2021 SLD Installation Guide.pdf

Installation & Operation

©2019 SLD Technology, Inc. SLD-IM-AFR-1G

AirFRAME® Operating Room Ceiling System Installation Manual

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System Description The AirFRAME® modular operating room (OR) ceiling system integrates all OR ceiling-mounted components — including ventilation, filtration, integral lighting, and other electrical components, as well as mounting plates, rails or other connection points for medical gas, audio visual, equipment/ lighting booms, and imaging equipment — into factory-assembled modules. The modules are installed as a complete system instead of following the linear process of installing each of these items individually, as is the case with traditional stick-built construction.

Components potentially included with the AirFRAME system include:

1. AF airflow modules

2. OB equipment mounting modules

3. RC rail mounting modules

4. Hinged damper/diffuser assemblies

Supply, Install, and Connect (SIC) Responsibility Matrix Table 1 represents the responsibility matrix for a typical AirFRAME ceiling system install. Please note that every project is unique, and that this flow can change from region to region, or for a whole host of other reasons. The actual flow for a given project is determined by the general contractor.

Table 1 – SIC responsibility matrix*

Item Supply Install Connect Anchor method Structural Install

Contractor Install

Contractor

Anchor hardware Install Contractor

Install Contractor

Install Contractor

AirFRAME modules SLD Tech Install

Contractor Install

Contractor

Truss modules SLD Tech Install Contractor

Install Contractor

Split connect hardware SLD Tech Install

Contractor Install

Contractor

Med-gas manifold Equipment Manufacturer

Equipment Installer

Equipment Installer

Med-gas stub-outs Equipment Manufacturer

Equipment Installer

Equipment Installer

Elect J-box SLD Tech SLD Tech Electrical Contractor

Power to AirFRAME

Electrical Contractor

Electrical Contractor

Electrical Contractor

Control sig to AirFRAME

Electrical Contractor

Electrical Contractor

Electrical Contractor

Data or AV to AirFRAME

Electrical Contractor

Electrical Contractor

Electrical Contractor

Supply air ductwork

Mechanical Contractor

Mechanical Contractor

Mechanical Contractor

Equip mounting plates

Equipment Manufacturer SLD Tech Equipment

Installer

Ceiling mounted equipment

Equipment Manufacturer

Equipment Manufacturer

Equipment Installer

Damper/diffuser SLD Tech Install Contractor

Install Contractor

Final clean Install Contractor

Install Contractor

Install Contractor

HEPA filter (if required) SLD Tech Install

Contractor Install

Contractor

Test & balance T&B Contractor

T&B Contractor

T&B Contractor

* This matrix represents a typical flow for jobs. The actual flow may vary based on the region, requirements of the job, or other factors.

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General Information

1. Read these instructions carefully before unpacking, installing, and using this system.

2. To prevent damage, modules should not be moved into the OR until all demolition, pre-construction, and clean-up in the space is complete.

3. Do not unwrap modules until they are ready to be installed.

4. Inspect the wrapping of modules for specific tagging numbers indicated by the factory to identify the specific OR where each module is installed.

5. Check the unit tag against plans to verify where each module is placed and what direction it faces.

The unit tag is typically located on the plan southwest corner of each module but may vary based on project specifics.

6. Verify that the electrical and mechanical connection points of the AirFRAME system match the drawings and will be accessible before installing modules.

7. SLD Technology recommends that the unit be covered during construction to avoid entrapment of dust in diffuser screens and dampers.

8. DO NOT install filters (if applicable) until all construction is complete and the OR is ready to be commissioned.

Installation Staging Most projects involve multiple ORs with multiple AirFRAME modules per room. Therefore, it is important to keep units wrapped until they are ready to be moved into the OR where they will be installed.

The tag numbers on the wrapping provide the most expedient way to identify module groupings by OR, so it can be helpful to group modules by room before beginning to move or unwrap them.

WARNING:

Installing and servicing the AirFRAME modular fully-integrated OR ceiling system can present lifting, system pressure, and electrical hazards.

Only trained and qualified personnel experienced in the installation of similar systems should install or service AirFRAME equipment.

Before connecting an AirFRAME system to power or performing any service on electrical components, always turn off the main power to the system. There may be more than one disconnect switch. Electrical shock can cause personal injury or death.

IMPORTANT NOTE:

AirFRAME systems should be carefully installed in accordance with the standards of the National Fire Protection Association (National Electrical Code) and/or any applicable local electrical codes.

Authorities having jurisdiction should be consulted before installations are made to verify local codes and installation procedures.

The hinged damper-diffuser assemblies and HEPA filters are expensive long-lead items and should be stored and handled with care. Make sure to keep them safe until installation.

