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B U ILT FO R L I V IN G
A S S E M B LY & I N S TA L L AT I O N
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01
INTRODUCTION
ASSEMBLY &
INSTALL A -
TION
The large KLH solid wood panels can usually be installed The individual components are cut exactly to fit. As a
easily and using very few tools. The fully packaged result, almost no field measurements need to be taken
assembly set is delivered directly to the construction site into account (e.g. for ordering windows and doors), which
by lorry or container. The relevant installation company in turn has a positive impact on the overall construction
(usually a wood construction firm) will check and accept time. In our experience, installation work can be com-
the delivery. The individual components are assembled pleted approx. 20 – 40% quicker than with conventional,
and screwed together by using appropriate lifting gear. traditional solid structures. Dry construction work, the
Compared to other construction materials, such as bricks, application of insulation material and the façade as well
concrete or steel, KLH building shells take much less time as the installation of doors and windows will also take
to be assembled. Follow-up work can start immediately about 10 – 30% less time. In summary, this provides an
after the components have been assembled, since this is a innovative and long-lasting construction that meets both
dry form of construction that does not require any drying economic demands as well as the criteria for ecological
time that would otherwise need to be taken into conside- sustainability.
ration.
02
G ENER A L INFO R M AT I O N
01 GENER AL INFORMATION
AS SEMBLY WORK COMPLETES THE PROJECT DE VELOPMENT CYCLE
The clients submit their planning documentation inclu- On the day of the assembly, 4 – 6 assemblers, at least 1
ding any additional information that we need in order lifting gear (crane) and a lorry with the delivered KLH
to prepare a quotation. After consultation and after the solid wood panels ready for assembly will be at the
order is placed, the actual preparation work with the construction site. It goes without saying that this day is
client starts, submitted to us in the form of work planning cost-intensive and is therefore of major importance.
documentation. Based on this work planning, which is
approved by the client, production and CNC cutting of the
relevant panels as well as delivery to the construction site The following organisational procedure is recommended
will be carried out. At the construction site the compo- for assembly
nents will be accepted, checked and put into position.
• Preparation of auxiliary tools required for assembly
Assembly work completes the project development cycle • Assembly of the components and appropriate protec-
as described in the previous chapter on “Project Manage- tion of construction parts
ment”. • Organisation of follow-up work and installation work
For successful assembly as well as a smooth work pro- on the building
cedure at the construction site it is of paramount impor-
tance to carefully prepare all work and to meticulously
organise the assembly.
03
P R E P A R AT I O N F O R A S S E M B LY
The means of transport delivering the components to the Usually, positioning takes at least one day, maybe longer.
construction site as well as the loading and unloading All resulting consequences have to be reviewed by the
order were already determined in the course of work client and have to be duly organised, such as road blocks
planning and project submission. In order to identify the or various official permits that may be required. The
required type of lifting gear and any necessary measures, parking space for the lorry delivering the KLH compo-
it is important to determine the exact position for the nents should be even and horizontal, if possible.
lifting gear and the delivery lorry.
In order to select the appropriate lifting gear, the following Assembly of components already stored at the construction
parameters are decisive site
• Distance from the lifting gear to the furthest assembly If, for logistics or technical reasons or any special situ-
position ation, assembling directly from the lorry is not possi-
• Maximum lifting weight (see list of components) ble, the KLH components must be temporarily stored
• Required lifting height from lorry to assembly position at the construction site. In this case the lifting gear
• Review of special situations (e.g. in case of installation must be able to cope with the unloading requirements.
in already existing buildings) The lifting gear for assembly may be different from the
• Special situations that might apply to the unloading lifting gear used for unloading. We do not recommend
procedure this course of action for visible surfaces.
From a logistics point of view we distinguish between 3 Assembly after unloading from containers
assembly situations In this case it must be determined in what way the contai-
• Assembly directly from the means of transport ners can be unloaded at the construction site (also applies
• Assembly of components already stored at the con- to unloading in ports, in case of reloading onto a lorry).
struction site
• Assembly or unloading of components transported by Unloading containers
container Containers are accessible for unloading as follows:
Standard 40´ container – only from behind (door)
Assembly directly from the vehicle 40´ open top container – from top or from behind
This type of assembly is the best in terms of costs. Un- 40´ flat container – from top, from behind or from
loading from the lorry and assembly work is performed side
step by step. The type of lifting gear must be selected according to the
unloading situation.
