Installation Instructions for. Seamless Acoustic Ceiling StoSilent Panel

Installation Instructions for Seamless Acoustic Ceiling StoSilent Panel Limited combustibility Building material class B1 to DIN 4102 It should be no...
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Installation Instructions for Seamless Acoustic Ceiling StoSilent Panel Limited combustibility Building material class B1 to DIN 4102

It should be noted that details, illustrations, general technical information and diagrams contained in this document are only general proposals and details which merely describe basic functions schematically. No precise dimensions are included. The applicator/customer is independently responsible for determining the suitability and completeness for the product in question. Neighbouring works are described only schematically. All specifications and information must be adjusted or agreed in the light of local conditions and do not constitute work, detail or assembly plans. The technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must always be observed.

General notes Objectives The acoustic systems must be capable of performing a dual function: As well as precalculated acoustic insulation, at the same time an appealing appearance is expected. Ingenious design is required to achieve these two objectives as well as trained and well-practiced applicators. For this reason, Sto acoustic products must only be applied by specialist personnel who use these materials properly in accordance with system-based principles.

Ceiling loads Ceiling installations within a flat-surfaced ceiling must be planned for in advance. If necessary, before boarding up the metal sub-construction, all requisite replacement parts and/or additional hangers must be provided. Loads Fixing elements < 2.0 kg/m² point load Cavity fixing < 10.0 kg/m² Direct mounting

> 10 kg/m²

Direct mounting

Notes max. 2 units/m² Directly into the metal sub-construction or convert into surface load Directly to the bare ceiling

Joints and interconnecting surfaces Joint widths The acoustic system StoSilent Panel must have an open, surrounding joint. Interconnecting surfaces Maximum surface area 200 m² Maximum projection length 20 m • Structural expansion joints must be incorporated. • On specialist building geometries and narrowed areas, expansion cracks must be planned for. • No fixed connections to neighbouring components

Ambient climate conditions • •

The ambient room temperature and the lowest permitted application and substrate temperature must not be less than 12 °C. The ambient humidity when when mounting the boards, filling and coating must not exceed 70 %.

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 2/24

1.

Fixing hangers -

Fix rigid Nonius upper part with approved anchor fixings, (nails not permitted) to the bare ceiling, as shown in figure 1. Hanger spacing max. 1000 mm centres in the direction of the primary grid. Tools: plumbline or laser guide device

 Note:

In the fully installed sub-construction, the tracks of the main runners face the primary light source. Where glazing is installed on multiple sides, the installation direction of the fine grid should by preference be from east to west (due to the low angle of the sun).

Figure 1

max. 1250 mm

max. 1000 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 3/24

2.

Install wall connection profiles − We recommend creating StoSilent Panel Alu ceilings with an open shadow joint to all connecting construction elements. − The open cross-section of the joint must be at least 0.8 % of the total ceiling surface. − Optional installation of a perforated L-angle (e.g. SC 3612 or SC 9309) according to figure 2. Install the perforated angle such that the perforated leg lies on the upper side of the acoustic panel. − Alternatively, a closed bracket can be fitted if this is located approx. 3 cm above the reverse side of the panel (rear ventilation of the panel must be assured by an open joint). - A laser guide device is recommended.

Figure 2

max. 1000 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 4/24

3.

Primary grid − Install and align primary grid with Nonius lower pieces − A laser guide device is recommended. − For connecting upper and lower Nonius pieces, use two Nonius staples (securing pins) each time. − Grid spacing of the primary grid max. 1250 mm, according to figure 3. − The coarse grid must be located at right angles to the incidence of light (i.e. normally parallel to the dominant window frontage).

Figure 3

Incident light max. 1000 mm

max. 1250 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 5/24

4.

Installing Main Runners − Install the main runners under the primary’s at 400 mm centres using system SC 6101 cross-connectors, ensuring that there is no movement in the main runners. − Main runner centres can be closed down to 200 mm in areas at risk of impact. − The fine grid must be placed parallel to the main light source (incidence of light).

Figure 4

Incident light

400 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 6/24

5.