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Tools Required tools (Figure 2) and recommended tools are as follows:

High Priority

• (1) ea. Forklift

• (1) ea. 3 ft. level

• (1) ea. Socket Set

• (1) ea. Wrench Set

• (1) ea. 16 ft. minimum Tape Measure

• (1) ea. Chain Fall

• (2) ea. Duct Lifts (Genie brand style, SLC-18 or

SLC-24 w/650 lb. working load capacity)

• (4) ea. Furniture Dollies

• (4) ea. Foam, Padding, or Furniture Blankets – for protection from fork damage

• (4) ea. Eye Bolts (5/8-12 x 6”, with 1” minimum ID)

• (2) ea. 5/8” Fender Washers per suspension location

• (2) ea. 5/8-12 Hex Nuts per suspension location

• (1) ea. Dyn-o-wrap blue plastic roll – large

• (4) ea. 6 ft. long 2x4 Lumber

• (4) ea. 1” wide Ratchet Straps

• (2) ea. Spud Wrenches/Drift Pins

• (1) ea. Cordless Drill with a 5/16” socket bit

• (4) ea. 12 ft. Ladders

• (1) ea. Pneumatic or Electric Rivet Gun

• (4) ea. PPE: Hard Hat, Safety Glasses, Vest, and

Gloves

Medium Priority

• (2) ea. Pallet Jacks

• (1) ea. Set of Fork Extensions

• (1) ea. Shop Vac.

• (1) ea. Duck-bill Vise-Grips

• (2) ea. Large Flat Blade Screwdrivers

• (4) ea. Soft Straps (min 1” wide)

Low Priority

• (2) ea. Flood Lights

• (2) ea. Extension Cords

• (1) ea. Laser Level

• (4) ea. Soft Rags and Cleaner

Contractor is responsible for all labor and tooling required. The list above is SLD’s recommendations for items that will make the installation of the AirFRAME system go faster and more smoothly but is not intended as an all-inclusive list.

Figure 2 – Tools required for AirFRAME installation

Storing Modules

1. Store modules indoor in a clean, dry environment on a level surface.

2. Store modules in the upright position. Do not rest modules directly on floor - always use wood blocks that extend across the depth of the module to support it above the floor. (Figure 3)

3. Do not stack modules.

Figure 3 – AirFRAME module storage.

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Receiving and Inspection

1. AirFRAME modules are inspected and double-wrapped in the factory prior to shipping. Ship-loose hardware and accessories are either crated or provided wrapped inside AF modules.

2. Modules can be removed from the freight truck using a forklift.

3. Carefully inspect all modules and shipped loose items after receiving them from the freight carrier and compare with the shipping documentation to verify that the shipment is correct, complete, and free of damage.

4. If shipping damage has occurred, notify the freight carrier immediately. Provide photographs of the damaged freight, call the local freight claims inspector to inspect the damage and file a claim with the carrier.

5. Notify SLD Technology of any damage or discrepancies as well by calling (503) 744-0002.

Moving AF Modules to the OR

1. Remove banding from shipping pallet.

2. Using a forklift with carpeting or some other protective covering on the forks, lift the module from the base of the shipping pallet.

3. Rest the module on moving dollies.

4. Transport the module to the installation area using the moving dollies (Figure 4). A minimum of two (2) persons should move each module – one to push the module and the other to verify the module is properly resting on the dollies and that the path is clear to avoid contact with walls and other objects.

Figure 4 – Moving AirFRAME modules to an OR.

Moving OB or RC Modules to the OR

1. OB and RC modules (Figure 5) are generally smaller and constructed of heavy-gauge steel.

Caution should be exercised to avoid damage to their powder coat finish.

2. Trusses can be lifted by hand or forklifted and transported to the installation area using dollies or carts.

Figure 5 – OB (outboard) mount.

Unwrapping a Module

1. DO NOT unwrap AirFRAME modules in a dirty environment. Components should only be unwrapped in a clean area.

2. AirFRAME modules are double-wrapped in the factory prior to shipping. Use a utility knife or similar to cut the wrapping along each edge, being careful not to scratch the unit. Ultimately, the wrapping should fold down around the unit.

Use extreme caution when cutting the wrapping of AirFRAME modules to avoid personal injury or scratching the powder coat finish and compromising its integrity.

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Preparing to Hang Modules

1. Position the module below the location where it will be attached to the building structure.

2. Lift the module with a pallet jack or duct lift, remove the dollies and replace with wood blocks.

3. Attach the chain hoist to a weight-appropriate structural member.

4. Attach the other end of the chain hoist to the factory-provided eyebolt on the module.

5. Slowly lower the module to the flat position and rest on blocks, taking care not to damage the aluminum grid.

6. Remove the eyebolt lifting lug(s) before lifting the module into place for final install.

7. Make sure to apply caulk between modules at all module-to-module connections before bolting modules together.

Hanging Modules

Verify that any lifting equipment for AirFRAME modules is rated for the weight being lifted. Failure to do so can result in equipment damage, personal injury, or death.

