Installation Manual

Installation Manual
Installation Manual
for Lay-in Modular Ceiling
Storage and Handling
• Ceiling panels must be kept clean, dry, and protected from the elements. Remove the panels from the cartons 24 hours
before installation to acclimatize to interior conditions.
• The installation site must be free from debris and dust.
• Irrespective of varying temperature and humidity recommendations which vary from product to product, all products must
be stored in a interior space and not exterior space.
Mineral Fibre
Metal & Soft fibre
FRAGILE
UP


Opening a grid carton
Step 1:Identify dotted line
Step 2: Cut along dotted line
Step 3: Open from one side
Step 4: Ready to remove
Opening a mineral fibre tile carton
Armstrong recommends that RH 99, 90 & 80 products are to be opened and left to acclimatize for 24 hours before fixing.
This makes the tiles dry and hard.

Wrong box opening method
2



Step 1: Cut the polythene film Step 2: Remove the polythene Step 3: Remove the tile
film
Index
Section I: Standard Modular Ceiling Installation and Maintenance
9 Step Ceiling Installation Procedure.............................................................4
MetalWorks Tiles Cutting Procedure............................................................17
Section II: Components, Safety and Tools
Ceiling Components..................................................................................18
Safety & Precautions..................................................................................19
Tools..........................................................................................................21
Section III: Appendix
Maintenance..............................................................................................22
Glossary....................................................................................................23
Note: The installation procedure for MetalWorks lay-in ceiling systems is similar to that for Mineral fibre ceiling
systems, except for the procedure required to cut MetalWorks tiles, which is given on page 17.
3
9 Step Ceiling Installation Procedure
1
3
2
B
Min 100 mm
A
M
A
1000
600
800
≤ 450 mm
B
1. Planning grid layout
4
2. Mark perimeter trim lines
3. Installing perimeter trims (Wall angle)
6
5
Max
600 mm
1200 mm
1200 mm
1200 mm
4. Mark hanger positions
5. Installation of hangers
7
6. Installation of Main Runners
9
8
A /B
A /B
7. Cross Tees installation
8. Installation of field and service tiles
9. Measure and cut
border tiles
Important Note: Please read Section II: Components, Safety and Tools before commencement of ceiling installation.
Sketch showing basic ceiling layout and placing of the components
ma
x6
00m
6
m
120
0m
4
m
5
3
2
min
300
mm
n
mi
1
600
60
mm
4
m
0m
600
mm
m
0m
60
m
0m
60
mm
600
m
0m
60
1. Main Runner
2. 1200mm Cross Tee
3. 600mm Cross Tee
4. Suspension System
5. Wall Angle
6. Tile
Step 1: Planning Grid Layout
A) Wall to wall (with field and border tiles)
This is one of the most important step before commencement of actual ceiling installation. Here grid layout is arrived by
taking into consideration room dimensions {length(l) x breadth(b) x height(h)}
Points to remember: In practical conditions, often the room dimensions are not exactly square in dimensions.
Thumb  rule: Armstrong recommends to have border cut tiles greater than half the size of the ceiling tiles on all
four sides of the wall.
Refer layout for diagram 1.1
Ceiling Module: 600mm x 600mm
Room dimensions: 4320mm x 2700mm (l x b)
Tiles calculation l: 4320mm
= 7 full tiles + 2 x 60mm cut tiles (incorrect calculation)
= 6 full tiles + 2 x 360mm cut tiles (correct calculation)
Note: Please follow the above method for breadth border cut tile calculation.
Wrong Method
600mm
450mm
360mm