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P R E P A R AT I O N F O R A S S E M B LY
2.3 CHECKING EMPLOYEE SAFET Y REGUL ATIONS AND PERSONAL PROTECTIVE EQUIPMENT AT THE
CONSTRUCTION SITE
Depending on where the assembly takes place, country- corresponds to the assembly of large, pre-fabricated
specific and local employee protection regulations as wooden construction components by wood construction
well as requirements regarding personal protective companies/construction firms.
equipment will apply. The assembly of KLH components
Assembly tools are auxiliary tools that assemblers need We distinguish between the following auxiliary tools
to complete an assembly or installation (fixing) of a com-
ponent. • Auxiliary tools for positioning and fixing of compo-
nents in their positions
• Auxiliary tools required to achieve the installation
situation and/or fixing of components required
05
Montage und Installation
P R E P A R AT I O N F O R A S S E M B LY
Abb. 3 - Leiter
F i g . 8 – Fu l l y t h r e a d e d s c r e w F i g . 11 – A s s e m b l y b r a c k e t
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P R E P A R AT I O N F O R A S S E M B LY
The appropriate detailed construction work requires KLH constructions or elastomer supports to improve
additional material to be available already during sound insulation.
assembly. This includes e.g. sealing tapes to form airtight
F i g . 12 – W i d e e l a s t i c a d h e s i v e t a p e F i g . 13 – N a r r o w e l a s t i c a d h e s i v e t a p e
F i g . 14 – E l a s t o m e r s u p p o r t , s o u n d p r o o f i n g l a y e r F i g . 15 – E l a s t o m e r s u p p o r t , s o u n d p r o o f i n g l a y e r
08
P R E P A R AT I O N F O R A S S E M B LY
The assembly work of KLH components requires nothing aluminium levelling rod, hammer, sledgehammer, rafter
more than conventional tools used in wood construction, clamps and the like. Figures 16 – 34 will give you an over-
such as e.g. chalk line, hammer drill and drill with bits, view of the most common tools used for assembly.
F i g . 16 – H a m m e r d r i l l F i g . 17 – D r i l l F i g . 18 – C o r d l e s s d r i l l
Fig. 22 – Planer F i g . 23 – G r i n d e r F i g . 24 – S l e d g e h a m m e r
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P R E P A R AT I O N F O R A S S E M B LY
F i g . 25 – H a m m e r F i g . 26 – A u g e r b i t s F i g . 27 – H o l e c u t t e r s
F i g . 2 8 – Fo r s t n e r b i t s Fig. 29 – Bits Fig. 30 – Chalk line
Fig. 34 – Lif ting gear from the firm WÜRTH (transpor tation anchor plus combined Assy- II -screw)
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P R E P A R AT I O N F O R A S S E M B LY
The number of assembly staff required depends on the • F astening the KLH solid wood panels
detailed planning as well as the unloading situation. As- to the lorry 1 person
suming that expert staff will be used at the construction • Placement of construction components
site, we suggest the following number of staff be required: and securing of position 2 persons
• Screwing components tightly, reworking
at construction site 2 persons
2.8 PREPAR ATION WORK FOR PANEL ASSEMBLY AT THE CONSTRUCTION SITE
Depending on the detailed planning, this work usually Ad 1. Applying wall positions on the substructure (concrete
consists of 4 activities. Depending on the detailed structure)
planning, the order of these activities may vary: The working drawing results in a ground plan projection
showing the positions of the individual walls. In coordi-
1. Applying wall positions on the substructure (con- nation with the detailed planning (transition details from
crete structure) concrete to wood), the planned measurements are trans-
2. Placing assembly brackets ferred to the concrete construction. This must be made
3. Applying horizontal moisture sealant accurately to the nearest millimetre. Angles should be
4. Height levelling checked several times by measuring the diagonal lines.
Setting the fastening brackets requires each wall to be
The above-mentioned work should be completed prior to sketched with the panel thickness. Marking on the con-
panel assembly. crete slab is carried out by using a chalk line.
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P R E P A R AT I O N F O R A S S E M B LY
F i g . 37 – Fa s t e n i n g a n a s s e m b l y b r a c k e t
Ad 4. Height levelling
At each fixing bracket the exact height will be determined
by using a levelling instrument. Inaccuracies will be
compensated with appropriate support material. Please
take into account the maximum possible compression at
these support points. The open joints between the KLH
wall components and the bottom slab must be filled with
mortar in order for the supporting wall to fully rest on the
substructure once the installation is completed. To this
end, the KLH panel will either be placed in a moist mortar
bed or the joint will be filled with swelling mortar after-
wards.