Modules can be hung individually or in groups, or all modules for a given OR can be joined together on the floor before being lifted and attached to the building structure. Be sure to verify that your lifts are capable of handling the load for the method chosen.

1. Arrange modules on the floor as they will be installed in the ceiling, making sure that all shared openings line up as well as connection points between modules (Figure 6). It is important that modules are installed tightly against one another to maintain overall dimensions of the system versus specifications.

2. Tighten bolts to “snug tight” as defined by AISC.

DO NOT overtighten bolts.

3. Be sure to use carpeting or some other soft material on the lift forks to avoid damaging underside of the unit. Slide lifting devices (i.e.

Genie lift) under each side of the AirFRAME system so that the weight is distributed equally between each lift for proper balance (Figure 7).

4. Lift the AirFRAME system enough to be able to strap each module to a lift. Ratchet tightly enough that it cannot slide off.

5. Align the AirFRAME system with the hanging points and lift the system into place.

6. Begin to install hanging hardware and the factory-provided suspension plate washer. Use a drift pin in cases where the alignment is difficult. Again, tighten bolts to a snug fit – DO NOT overtighten.

7. When lifting and bolting adjacent modules, take care not to pinch or crush wiring between modules. Make quick-connect connections before pushing modules together, where applicable.

Figure 6 – Verify that shared openings and connection points line up before lifting modules to the ceiling.

Figure 7 – Lifting modules. Cover the lift forks with protective materials and strap the unit to the lift.

Ensure that the lift you are using is capable of handling the load of the modules.

It is much easier to cut each of the all-thread rod drops for each module at a slightly different length, to prevent having to feed all of them through the suspension holes simultaneously.

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Level System, Verify Dimensions

1. Begin with one module to make sure it is level and on the plane described in the owner's specification drawings. If module is not level, adjust the module supports that are connected to the roof (or side) of the module.

2. Monitor each module and overall SLD dimensions during the course of installation to verify that the overall dimensions match specifications.

3. When the system is fully level and dimensionally correct, tighten all bolts to secure each module into place so that they will not move.

4. Trim all-thread rod.

Wiring SLD recommends that a licensed electrician make all electrical connections in accordance with wiring diagrams and local electrical codes.

1. All integral lighting fixtures on AirFRAME systems are factory installed and ready for connection to power at the job site. All that is required at the jobsite is to couple quick-connects between modules (Figure 8).

2. Quick connects are located at module splits.

3. Typically, there is one LED driver enclosure

(Figures 9 and 10), per lighting circuit, mounted on the outside of a module. Power is supplied only to the electrical junction box(es). Follow all applicable codes and site safety procedures when connecting power. All connections should be accessible from the operating room side.

Unless otherwise specified, electrical markings and wire colors are for 277 volts. However, any voltage between 120 and 277 can be applied.

Figure 8 – Quick connect electrical connector at module split

Figure 9 – LED driver enclosures are labelled by circuit

Figure 10 – LED driver enclosure

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Module Penetration Protection

1. SLD Technology provides screw tip covers (#3- 142-100-TP) for any potential screw penetrations into the sides and top of the modules (Figures 11 and 12).

2. Put a dab of caulk into the cover and twist it onto the exposed end of the screw.

Figure 11 – Protective cover

Figure 12 – Caulked cover

Caulking Requirements

1. It is critical that the modules be installed tight against one another as noted in the section on bolting — this is the contractor’s responsibility.

2. Maintain protocol cleanliness prior to caulking.

Thoroughly clean all surfaces on which caulk will be applied, using IPA wipes and the proper PPE as defined in the safety data sheet. We recommend that the same personnel apply the caulk within each module.

3. Use an approved primer (Dow Corning OS 1200 Primer) on the surface prior to caulking. Follow product instructions for cure time.

4. Completely caulk seams using SLD-supplied caulk. After the bead has been applied, tool the caulk — with either a gloved finger or smoothing tool — pressing the length of the bead down into the seam to produce a complete seal. The grid seam must be a continuous seal as it is the final barrier to the sterile field.

5. Caulk all bolt locations and structural washer plates (Figures 13 and 14), making sure to form a complete seal all the way around. Caulk around all screw tips.

6. Allow caulk to cure to 24 hours. At this point, the caulk should be cured to a depth of around 3mm.

Figure 13 – Caulked bolt location

Figure 14 – Caulked structural washer plate

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Corner Cap/Split Cover Installation

1. Corner caps are used on every AirFRAME installation. If the AirFRAME has been designed with more than one air delivery module, split covers will be used as well. Both are installed in a similar manner.