Channel connections − Connect both the main and primary channels by use of a internal splice connector SC 6078 as in figure 5. − Do not butt-joint channels. Spacing must be approx. 10 - 15 mm.

Figure 5

10-15 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 7/24

6.

Align sub-construction − Align sub-construction as shown in figure 6 using 3-4-5 configuration and ensure that it is absolutely level. − A laser guide device, a water level or spirit level is recommended. − The sub-construction must not demonstrate any stresses. − Inclined ceilings must be sufficiently secured against lateral displacement with cross hangers.

Figure 6

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 8/24

7.

Ceiling installations − Cut-outs for lights, ventilation, inspection panels, etc. to be installed according to existing ceiling level and sub-construction to be planned accordingly. − If, despite planning, cut-outs still lie in the area of the main runners, the subconstruction should be separated before assembly, as in figure 7, and firmly replaced. − Load distributions and fixings should be executed as detailed in the Applicator Handbook for Acoustic ceilings. − When separating the primary grid, it must be secured with additional hangers as shown in figure 7. − Do not cut into the primary grid at a later time, as experience shows that this leads to cracks in the ceiling finish.

Figure 7

Opening

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 9/24

8.

Bond sealing tapes to the fine grid − The entire fine grid must be masked across its complete length with self-adhesive StoSilent Profile Tape. − All tape ends must be arranged seamlessly. The tape can be applied seamlessly using double cuts. − Avoid wrinkles in the sealing tape. If any occur, remove them.

Figure 8

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 10/24

9.

Installation of the first StoSilent Panel Alu − StoSilent Panel Alu has to be installed with an open surrounding joint to all adjoining structural components. − The open cross-section of the joint must be at least 0.8 % of the total ceiling surface. − StoSilent Panel Alu should be fixed lengthwise to the main runners as shown in figure 9. − Beginning of board installation from a mid-line of the room. − Boards must only be screwed to the sub-construction using 25mm / 35mm dry wall phosphated screws. − We recommend the use of a screwgun with depth attachment. − Sink screw heads to a depth of max. 1 mm into the board. − Screw spacing approx. 200 mm, distance from board edge approx. 20. − The upper side of the board is printed for identification. − Under no circumstances should boards be screwed to the surrounding profiles.

Figure 9

400 mm

max. 1250 mm

max. 1000 mm

Incident light

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 11/24

10. Installation of subsequent boards − Boards for subsequent installation should be coated on 2 sides (long and short sides respectively) with StoSilent Fix. Consumption approx. 0.3 kg/m² (with small format boards). − Boards should be slid into place on the installed ceiling and fixed with screws. − In order to ensure filling over the entire area, StoSilent Fix should squeeze out on the upper and lower sides of the board along the entire length of the joint. − StoSilent Fix must not penetrate between board and grid. − Allow StoSilent Fix bead to dry for a short time, knock off cleanly and remove. Do not spread StoSilent Fix on the fleece of the board surface.

Figure 10

2 1

wrong

right

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 12/24

10.1. Installation variant with StoSilent Coll adhesive − Apply StoSilent Coll to the required edge areas of the pre-installed StoSilent Panel Alu. − Fit the cartridge at a sloping angle relative to the upper half of the panel edge. − Apply as uniform a bead of adhesive as possible in the sufficient thickness. − Press the next StoSilent Panel Alu onto the fine grid of the sub-construction, then push and screw onto the previously mounted ceiling (figure 10.1). To assure that the full-surface area of the panel edges are bonded, StoSilent Coll must be visible right down the length of the joint. − The remaining joint width should not exceed 1 mm, since otherwise the cost of post-treatment of the adhesive being squeezed out rises and the drying process is delayed. − Do not smooth adhesive residue across the surface of the panel. − Allow emerging, i.e. surplus, adhesive to harden for no longer than 24 hours, then scrape it off (for this operation, also refer to paragraph no. 12.1).

