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Installation of Toledo CR2 cleanroom panel systems

The aim of these instructions is to give the installer an idea of the correct technique to be employed for the installation and
assembly of a typical Toledo CR2 system

Tools:

The following tools represent a minimum requirement for successful installation. Alternatives can be used at the discretion of
the installer, though it is not recommended. In the case of certain tools, such as spanners etc, it is worth remembering that
the quality of each tool required will depend upon the scale of the installation and the number of people involved. In some
cases further tools may be required.

Drill + drill bits Hacksaw Screwdriver

for: 4.2, 8, 10
& 12mm holes

Hammer Tape measure

Power drill with
hammer action

Pliers or mole grips Spirit level

File

Vacuum cleaner Pop rivet gun Adjustable

spanner

Metal Shears

Tek screw holder

5mm Alan key

Installation:

The following steps represent the correct order for the installation procedure.

· Identify all the components and label the parts where necessary.
· Prepare the surface upon which the panels are to be installed. The surface should be clean, smooth and level.
· Mark out the positions of all the panels, doors and posts.
· Install the floor channel.
· Install panels / mullions / doors.
· Fit top capping.
· Fit skirting.
· Fit roof panels if supplied.
· Fit top fascias if supplied.
· Check alignment and geometry of all panels before final tightening of all nuts and bolts.
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Before you begin

- Identify all the components for the installation and mark each with chalk or another non-permanent marking method.
- Choose a datum point from which to measure all the positions of the panels. A corner or point at the base of a wall is ideal and should be marked in a
way that cannot be erased accidentally.
- Measure and mark the position for the installation. Remember to allow for the width of the joints between the panels and posts. A little care at this point
can save a great deal of time later on.

Initial installation
Pierced upright
Cut the lengths of floor channel to the correct size
for the bottom of the panels. Remember to leave
spaces in the floor channel for mounting mullions
and doors.

Position the floor channel and drill holes through

the channel into the floor at approximately 1m
intervals. These holes must be 6mm diameter and
at least 45mm deep.

Re-check that the floor channel is in the correct

position and push spithit fixings through the holes
in the channel into the floor.

Spithit fixing Gently hammer the head of the fixing until only
Floor channel
5mm of the screw is proud of the base of the
40mm deep
channel.
0.7mm thick
Screw the remainder of the fixing in using a
crosshead screwdriver.

Assembling mullions

The mullions come supplied in 2 parts. The first

part consists of a length of RHS with a base plate
Tek screw welded to one end. The second part is a length of
formed steel know as a blank end post.

50 x 50 x 3 RHS Before the mullions are fitted they must be

assembled. To do this use the tek screws to
secure the blank end post to the mullion, ensuring
Blank end post
it is positioned centrally.

All mullions should be prepared before further

assembly is attempted.

10mm thick base plate

Mounting mullions

The mullions are mounted to the floor using M10

threaded expansion bolts.

Position the mullion and, using the holes in the

base plate as guides, drill 12mm diameter holes
into the floor. These holes should be at least
120mm in depth.

M10 csk expansion bolts Remove the mullion and clean away the excess
dust from the drilling. Replace the mullion and
push the expansion bolts through the base plate
into the hole in the floor. A hammer may be
required to gently drift the expansion bolt into the
hole.

Check to ensure the mullion is vertically level at

this stage as any discrepancy will be duplicated in
the panels. If the mullion is not level packing can
be used between the floor and base plate to
Floor channel
correct it.

Tighten the bolts and re-check the alignment.

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Creating joints with panels and posts

There are 3 types of joints used when joining panels and / or posts:
- Panel, panel straight joint.
- Panel, post straight joint.
- Panel, preformed corner joint.

All the joints are constructed using the same group of components and the same techniques.

H - Cleat Cover channel with spring clip Pierced Upright

3mm thick mild steel 0.9mm thick mild steel 0.9mm thick mild steel

51mm

47mm

50mm

51mm Panel - panel or panel - post joint

Position the panel next to the panel / post to

20mm which it is to be joined. The base of the panel
should rest in the floor track. The distance
between the closest points of the panel should
be ~20mm. The distance between the panel
skins should be 51mm.

