flat-grade area that is not suscepable to standing water, erosion or setting.

5.Keep the material covered and banded until ready for installation.

6.Excessive handling may cause damage. Set delivery schedule to match the erection sequence.

7.Chips and spalls can be repaired. If any reinforcing is visible, contact and authorized AAC representative.

8.All damaged surface areas may be repaired using a comparible AAC patching compound.

9.AAC panels that have surface or minor cracks are usable. Contact and authorized AAC representative when cracks extend completely through the panel.

10.Stored or staged materials should always be set on flat, stable grade on pallets or dumage.

11.Observe and provide all necessary temporary support and bracing in addition to following all safety laws and requirments.

12.Caution: Use safety gear, including hard hat, dust mask, and goggles to avoid inhatation of dust and protection of the eyes when handlingEastland AAC Floor and Roof Panels.


Eastland AAC Floor and Roof Panels
Eastland Floor and Roof Panel Is an Autoclaved Areated Concrete (AAC), steel reinforced element. The steel wire reinforcement is covered with an anti-corrosion coating.

Eastland AAC Floor and Roof Panels are lightweight, fire resistant, water penetration resistant, pest resistant, fast and easy to install, versatile and affordable.


Uses
Where appropriate, Eastland AAC Floor and Roof Panels can be used in conjunction with Eastland Masonry Components, CMU Walls, steel or concrete beams. These panels are used in residential and commercial buildings.


Design Considerations
Eastland AAC Floor and Roof Panels generally can be used as floor or roof systems and can be manufacturerd to meet certain safety and serviceability requirements as specified by ACI 318 and following  guidelines of ACI SP226.
Floor and Roof panels generally can be supported by Eastland Masonry Walls, CMU walls and concrete or steel beams.


Preparation
Before Installation of Eastland Floor and Roof Panels:

1. Clear the unloading and provisional storage area
     Flat surfaces are required for unloading pallets, preferably close to final position.
     Place pallets over wood blocks (panels must not be in contact with ground).

2. Check material and installation logistics
     Verify dimensions, positions and quantity of the panels according to Heble shop 
     drawings.
     Define sequence of panel installation according to Eastland shop drawings. To help
     speed installation, place the panels with the groove side at the beginning and 
     continue.
     Define type of installation equipment (crane or similar).
     Evaluate quantity of personnel required.

3. Check sxisting steel accessories
     Steel accessories for holes in floor and roofs.
     Steel accessories for holes in walls.
     Steel accessories for cantilevered panels.
     Fasteners to fix steel accessories.

4. Check support structure
     All support elements (walls, beams, etc.) must be already finished before receivig 
     floor and roof panels.
     Check layout and top of supporting structure. Eastland masonry block adjustments must 
     not be less than 2'' in height, or else cement-sand mortar (1:4) must be used.
     Place steel accessories if required (holes in walls, supporting areas, etc.)
     Mark guidelines on top of the supporting elements, according to bearing lengths in   
     Eastland shop drawings.
     For non-load bearing elements, put compressible sheets (polystyrene or similar) on top.


Installation of Eastland Floor and Roof Panels
1. Identify panels to be installed according to previous logistics.

2. Unpack panels using scissors or hammer ax

3. Mark center of panels.

4. Place lifting gear at center of panel 

5. Using the pulleys, close clamps, clipping the tongue and groove sides of the panel.

6. Lower safety bars prior to lifting panel.

7. Raise the locking lever and indicate to crane operator to lift the panel.

8. Two people will lead the panel to place it on the supports.

9. Clear safety bar from adjacent panel prior to placing panel on supports.

10. Place the panel on the guidelines previously traced.

11. Once the panel is placed, remove the lifting gear.

12. This procedure should be followed for each successive panel.

Caution1: Handle panels with care to avoid damage. Make chases needed prior to installation.

Caution2: Use safety gear, including hard hat, dust mask, and goggles to avoid inhalation of dust and protection of the eyes when handling Eastland AAC Floor and Roof Panels.



Utilities Installation
Openings 
Openings in floor and roofs for AAC ducts, staircases, etc. are built using steel supports.

Electrical Conduits
Electrical conduits with a diameter < 1'' can be lodged through longitudinal joints on top or bottom of the panels. For electrical conduits with a diameter > 1'', longitudinal joints can be widened to lodge them. It is not recommended to chase on top of panels. It is possible to define cut surfaces in panels regarding installations.

Caution

Concrete dust contains quartz silica, a potential human carcinogen. Inhalation of concrete dust above required or recommended exposure levels may be harmful. Wet sawing is recommended. 

Piping Lines
When required, PVC and other piping lines can pass through holes in the panels. The maximum hole diameter permitted in panels in 4''. If more than one hole is required, they must be aligned along the length of the panel. Only the panel can be cut.

Surface Patching
Use Eastland Repair Mortar to patch chips, breaks and other imperfections on surfaces of Eastland Floor and Roof Panels.

Eastland Repair Mortar is prepared in a bucket, adding water and mortar from the bag and mixed with a stirrer using a power drill or by manual means (depending on quantity to be used).
It is applied using a spatula.

Note: Technical support is available for builders and architects.

Caution: Use safety gear: Hard hat, gloves, dust mask and goggles to avoid inhalation of dust and protection of the eyes when handling Eastland Floor and Roof Panels.