Figure 10.1

2 1

wrong

right

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 13/24

11. Continuation of assembly − In order to avoid linear joints, install StoSilent Panel Alu with staggered transverse joints with an offset of min. 400 mm as shown in figure 11. − Minimum temperature for installation 12 °C at max. 70 % relative air humidity. − Before commencing levelling work, allow ceiling to dry for at least 24 h in these climatic conditions. − In case of unfavourable weather conditions, the drying time for the ceiling may be longer. If necessary, schedule the use of dehumidifier equipment. − All retrospectively created cut edges and ones cut on site (where expanded glass has been exposed) must be sealed using StoSilent Fix and/or coated with system paint. Bonding with StoSilent Coll can be performed wet in wet with the system paint. − If there are gaps on the factory-sealed panel edges, or there is any damage to the reverse side of the fleece lamination, these defects must be remedied before or during the bonding process using StoSilent Fix and/or be sealed using system paint.

Figure 11 Incident light

min. 400 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 14/24

11.1. Installation details Integration of lamps or similar installations − All retrospectively created cut edges and ones cut on site must be sealed using StoSilent Fix and/or coated with system paint, as shown in figure 11.1. − The pure expanded glass on the panel cutouts must not be visible after the sealing process.

Figure 11.1

StoSilent Fix or Systempaint

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 15/24

11.2. Touching up of drill hole mistakes or mistakenly located apertures in the ceiling − All instances of reparation or drill hole mistakes must be protected in a systemcompliant manner by sealing all cut edges, and/or resealing the damaged areas on the reverse side of the ventilation-impermeable panel lamination. − Small gaps in the ventilation-impermeable lamination on the reverse side of the panel can be sealed by pressing in system adhesive. If necessary, remove expanded glass granulate locally to improve access to the gaps, seal gap with adhesive, then fill and smooth over the panel defects with StoSilent Fix. See figure 11.2. − Larger gaps must be touched up by installing a shaped section (i.e. one cut to size). For this, every cut edge (including on the shaped section) must be sealed using StoSilent Fix or system paint. − The pure expanded glass on the panel cutouts must not be visible after the sealing process.

Figure 11.2

System adhesive

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 16/24

11.3. Wall connection detail StoSilent Panel Alu Open wall connection without perforated L-angle − Fix main runners to the sub-construction with approximately 50 mm spacing from the wall and create open connection joint (figure 11.3) − Continuous hanging ceiling area ≤ 100 m² joint width min. 20 mm − Continuous hanging ceiling area ≥ 100 m² joint width min. 25 mm − Note: the open cross-section of the joint must be at least 0.8 % of the total ceiling surface.

Figure 11.3

approx. 50 mm

min. 20 bzw. 25 mm max. 100 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 17/24

11.4. Wall connection StoSilent Panel Alu Open wall connection with perforated L-angle − Fix main runners to the sub-construction with approximately 50 mm spacing from the wall. − Continuous hanging ceiling area ≤ 100 m² joint width min. 20 mm − Continuous hanging ceiling area ≥ 100 m² joint width min. 25 mm − Note: the open cross-section of the joint must be at least 0.8 % of the total ceiling surface. − Perforated L-profile (e.g. SC 3612 or SC 9309) must lie around the edges on the rear side of the acoustic board. Caution: StoSilent Panel Alu must not be screwed to the surrounding angle.

Figure 11.4

approx. 50 mm

min. 20 bzw. 25 mm max. 100 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 18/24

11.5. Wall junction for StoSilent Panel Alu Open wall junction with closed L-angle (set higher) − Fix fine grid to compression-proof sub-contruction about 50 mm from the wall as shown in figure 11.5. − Continuous ceiling surface area ≤ 100 m² min. joint width 20 mm. − Continuous ceiling surface area ≥ 100 m² min. joint width 25 mm − Note: the open cross-section of the joint must be at least 0.8 % of the total ceiling surface. − Closed L-profile with a space of min. 25 mm between the reverse side of the panel and the bracket fixed to the wall (assure good rear-ventilation the panels).