2985mm
2985mm
600mm
600mm

1200mm
250mm
600mm
2700mm
600mm
Correct Method
450mm
4320mm
Main Runner Connection
250mm
Diagram 1.0
Main Runner
1200mm Cross Tee
600mm Cross Tee
Suspension System
(Hanger Wire)
Service Tiles
Field Tiles
Border Tiles
Walls
360mm
1335mm
120mm
1335mm
Main Runner Connection
4320mm
MODULAR
LIGHT
FIXTURE
2700mm
Diagram 1.1
T
OINTE
P
Y
KE TO NO
Border tiles should
be more than
≥ 300mm
5
Step 1: Planning Grid Layout
B) With Plaster bulk heads (full tiles module)
Plaster bulk heads are used to design spaces to enclose full border tiles and enclose vertical grilles for HVAC.
Below mention is a simple thumb  rule to calculate ceiling installation with full border tiles.
(A-T/2)
F
A
T
D
Bulkhead
n = Number of panel
F = Full tile size
T = T-grid face width
A = Distace between angle moulding face and bulkhead
D = Distance between bulkhead
D = nF + (2A-T)
Diagram 1.2
Assuming, we are developing a module of 3600mm X 3600 mm i.e 6 tiles X 6 tiles within the plaster bulk head.
• Most often one would take an internal measurement, between the bulkheads of 3600mm X 3600mm. But this
is an incorrect method and while doing final installation, you may end up cutting the border tiles on all the four sides.
• Thumb  rule: Add two sides wall angle width and deduct the width of the main tee to get the extra length.
• Assume we use 19mm wall angle and 24mm grid facing, then the overall length should be 3614mm to achieve the full tile
visual.
Thumb  rule calculation
Wall Angle
Description
Wall Molding
Shadow Molding
Steel Angle Face Width
Size (mm)
15mm
24mm
19x19x3000mm
Add 23mm
Add 14mm
19x7x7x14x3600mm Add 13mm
Add 04mm
Wall Molding
32x24x3000mm
Add 33mm
Add 24mm
Aluminium Wall
Molding
19x25x3000mm
Add 35mm
Add 26mm
19x32mm
Add 49mm
Add 40mm
22x22x3000mm
Add 29mm
Add 20mm
Stainless Steel Wall
Molding
Wall Molding
Note: The addition to the original length or breadth will avoid the need for border tiles.
T
OINTE
P
Y
KE TO NO
Arriving at
bulkhead dimensions
critical for full tiles
module
6
Step 2: Mark Perimeter Trim Lines
• Measuring the ceiling height is the most crucial stage before commencing installation.
•The minimum plenum height from the ceiling slab should not be less than 100mm for lay-in system.
• The reference ceiling level should be established by the main contractor with the help of all other services vendors
like light fixtures, Air condition grilles, sprinklers, speakers etc.
•Using a plumb mark as a reference point, place line laser leveller on it. Then with the help of laser point, mark wall angle
level on all sides of the room.
T
OINTE
P
Y
KE TO NO
Line laser leveller
saves time and
ensures precision
7
Step 3: Installing Perimeter Trims (Wall Angle)
•The marking with the help of line laser leveller has to be done above the wall angle level on all the walls.
• Post marking used hand drill to installed the wall angle.
• The first and the last fasteners on wall angle should be installed at 150mm from the wall (see for details recommended
fastener on page no.19).
• Subsequent fasteners to be installed at 450mm spacing in between.
T
OINTE
P
Y
KE TO NO

150mm



450mm
Secure to wall at
450mm maximum
centres
•At the corners of the room, the conjunction area of wall angle should be miter cut for a clean finish
X