12
A S S E M B LY O F C O M P O N E N T S
03 ASSEMBLY OF COMPONENTS
3.1 AS SEMBLY OF KLH CONSTRUCTION
COMPONENTS
The aforementioned preparation work should be completed The KLH components are fastened to the crane hook with
prior to starting the assembly work. Due to the high number their lifting gear already installed at the factory, unloaded
of staff and tools used, the assembly day is very cost- in the correct order of assembly and put in their appro-
intensive. It is therefore particularly important that all priate positions.
work and organisational preparation completed up to this
point have been carried out with due care.
13
A S S E M B LY O F C O M P O N E N T S
The assembly team (2 persons) bring the components nents per delivery and 5 lifting operations per hour we get
into the right positions and fix them, so the crane can get an assembly time of approx. 8 hours. For larger buildings
the next component. The assembly of the components this will result in an approximate orientation value of one
is performed according to the construction plan and/or lorry load per day.
detailed planning. The 2 persons from the screwing team
connect and/or fasten the components according to the In case of a larger number of deliveries, allow for a time
detailed plan and/or according to the information provided buffer between deliveries for bad weather and reworking
by the structural engineer. at the construction site.
In case of conventional assembly work with KLH com- The aforementioned values refer to regular assembly that
ponents, it is safe to assume 4 – 6 lifting operations per meets the Central-European standard in terms of tech-
hour as a general rule of thumb. One delivery consists of nical knowledge, auxiliary assembly tools and employee
25 to 40 components on average. Assuming 40 compo- protection regulations at the construction site.
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A S S E M B LY O F C O M P O N E N T S
KLH components are designed for applications of the In case of visible surfaces, direct weather exposure will
service classes 1 and 2 and must therefore receive effective usually result in the soiling of these surfaces. We recom-
protection from direct weather exposure in constructions. mend organising follow-up work to commence immedia-
Based on our experience we know that KLH components tely after the assembly of the KLH components, especially
will survive short-time weather exposure during assembly for companies contracted for roofing, window installa-
without any damage. It is important to allow increased tions and façade work.
moisture to evaporate later.
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FO LLOW - UP WO R K A ND IN S TA LL AT I O N WO R K
As already mentioned, the assembly times for the build- In some cases the performances provided by follow-up
ing shell of KLH buildings are much shorter than for contractors will also influence the installation process of
conventional solid constructions. Follow-up work will KLH components. For example: if prefabricated chim-
also be significantly more time-saving. In order to benefit neys are installed during building shell assembly work,
from this advantage and to maintain it until completion or if prefabricated flights of stairs are installed. The same
of the building, follow-up contractors must be instructed applies to any storage of dry construction materials. Very
appropriately and made familiar with the KLH construc- often they are already lifted inside during assembly work
tion method. in order to use the crane that is available at this point.
These aspects must be taken into consideration for the
organisation of the assembly work.
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FO LLOW - UP WO R K A ND IN S TA LL AT I O N WO R K
For most construction projects, installations are made in individual cases. Generally, in case of a very large number
the conventional construction form. The foundations as of cables as well as water and sanitary installations, front
well as the suspended ceilings are used for cable routing. wall installations should be undertaken. In case of water
Vertical grooves are milled in supporting interior and pipes, sufficient sound insulation must be ensured.
exterior walls. As regards milling at the construction
site, it must be ensured that they will only be performed If installation pipes or cables are run through sealing
in the direction of the cover lamination. If milling at an layers – e.g. electric cables for outdoor lighting or water
angle to the cover lamination becomes necessary, static pipes for garden water taps – these penetrations must be
examination of this area will be required because such appropriately sealed. If the sealing layer is formed by a
milling will result in static weakening of the KLH solid wood convection barrier, penetrations must be sealed with
panels. As regards wall ends (for example next to doors), a film. If the sealing layer is formed by the KLH con-
it must be taken into account that static bearing capacity struction, appropriate sealing towards the wooden con-
may be reduced by up to 30% if a large number of cables struction will be necessary. The same principle applies to
are laid together. Structural analysis may be required in chimney or ventilation penetrations and the like.
