INSTALLATION GUIDE PermaTrak. Patented Product: U.S. Patent #5,906,084 #8,302,362 #8,522,505 #8,839,588 #9,096,975

Transcription

1 INSTALLATION GUIDE PermaTrak. Patented Product: U.S. Patent #5,906,084 #8,302,362 #8,522,505 #8,839,588 #9,096,975

2 Table of Contents Project Overview Forward, Acceptability Criteria, Safety, Waste Materials You Need Shims, Non-shrink grout, Threaded bar with nuts and washers, Patch kit, Lifting gear Foundations PermaTrak piers, timber piles, cast-in-place concrete shallow footing, concrete caisson, steel piles, etc. Installing the Boardwalk Components Setting the Abutments H-Connectors Setting the Pedestal Components Precast concrete piers (by PermaTrak) Setting pedestal cap on top of timber pile Setting the Beams Setting the Treads Setting the Treads - General Notes Tread-to-Beam Connections Clip & Stabilizer Angles Precast Concrete Curbs Hand Rail Bracket 2

3 Forward This installation guide is to be used as a reference only. The construction of the PermaTrak system may vary from information contained in this guide due to different field conditions, special components, or other construction requirements. Please contact your PermaTrak field representative with any questions regarding installation details or product features. Acceptability Criteria for Treads and Curbs The finished visible (in the final installed position) surface shall have no obvious imperfections other than minimal color or texture variations from the approved samples or evidence of repairs when viewed in good typical daylight illumination with the unaided naked eye at a 20 ft. viewing distance. Safety All safety codes and construction guidelines for handling heavy material should be closely followed. Those working at the job site should comply with all health, safety, and environmental policies. Waste Ensure that all waste is removed from site and responsibly discarded. 3

4 Materials You Need Shims Non-shrink grout 4

5 Materials You Need (continued) Patch kit provided by PermaTrak Lifting gear Threaded bar with nut and washer 5

6 Foundations Refer to installation drawings for required connection components. PermaTrak piers Timber piles Cast-in-place concrete shallow footings Concrete caissons Steel H-pile Helical piles 6

7 Precast Unit Handling - Installing the Boardwalk Components All lifting equipment that comes in contact with the precast components should have rubber padding installed for protection. We recommend that adequate padding be used on both the top and bottom of the handling forks. Setting the Abutments The abutments have two threaded lifting inserts on the inner wall for handling. Refer to the shop drawings for specific sizes of threaded lifting inserts. Place abutments on prepared subgrade, specified in the installation drawings. Clean debris from the prepared subgrade and abutments. There should be minimal gap between the units (less than 1/4 ). 7

8 H-Connectors for Abutment-to-Abutment Connection The optional H-Connector (supplied by PermaTrak) may be required to secure multiple abutment sections together. Pre-formed slots cast into the back of the abutments receive the fieldinstalled H-Connectors. Hold the H-Connector parallel to the opening in the back of the abutment sections. Using a block of wood (approximately 1 x 4 ), tap in the connector until seated in pre-formed slot on both abutment sections. If multiple abutments are used, apply the adhesive seal wrap (provided by PermaTrak) to cover the entire joint. 8

9 Setting the Pedestal Components Laser levels are recommended to ensure accurate elevations throughout the installation process. Precast concrete piers (by PermaTrak) The bases should be set onto a prepared subgrade of compacted sand, gravel, or concrete per the installation drawings. Consult the installation drawings in order to set the bases on the subgrade, level, and check for proper elevation. 9

10 Setting pedestal cap on top of timber pile 10

11 Setting the Beams We recommend lifting the beams with lifting straps per the location detailed on the shop drawings. Slings and equipment with forks may also be used. Beams may be damaged if they are lifted with incorrectly placed slings or forks. Some beams have pre-formed holes on the bottom surface. Refer to shop drawings for size and location. 11

12 Setting the Beams (continued) PermaTrak beams tied down to foundation and filled with epoxy grout 12

13 Setting the Treads Maintaining the proper physical appearance of the tread exposed surfaces ensures an acceptable installation. Treads sit on a rubber leveling pad (provided by PermaTrak) on top of the beams. These 6 wide strips should be laid end to end along the top of the beams. To maintain the specified spacing between treads, it is recommended that contractor-provided spacers be utilized - (1) per each end of the tread. A 1/8 piece of sheet metal works well to ensure proper spacing per the installation drawings. 13

14 Setting the Treads (continued) The treads may have provisions for a urethane stop pin (provided by PermaTrak). Install the tapered end of the urethane pin into the tapered holes on the bottom surface of the tread. These pins require no lubricant and should be tapped in until they are snug. We recommend checking the linear measurements as tread installation continues. It is much easier to adjust tread spacing (if needed) as you proceed, rather than to return and move previously installed treads. It is recommended to check this linear measurement every beam span. 14

15 Setting the Treads (continued) After the tread is installed, the top surface must be protected from abrasion or wear caused by wheels, tracks, or construction material. Always protect the tread surface with plywood or OSB sheeting. Consult with your PermaTrak representative for special requirements if the boardwalk is to be constructed top-down. Your representative will advise on handling equipment and techniques applicable to your project. 15

16 Setting the Treads - General Notes Handling Larger Treads The handling beam/spreader bar should be configured such that the treads may be lifted from the ends. This will provide for easier handling and positioning. Proper rubber padding should be used with any lifting device. Setting End-to-End Tread Configurations (Observation Decks, Platforms, etc Proper fork spacing is critical, and forks should be covered with rubber padding on top and bottom. 16

17 Tread-to-Beam Connections Clip & Stabilizer Angles for Uplift Resistance Refer to installation drawings for required connection components. Steel clip angles PermaTrak treads tie down Steel clip angle Composite clip angle 17

18 Precast Concrete Curbs Refer to curb connection details on installation drawings. 18

19 Hand Rail Bracket (only used with timber railing systems) If applicable, handrail brackets and corresponding fasteners are supplied by PermaTrak. Refer to installation drawings for more details. The closed part of the bracket should be facing the center of the walkway (drawing on the right). Place the timber posts into the bracket and mark location of the holes. Prior to drilling the holes thru the post, remove the post from the mounting bracket. Do not drill thru the bracket - this will remove the corrosionresistant properties of the plating on the bracket. Bolt the post into position using the post mounting hardware (provided by PermaTrak). Railing brackets for projects with timber railing Preformed holes for railing bracket fasteners 19