1200
600
Bottom view

Bottom view

Y
b
a

8
600
Top view
Top view
Step 4: Mark Hanger Positions
• The hanger on the main runner shoud be placed at or within 600mm distance from the wall angle
(450mm is recommended in case of heavier ceilings) and then subsequently at 1200mm centres.
1200mm
600mm
T
OINTE
P
Y
KE TO NO
450mm
360mm
450mm
2985mm
600mm
Hanger position
must be within
600mm distance
from the wall
Main Runner Connection
4320mm
x
x
x
Main tee connection
Suspension System
(Hanger Wire)
360mm
1335mm
Main Runner
x
Walls
2700mm
Diagram 1.0
• There should also be a hanger within 150mm of any main runner to runner connection.
1200mm
600mm
450mm
2985mm
600mm
360mm
450mm
Main Runner
1200mm Cross Tee
600mm Cross Tee
Suspension System
(Hanger Wire)
Service Tiles
Field Tiles
Border Tiles
Walls
360mm
1335mm
Main Runner Connection
4320mm
MODULAR
LIGHT
FIXTURE
2700mm
Diagram 1.1
T
OINTE
P
Y
KE TO NO
Hanger position must
be within 150mm
distance of every
main runner
connection
9
Step 5: Installation of Hangers
•Use a rotary hammer machine to drill and install the hangers from the concrete ceiling slab.
300mm
0
45 0
1.80mtr.
45
300mm
T
OINTE
P
Y
KE TO NO
Use counter
splaying wires if
hanger length is
≥1.8mtr.
WIRES PLUMB:
MAX. SLOPE 1 IN 1.8MTR IN ANY PLANE
IF MORE, USE COUNTER SPLAYING WIRES
Diagram 1.3
• If the hanger wire plumb more than 1.8 meter then use counter splaying wire refer above diagram.
• In counter splaying, two hanger wires from the structural slab form an angle of 450 near the main runners. One
suspension countering another in the same plane.
•Install the hanger wire as per the position in the diagram 1.1.
• Suspension hanger wire shall be pre-straightened with minimum 2.5mm dia (# 12 Gauge).
• Insert wire of required length into hanger wire hole and encircle the wire 3 times within 75mm.
Installation under AC duct
• If AC duct is greater than 1200mm in length, then ensure you suspend a separate bracket under the duct and from it, a
hanger-wire can be suspended for ceiling installation.
Ceiling Soffit
T
OINTE
P
Y
KE TO NO
1400mm
Duct Section
90
Ensure suspension
free from services
Suspension
100
Duct Suspension
1200mm
Ceiling Tile
Diagram 1.4
Threaded
Rod/Hanger Wire/
Vertical Support
Slotted Bar / Main tee
for Suspending the
Ceiling
Typical Sectional Sketch - Below Duct Suspension (Trapeze Installation)
10
Step 6: Installation of Main Runners
• Run a string line the length of your first main runner offset to the edge flange. This will help to keep the main runner set
distance of the wall.
T
OINTE
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Y
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Main runner
Use only aviation
snip for precise
cutting of main
runners
Cross tee
String Line
•Cut the main runner to the length with respect to the border tile, so that the rout hole on the adjacent main runner
matches.
• E.g. As per diagram 1.5, the main runner will be cut at 15 mm using an aviation snip cutter to ensure that the rout hole
will be at a distance of 360 mm.
Rout hole
360mm
Cut main beam so that a
rout lines up at border
tee location
Diagram 1.5
• Cut the main runner at inclination of 30-45 degree to avoid obstruction of protruding screws.
Armstrong provides following grids.
Grids
Rout Hole
Interval (mm)
Distance of 1st
Rout Hole from
the End Clip
(mm)
Prelude 32
150mm
75mm
Prelude 38
150mm
75mm
Prelude 43
100mm
50mm
Suprafine 32
150mm
75mm
Suprafine 38
150mm
75mm
Suprafine 43
100mm
50mm
Silhouette 38
600mm
300mm
Silhouette 45
600mm
300mm
Select 38
600mm
300mm
Select 45
600mm
300mm
11
• The first main runner should be less than 600mm from the perimeter wall.
• The distance between next main runner shall be at 1200 mm maximum.
•You may incline the first suspension system slightly to push the main runner in one direction so that the rout holes
are better aligned.
•Hangers with hook clip options can be inserted in alternate direction on the main runner for better stability.
• Border cross tees should be more than 300mm but less than 600mm in length.
•Cut the excess portion or bend the wire as shown in the picture.
• Insert an additional row of main runner or alternatively suspend all
border cross tees longer than 600mm.
12
INTE
O
YP T
KE TO NOMain runner
and border cross
tee should not be
more than 600mm
distance from
the wall
Step 7: Cross Tees Installation
• As per diagram 1.1 (page 5) install border cross tee 448mm (2mm allowance is kept for cross tee to rest on the
wall angle easily).
• Install border cross tees temporarily to the wall molding using a clamp to keep them intact.
Clamp
•Install two 1200 cross tees between the two main runners at an distance of 600mm.
• A click sound confirms that the cross tee has been properly locked into the main runner.
T
OINTE
P
Y
KE TO NO
Click sound
confirms cross
tee locked
•Measurements should be taken diagonally in the 600 x 1200mm module. Both the diagonals must be of the same length.
X
1200
600
Y
b
a
600
•In case of any deviation in the measurement of the diagonals gently tap at the corners.
• This will ensure that the entire ceiling grids will be in a perfect shape.
Main runner
MAIN
RUNNER
(a-b) shold be less than
1mm for 600x600mm tiles
and less than 2mm for
600x1200mm tiles.
Diagram 1.6
Cross tee
String Line
• Once the system is in perfect shape run another string line at the first cross tee slot on the main runner to the far adjacent
wall angle using the first two square mains as the guide. This ensure the tee rout holes on all the main runners stay in
aligned.
13
Step 8: Installation of Field and Service Tiles
• Check the level once again using line laser leveller.
•Ensure that all the services placed on service tiles are tested and confirmed by the principal contractor. Only after that,
laying of field tiles can be commenced.
•While installing down lighters, spotlights, sprinklers, speakers, smoke detectors etc. 6mm plywood (pattress backing
must be placed on the grid).
T
OINTE
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Y
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Patress a must for
installing services
to avoid direct
loading on
ceiling system
Patress backing
•It is mandatory to independently suspend modular light fixtures.
• GI wire 2.5 mm is recommended to suspend the light fixtures.
• Hook Clips and Chains are not recommended.