2. Every corner cap and split cover must be sealed to prevent leakage to or from the interstitial space. Provide a contiguous bead of caulk on the back side of the cap/cover, passing all the way around the outside of the screw holes and finishing where started so that there is no break in the seal.

3. Align the cap/cover with the appropriate gap in the sidewall of the AirFRAME and stick in place with the caulk, making sure not to compromise the integrity of the caulk seal.

4. Using the provided cover/cap self-tapping screws (#18075HWHSD3ZICC), screw the cover/cap into place via the screw holes.

5. Cap the exposed screw heads on the inside of the AirFRAME with the provided screw tip covers (Figures 11 and 12), making sure to put caulk on the inside of each of the covers before installing them.

6. Double-check the caulk seal against the sidewall of the AirFRAME. Fill in any holes as necessary to ensure a continuous seal.

Figure 15 – Installed corner cap

Perimeter Angle Installation

1. Using the AirFRAME ship loose drawing as a guide, make sure to position each piece of perimeter angle in the correct location.

2. Align the edges of the angle with the edges of the outside of the module and align the holes in the angle with the topmost groove in the side of the grid. The top of the ledge should finish at finished ceiling height.

3. Using the provided perimeter angle self-tapping screws (#15050PPHSD2Z), screw the angle into place via the screw holes, making sure that the holes remain aligned with the groove.

Figure 16 – Perimeter angle

Cleaning

1. SLD Technology recommends that a 24-48 hour

“blowdown” of the HVAC system be performed prior to final cleaning and HEPA filter installation.

2. Vacuum and clean the grid of all foreign objects.

3. Once the operating room is ready for filter installation, wipe down all grid members with a site protocol-approved cleaning solution.

The light lens material should be cleaned using 100% deionized water only. Alcohol or other cleansers can cause immediate and irreparable damage to the lens material.

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Filter Installation (if applicable)

1. Prepare site to accept and adequately handle

HEPA filters. Please note that, as filters purchased through SLD are drop shipped directly from the filter manufacturer, a 24-hour notice before arrival cannot and will not be given by SLD. Upon arrival, store filters indoors in a clean and dry space.

2. To begin install, open the damper/diffuser cam locks and lower both the diffuser and damper.

3. Follow the original filter manufacturer’s handling instructions at all times (see the Camfil Farr Users Guide included in section 4 of the AirFRAME submittal). Do not rack or twist the filter frame or put pressure (even hand pressure) on the filter media at any time. It is recommended, but not necessary, for two people to handle each filter install.

4. Rotate the filter clips so that they are free and clear of the knife edge of the diffuser.

5. Rest one edge of the filter on the ledge created by the damper/diffuser hinge and position yourself to lift the filter gel seal into the knife edge.

6. Push up on the frame of the filter to ensure a proper seal of the filter.

7. Rotate the filter clips perpendicular to the grid to support the filter (Figure 17).

8. Reverse these instructions for filter removal.

Figure 17 – Filter installation

Damper/Diffuser Installation

1. Locate the damper/diffuser rivets (#45BRAW) and hinged damper/diffusers.

2. On the hinge for each damper/diffuser, there is a set of rivet holes. Align these holes with the holes located on the frame around the vent opening space into which it will be installed (these holes are only located on one side, so the damper/diffuser can only be installed in one direction).

3. Using a pneumatic or electric rivet gun, rivet the damper/diffuser hinge into place with the damper/diffuser rivets, checking that each rivet makes a solid connection, and that the hinge remains flush against the frame.

4. Once all rivets are installed, fully open the damper/diffuser and allow it to hang downward.

Bend the diffuser screen backwards slightly to put a slight arc in its frame (Figures 18 and 19). The damper/diffusers tend to settle during shipment and may sag slightly if this is not done. Be careful not to apply too much pressure, as the diffuser screen can be easily damaged.

5. Close the damper/diffuser, making sure to use all the cam locks to lock it in place. Check that the diffuser screen finishes flush against the frame.

6. If there is a significant gap, repeat steps 4 and 5 until it is resolved.

7. If the AirFRAME has been designed with more than one air delivery module, locate the frame rivets (#42BRAW).

8. In all locations where two air delivery modules come together, the frame(s) on one side of the split will need to be riveted to the grid on the other side. Using the pneumatic or electric rivet gun, rivet the frame(s) to the grid with the frame rivets, checking that each rivet makes a solid connection, and that the frame remains flush against the grid.

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Figure 18 – Damper installation

Figure 19 – Damper correction

Damper Adjustment All balancing components are downstream of the filter and can be adjusted without removing ceiling diffusers.

1. Using a hex key wrench, insert it though the center hole of the diffuser screen (Figure 20).

2. Turn the hex key to adjust the guillotine slide plate to the desired position.

3. Remove the hex key.

Figure 20 – Damper adjustment