It must be determined where and how installations will layer) and to plank walls directly. 4/5ths of the panel
run. In case of wall components in non-visible quality, it is thickness should be used as the maximum milling depth.
possible to run installations in facing formwork or to mill If a building is to be made airtight with the KLH building
lines into KLH walls and to plank them afterwards (e.g. shell (i.e. film-free), we regard it as necessary to maintain
with type X gypsum boards). If possible, we recommend at least a glue joint. We also recommend the installation of
milling in lines (milling in fibre direction of the covering airtight sockets and, if necessary, masking of these areas.
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FO LLOW - UP WO R K A ND IN S TA LL AT I O N WO R K
F i g . 52 – I n s t a l l a t i o n o f t y p e X g y p s u m b o a r d s b y a d r y c o n s t r u c t i o n F i g . 5 3 – P l a c i n g a n d f i x i n g o f t h e s o c k e t (e l e c t r i c i a n)
worker and socket drilling in the course of that process
Grooves are usually made with a groove cutter. Approx. In case of visible surfaces, lines are milled on the back,
20 cm distance will remain to the floor and ceiling. They e.g. on the upper side of ceiling and roof elements, on the
are inaccessible due to the front and back supporting outside of exterior walls (mind the sealing layer – mask
table. In these areas the grooves will be completed by these areas or apply a convection barrier, as appropriate).
using a Forstner drill bit; ceiling penetrations will be made
from the bottom by way of an auger drill.
F i g . 5 4 – I n s t a l l a t i o n o f a s w i t c h/w a l l s o c k e t c o m b i n a t i o n f o r w a l l s
with visible sur faces. The drill hole on the visible side must be sized
according to the socket diameter and the covering f rame (usually 6 8 mm
diameter)
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FO LLOW - UP WO R K A ND IN S TA LL AT I O N WO R K
KLH-Wall
selectively. Larger pipes must be covered by facing form-
Type X gypsum board
work, such as downpipes for water drainage piping. When e.g. stone wool
fastening pipework, ensure sufficient sound insulation. As
regards pipe penetrations (e.g. ceiling penetrations) and
installation shafts, ensure sufficient sound insulation or
fire and sound stoppers. Penetrations of sealing layers
must be sealed appropriately. For bathrooms we recom- e.g. Polokal pipe
Fasten with appropriate
mend a horizontal surface sealant below the floor structure. acoustic insulation!
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FO LLOW - UP WO R K A ND IN S TA LL AT I O N WO R K
T h e K L H s o l i d w o o d p a n e l i s m i l l e d w i t h a r o u t e r. We r e c o m m e n d
milling in several stages. It is impor tant not to take away too much
wood at a time.
I n s t a l l a t i o n o f a n I n s t a b o x f o r a v a l v e r a d i a t o r. Fa c i n g o f K L H s o l i d w o o d p a n e l a n d I n s t a b o x – i n t h i s c a s e w i t h a t y p e
X g ypsum board.
P r i o r t o t h a t , h o w e v e r, m a k e s u r e t o c u t b o t h w a t e r c o n n e c t i o n s f o r
Figs. 56 to 59 – Use of an mhs radiator box the radiator to size.
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FO LLOW - UP WO R K A ND IN S TA LL AT I O N WO R K
A p p li c a t i o n o f t w o 5 x 8 cm t hi ck la t hs t ha t w ill b e us e d la t er t o ins t all Once the correct height for the water connection and the drain pipe
t h e dr y c o ns t r u c t i o n b ox an d t o f as t en t h e t y p e X g y psum b o ard has been determined, the installation box can be fastened on the
5 x 8 cm laths with countersunk bolts
Af ter fastening the installation box, it should be faced with a t ype X Tiling the t ype X g ypsum board.
g ypsum board and also fastened onto the 5 x 8 cm laths We t r o o m s s h o u l d a l w a y s b e t i l e d . We r e c o m m e n d u s i n g m o i s t u r e -
resistant t ype X g ypsum boards. In splash water exposed areas
( b a t h t u b a n d s h o w e r a r e a) a s w e l l a s o n t h e f l o o r, a n a d d i t i o n a l
sealing layer should be included bet ween tiles and g ypsum boards.
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FO LLOW - UP WO R K A ND IN S TA LL AT I O N WO R K
Additional examples of installation shafts (in splash water areas of bathrooms and wet rooms we recommend the
integration of sealant on walls and floors)
22
LIST OF FIGURES
05 LIST OF FIGURES
PAGE
23
NOTES
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