H. Special Instructions

ConCore Panels

Installation of the ConCore panel can proceed using the procedures for unfilled panels.

When you are ready to install cut ConCore panels, the following steps are to be observed.

  1. Consider the use of protective personal equipment normally recommended in machine shop practice.
    1. Safety glasses.
    2. Comfortable leather or cotton-face gloves.
    3. Dust mask--fiber cup, the type recommended for paint spraying and wood cutting work environments.
  2. Attach vacuum cleaner nozzle to bandsaw table. Allow proper clearance for cutting the panel. Start vacuum cleaner before starting bandsaw. A Rockwell Manufacturing Model 49-255 portable tank type vacuum cleaner is an example.
  3. Place protective material on floor surface under and around where bandsaw is set up.
  4. Cut the panels as specified by field supervisor.
  5. Unless there is a concern by the customer, cut edges of perimeter ConCore panels need not be sealed. However, it is recommended that cut edges of cable and grille cutouts be sealed. The sealant to be used can be either:
    1. 60 parts by volume of Elmer's woodworking white glue mixed with 40 parts cold tap water. Apply a generous layer of the sealant mixture with either a 1-inch nylon bristle brush, a 2-inch nap finish roller or an open cell sponge.
    2. Tru-Test clear coat HI-Q No. 1336 clear spray enamel.
  6. At the end of the day, collect all dust and debris around bandsaw cutting area.

NOTE: The bi-metal, 14-tooth, ½-inch wide, .034-inch thick bandsaw blades are more than adequate for cutting ConCore panels.


Wraparound Carpeted Panels

If you are installing wraparound carpet panels, you will probably experience some growth or shrinkage in the floor as it is very difficult to maintain exactly 24 inches in the panel size due to variation in and compression of carpet pile. Therefore, a periodic measurement must be made to check the grid dimension. If the grid lines are intended to center on columns or other particular objects, a growth or shrinkage can be a problem. In any case, the floor must be kept tight. When the project conditions specify that the grid must fall on column center line or at a designated point, it is important to notify your customer that the panel size can be a problem.


Monolithic Carpeted Panels

When installing monolithic carpeted panels, the use of carpet shoes is a must! If they are not used, a considerable amount of carpet piled will get trapped between the steel edges of the panels. This will affect the tightness of the floor and cause carpet damage. See figure 10 for correct installation procedure.



Bolt-Down Stringer

When installing a bolt-down stringer system, you will often find that movement of the bases is much harder. Therefore, do not glue and bolt up as large an area in front of panel laying as you would for other systems.


Stringerless Floor

When installing a stringerless floor system, it is critical that no one be allowed onto the floor before it is cut in and well contained on all sides. This floor system has a greater tendency to loosen up until contained.


Diagonal Bracing

If diagonal bracing is required for containment, it should be at a 45° angle to the bottom of the panel. In using bracing, the normal procedure is to screw the brace to the bottom of the panel with sheet metal screws and anchor the other end to the subfloor with the power actuated fasteners. Diagonal bracing usually occurs at the top of ramps, steps and fascia. See figure 11.


Fastener Torque

The following torque values should be observed with these various systems.

707 Stringer             40 inch-pounds
807 Stringer             35 inch-pounds
703 Stringer             60 inch-pounds
803 Stringer             60 inch-pounds
706 Stringer
806 Stringer             50-inch pounds
915 Stringer
912 Corner Lock      20-inch pounds
812 Corner Lock


A/F Protection

As the A/F installation progresses, the system should be protected from abnormal foot traffic and other abuses. Restrict movement of heavy loads and work upon the A/F by providing signs and barricades. If you are required to provide paths for such traffic and work, lay down tempered masonite, plywood or other suitable load-distributing material. You can also utilize nonstaining reinforced kraft paper in areas which could receive harm to the finished panel surface; be sure to tape seams. Prior to covering the A/F with protection, be sure to clean or vacuum.


Removal and Reinstallation

When access to the cavity under the floor system is required, only those panels directly over the area of work should be removed. The first panel removed must be removed with the use of an approved lifting device. Place the lifter in the corner of the panel, and lift up vertically. Once the panel is up far enough above the plane of the adjacent panels, remove the panel by hand. The use of screwdrivers, pliers, etc., is absolutely not permitted. If additional panels immediately adjacent to the first panel removed require removal, then place a hand under that panel and lift out. All caution should be taken not to disturb the level adjustment or perpendicularity of the access floor pedestal supports while the floor panels are out of the system. When re-installing monolithic carpeted panels, the use of carpet shoes is a must! When re-installing tiled panels, exercise caution not to damage trim edge.


Final Adjustment

Inspect the installed floor and make the following normal adjustments as required:


STEP 1. Rocking panels: Either adjust the pedestal leveling nut, or check to see if pedestal is sitting perpendicular. Try rotating panel 90° on VAT or HPL surfaced panel for stubborn rockers. Check to see if pedestal head gaskets are positioned properly or if stringers are correctly fastened. Check to see if carpet pile is preventing panels from seating properly.


STEP 2. Tipping at cut panels: This generally occurs when the cut panel is supported improperly. Adjust or modify support until no tipping occurs.


STEP 3. Loose cut panels at perimeter: This situation occurs when panels cut into walls and columns are too short. If cove base is to be installed and will cover such short cut panels, then you can glue shims of metal or treated wood in place to provide a tight fit. In cases where cuts are extremely short, a new panel will have to be cut to fit.  If you use shims, cut them off even with top of floor panels.


STEP 4. Check carpet floors for:
(a) Proper grain directions; rotate as necessary.
(b) Loose tufts of carpet; snip off.
(c) Panels which were not properly placed using shoe horns; re-install using shoe horns.


STEP 5. Check-all accessories for proper placement and workmanship. Correct all marginal work or damaged material.