Using Two Clamps with Spreader Beam
Lifting floor/roof panels with a length of 6'-6'' to 19'-8'' (1980-5995 mm) and max. load of 2860LBS.

1. Mount both clamps on the spreader beam and lock the suspension bolts with the R pin.

2. Each side of the clamps must be aligned with one another (marked as tongue and groove side).

3. Attach the lifting eye to the crane hook.

4. Measure the width of the floor/roof panel which is going to be lifted.

5. The clamps are provided with an automatic locking system. Each clamp has a locking mechanism.

6. The clamps must be in the open position before adjusting the width for the panel. If not, lower the two clamps onto a firm and level surface and the clampswill lock in open position automatically. If the grabs are not working synchronous, one of the clamps must be reset by means of turning the cam wheel 1/6 of a turn. The cam wheel is turned by rotating the bushing sticking out through the guard at the locking mechanism.

7. Lift the clamps in open position 20'' above the ground. On the side of each clamp are two spring loaded pins at the sides. By pulling the pin out of its locking position, you can slide the jaw over the I-profile in order to adjust the clamp width. When the jaw is in the correct position the spring loaded pin will slide into the hole.

8. All jaws must be placed in the same position. The clamping jaws must be placed in the appropriate position for the panel width being lifted as listed in the table below.

9. On each clamp are height adjustments to be adjusted by means of rollers. Adjust the height of the rollers based on the thickness of the floor/roof panel. The round bar must always be at the deepest in the tongue and the round bar at the opposite side must be in the centre of the groove.

10. All rollers must be in the correct position and locked with the pin.

11. Adjust the safety bars. The safety bars must be adjusted as close under the panel as possible but still being able to rotate under the panel after the panel has been lifted. All bars must be adjusted to the same position and locked with the pins.

12. Mark the centre of the floor/roof panel to be lifted. The centre of the spreader beam must be at the marked cnetreline!

13. Lower the clamps completely on the panel.

14. Now lift the clamps slowly.

15. Note: Verify that both clamps start gripping the panel.

16. Lift the panel 12 inches above the ground and rotate the safety bars under the panel.

17. Now carefully hoist the floor/roof panel up and maneuver it into position. rotating the safety bars upward just prior to setting.

18. When the panel has been positioned correctly, lower both clamps on the panel so that the locking mechanisms keeps the clamps open.

19. Now you can lift the clamps carefully from the panel.




Using One Clamp
Lifting floor/roof panels with a max. length of 10'-0'' (3000 mm) and max.oad of 1430 LBS.

1. Dismount 1 clamp from the spreader beam.

2. Mount the separate lifting eye on the clamp and lock it with the bolt and R pin.

3. Attach the lifting eye to the crane hook.

4. Measure the width of the floor roof panel which is going to be lifted.

5. The clamp is provided with and automatic locking system.

6. Use 2 safety bars from the other clamp and mount them on the brackets.

7. Lift the clamp in open position 20'' above the ground. On the side of each clamp are spring loaded pins at the sides. By pulling the pin out of its locking position, you can slide the jaw over the T-profile in order to adjust the clamp width. When the jaw is in the correct position the spring loaded pin will slide into the hole. Both jaws must be placed in the same position. The clamping jaws must be placed in the appropriate position for the panel width being lifted above.

8. On the clamp are height adjustments to be adjusted by means of rollers. Adjust the height of the rollers based on the thickness of the floor/roof panel. The round bar must always be at the deepest in the tongue and the round bar at the opposite side must be in the centre of the groove. All rollers must be in the correct position and locked with the pin.

9. Adjust the safety bars. The safety bars must be adjusted as close under the panel as possible but still being able to rotate under the panel after the panel has been lifted. All bars must be adjusted to the same position and locked with the pins.

10. Mark the centre of the floor/roof panel to be lifted. The centre of the clamp must be at the marked cnetreline!

11. Lower the clamp completely on the panel.

12. Now lift the clamp slowly.

13. Lift the panel 12 inches above the ground and rotate the safety bars under the panel.

14. Now carefully hoist the floor/roof panel up and manoeuvre it into position, rotating the safety bars upward just prior to setting.

15. When the panel has been positioned correctly, lower the clamp on the panel so that the locking mechanism keeps the clamp open.

16. Now you can lift the clamp carefully from the panel.


Important
Always use the safety bars during lifting a floor/roof panel
It is strictly forbidden at any time for persons to be under the load during lifting!
Handle the clamps with care,.

The maximum load-bearing capacity of the clamp may never be exceeded.
Never put hands, arms, feet, head or legs under the load, or between the jaws of the clamp.

The load must always be hoisted, it may not be dragged along the ground.
Avoid sudden movements to prevent accidental release of the load.

No alterations may be made to the clamp without the manufcturer's written permission. Any breach of this condition automatically invalidates all warranties.

If the lifting eye on th clamp is attached directly to the crane hook, the hook must be able to move freely in the lifting eye on the clamp. If it can't, use an extension.

In freezing werther, do not attempt to lift panels on which ice has formed.

Do not attempt to lift panels which are greasy or in any other way are dirty or slippery which may cause less friction between the clamp rubbers and the panel.


Daily
Check the clamp to insure it is in good condition and working properly.
Any parts showing defects or wear must be replaced by an authorized service representative.


The clamp must be serviced and checked by an authorized service representative every six months.

In the event that the clamp is not operating properly, contact an authorized service representative.

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