Post or panel

Slide a H-Cleat between the panels / posts by

turning diagonally and rotating away from you.
This will locate the H-Cleat between the
centres of the Pierced Uprights.

Rotate the H-Cleat until it locks in place.

Repeat this process until sufficient H-Cleats
are in place. It is recommended that:

2440mm panel - use 5 H-cleats

2745mm panel - use 6 H-cleats
3050mm panel - use 7 H-cleats

Fit the cover channels on both sides of the

joint. 5 - 6 clips are used, equally spaced on
each channel. Clip in the cover channel from
top to bottom.

Please note:
It is important to fit the cover channels as
the panels are erected. Failing to do this
may result in fitting problems.

Finished panel - panel / panel - post joint.

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Fitting pre-formed corners

Panels fit to the pre-formed corners using the standard H-cleat and cover channel method shown on the previous page. There are two
types of pre-formed corner sections, shown below.

2-way 90 degree section 3-way T-section

Panel skin Panel infill Pierced upright

Fitting top capping

There are various types of top capping (shown below) which may be supplied depending upon the application of the cleanroom
partitioning.

Ceiling supporting top capping Heavy duty top capping Drop in ceiling top capping Top channel
applications - double lifts & free standing applications - short span ceilings applications - floor to ceiling
applications - supported ceilings
partition

Top Capping Joint cover Splicing strip

1.5mm thick mild steel 0.7mm thick mild steel 3mm thick mild steel

Top Capping Corner Cover

0.7mm thick mild steel

Cut the top capping to Where joints occur a splicing strip At corners a corner cover is
correct length and place on and joint covers are pop rivited to applied to neaten the joint.
the top of the panel. the top capping to add strength. This must be bent to match the
angle of the corner. These are
pop rivited to the top capping
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Fitting Double Skin Ceiling

When a double skin ceiling is being used with the partitioning a different top capping is used. It is fitted in the same way as the standard top
capping. The roof also consists of tongued roof panels and Z-section.

Fig: 1 Roof Top Capping Fig: 2 Double Skin Roof Panel Fig: 3 Roof Z-section
1.2mm thick mild steel 1.0mm thick mild steel 1.0mm thick mild steel

Fit the Roof Top Capping as usual.

Double Skin Roof Panel Pop rivet (see page 4)

Place the Double Skin Roof Panels (fig: 2) on

top of the partitioning and arrange according
to the manufacturing drawing.
Z-section

Identify and cut the Z-section (fig: 3) to length

and place around the edge of the roof so that
it covers the outside edges of the roof panels.

Drill 6mm holes through the Z-section into the

Roof Top Capping (fig: 1) and through the Z-
Roof Top Capping section into the Double Skin Roof Panel.
These holes should be drilled at approximately
1m intervals around the Z-section.

Pop rivet the Z-section to the Roof Top

Capping and Double Skin Roof Panels.
Panel

If desired, extra screws can be used to join the

Double Skin Roof Panels to each other though
this is not strictly necessary.

Fitting hinged doors

Installing hinged doors is extremely simple. The single hinged doors are pre-assembled during manufacture and should not require further
assembly other than glazing if appropriate. If glazing is to be fitted by the customer all glazing components will be supplied in the correct
position or ready to use. The glazing technique will vary depending on the thickness, quantity and type of glazing material used. To all
intents and purposes the installation of hinged doors can be treated in exactly the same way as a standard Toledo partition panel.

*
Please note, however, that to ensure safe transit from works to site a steel strip is often fixed between the bottoms of the frame
uprights. This piece of metal is purely for packaging purposes and should always be removed before installation, otherwise it will
prevent the correct fitting of the frame.
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Fitting Exterior Skirting

Concealed Fixing Aluminium Skirting

2mm thick Aluminium 2mm thick Aluminium

70mm 100mm

Drill holes in each of the concealed fixing

components as shown in the diagram.

Pop rivet the concealed fixings to the base of

the panels at intervals of 1.5m.

(Note: The height the bottom side of the

concealed fixing is placed from the floor is the
same height the bottom of the aluminium
skirting will be from the floor when installed.)

Place the aluminium skirting in position,

slotting it into the concealed fixing as shown.

Panel

Skirting

Concealed fixing

Floor track