Figure 11.5

min. 25 mm

min. 20 bzw. 25 mm max. 100 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 19/24

12. Smoothing and sanding Level joints and screw heads sparingly smooth with StoSilent Plan Filling width max. 30 mm. Material use should be as low as possible, consumption approx. 0.2 kg/m². After drying, sand ceiling until absolutely level with emery board and sanding grid as shown in figure 12. − No levelling material must be allowed to remain on the fleece surface, as this impairs the acoustic effectiveness of the ceiling. − It is advisable to wear protective goggles and a P1 dust mask. − − − −

Figure 12

StoSilent Fix

StoSilent Plan after leveling with StoSilent Plan

StoSilent Fix

StoSilent Plan after sanding

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 20/24

12.1. Smoothing and sanding with StoSilent Coll − After the adhesive has cured (max. 24 hrs for a joint width of 1 mm) the surplus adhesive can be trimmed off using a sharp blade or a sharpened spatula. − The blade must be guided flat down the top of the panel and held at a sloping angle to the joint. − Fill joints and screw heads with a narrow bead of StoSilent Plan, using as little material as possible. Spatula width max. 30 mm. − Grind ceiling down smooth after drying using an emery board and an abrasive grid, as shown in figure 12.1. − No filler must be left on the surface of the fleece because this would adversely affect the acoustic effectiveness of the ceiling. − It is advisable to wear protective goggles and a P1 dust mask.

Figure 12.1

StoSilent Coll

StoSilent Plan After leveling with StoSilent Plan

StoSilent Coll

Sto Silen t Pla n After sanding

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 21/24

13. Check evenness − Check the evenness of the ceiling at board joints with a straight wide area leveller (60 cm) (see figure 13). − The wide leveller must not wobble over board joints or demonstrate any hollows. It is recommended to use construction lighting to cast rim light along the surface, in the direction of the expected primary light source (e.g. indirect lighting, windows).

Figure 13

wrong

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 22/24

14. Finish coating with StoSilent Superfein − Apply finish coating of StoSilent Superfein with stator-rotor pump (e.g. Strobot 203) or peristaltic machine (e.g. Inomat M8) and flow (0 – 15 l/min) and fine spray set (nozzle size 6.5 mm) − Spraying distance 70 - 90 cm − Spraying angle 90° − or use hopper gun to spray (nozzle size 6 mm) − Spraying distance 50 - 70 cm − Spraying angle 90° as shown in figure 14 − Observe drying times (at less than 70 % air humidity and + 18 °C temperature): o min. 5 h between 1st and 2nd spray coats o min. 12 h between 2nd and 3rd spray coats − Observe weather influences: o high air humidity − low temperatures prolong drying times. − Increasing material quantities (1st coat approx. 0.7 kg; 2nd coat approx. 0.9 kg; 3rd coat approx. 1.1 kg) − If necessary, apply a 4th spray coat. − See Sto Folder for further information on StoSilent Superfein. − Additional layers may be required, depending on the colour shade. − It is advisable to wear protective goggles and a P1 dust mask.

Figure 14

50 - 70 cm Joint 20-25 mm

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 23/24

15. General notes − This installation guide should serve as an aid to installation. − Additional information on detail creation, expansion joints, and the installation of a curtain wall are given in our technical handbook for acoustics. − The guide cannot detail and treat all eventualities occurring in installation. − It does not release the applicator from his responsibility for execution and quality. − The contents of the following DIN standards also apply - DIN 18 168 - DIN 4715 - VDI 2569 - DIN 18 182 - DIN 4706 - VDI 3755 - DIN 18 041 - DIN 4102 - VDI 2035 - DIN EN ISO 11 654 - and the Technical Data Sheets for the Sto AG products are to be observed. − The StoSilent Panel Alu may only be installed after an constant ambient temperature humidity level in the room has been achieved. − In the working steps shown in figures 12, 12.1 and 14, it is recommended to wear protective goggles and dust protection mask. − Special construction details and up to date documentation can be obtained from Sto AG on +49 (0) 7744 57 1131. − Before commencing work, a training or introductory session is strongly recommended.

The concrete technical specifications and information on the products contained in the Technical Data Sheets and system descriptions/approvals must be observed.

Rev.-no.02/06.11 - 24/24