14

Step 9: Measure and Cut Border Tiles
• Measure the border tile size.
•Mark the border size on back side of the tile.
•Use a grid or a steel ruler (2 ft long) to mark and cut the border tiles.
•While installing, slightly tilt the tile and gently rest it on the main runner and adjacent cross tee and wall angle.
T
OINTE
P
Y
KE TO NO
How to make tegular and curved shape edges on border tile
Chalk the cut
edges of
border tiles
A) Tegular edge
•Use a sharp knife.
•Lay the tile on a smooth surface.
•Make vertical cut into face of the tile.
•Make horizontal cut to form tegular edge.
15
Installing end cap in tegular edge installation
• End cap ensures that a tegular look is achieved at the border.
•Lift the steel angle and insert the end cap between the tee and the wall angle.
•End cap ensures aligned level difference at the perimeter.
B) Curved shape (square edge)
•Use a sharp knife.
•Lay the tile on a smooth surface.
•Use a cardboard or plywood template.
•Mark outline of the template.
•Use a sharp knife to cut through.
16
Metalworks Tiles Cutting Procedure
•Measure and mark the line on the metal tile using a pencil.
• The bent edge of tile should be cut using aviation snip.
•Use a shear machine to cut the face of the metal tile.
T
OINTE
P
Y
KE TO NO
Cut the metal tile
edge using aviation
snip and only then
use shear machine
•Use an end profile for MetalWorks lay-in cut tiles.
T
OINTE
P
Y
KE TO NO
Use edge cap for
cut tiles
• Slide the edge cap in to the cut tile. Install the tile into the ceiling grid.
17
Ceiling Components
Wall angle and Shadow molding: Available in 3.6mtr. and 3mtr. lengths respectively
Section
Applicable Tile Edge Details
'L' Angle
1) Board (site cut or full tile) for wet-felt or soft
2) Tegular or Bevelled Tegular (site cut square) for wet-felt, soft or wood with cross
tee supported by perimeter fill-in block
3) Tegular or Bevelled Tegular (site recut to recess edge) for wet-felt or soft with cross
tee supported by perimeter trim
4) Bevelled Tegular (site cut square) on Silhouette steel angle with cross tee
supported by perimeter trim
'L' Angle
1) Board (site cut or full tile) for Ceramaguard used in 100% RH areas and other
applications using corrosion resistant steel angle
2) Metal clip-in tiles
32
19
Shadowline
1) Bevelled Tegular (site cut square) on Silhouette steel angle with cross tee
supported by perimeter trim
2) Vector (site cut square) for Ultima wet-felt or Optra soft tiles with
cross tee supported by perimeter upper ledge
19
7
7
14
*All above measurements in mm.
Main Runner: Available in 3.6mtr. and 3mtr. length respectively.
Cross Tees: Available in 1200mm and 600mm respectively.
Mineral fibre Lay-in tiles: Sizes available in 600x1200mm, 600x600mm and 300x1200mm.
Tile Edge Compatibility
Grids/Edge
Flange
Board/Square edge
24mm face
Angle Tegular
24mm face
4.7mm
Bevelled Tegular
15mm face
9.5mm
Silhouette Bevelled Tegular
9.5mm
18
15mm face (Silhoutte)
Ceiling Components
Accessories: (refer accessories manual for more details)
Hook clip: This is a height adjustment clip to align the ceiling system and ensure it’s rigidity.
Hanger wire: 2.5mm pre-straightened wire to hang the suspended ceiling from the ceiling slab.
Anchor fastener: It is anchored into the ceiling soffit and used to suspend the GI wire.
Recommended fasteners:
• 1½ “ screws/nails on wood
• Screws on metal surface.
• Expanded fasteners on concrete and brick wall surfaces.
• Fence staples for dry wall partitions.
Safety & precautions
Ladder safety:
Ladders are recommended for ceiling heights from the flooring up to 3 meters, provided the flooring surface is level, with a
plain finish.
Ladders are not recommend for ceiling heights exceeding 3 meters, a Platform with 4-sided pillars is recommended.


Wheels
Locked
Wrong standing position
Right standing position
Platform
Armstrong recommends that installers wear a tool belt for easy access to tools during installation.
It is unsafe to keep tools on the ceiling tiles.

19
Safety & Precautions
Personal protective equipment (PPE):
Armstrong World Industries advocates a strong safety policy and thus all installers MUST wear PPE consisting of hard hat,
rubberized gloves, jacket, steel toes and glasses during installation of the ceiling system.
Item
Hard Hat
Rubberized Gloves
(CL3)
Jacket
Glasses
Steel Toes
20
Description
Prevents injury to the head from small falling
objects at construction site.
Prevents injury to the hand from flared edges.
Provides better visibility at low visibility
construction site.
Prevents small particles while cuting from entering
into the eyes and causing injury.
Prevents toe injury due to sharp or obstructive
objects laying on the floor.
Tools
Measuring Tape:
Distance meter:
Line laser leveler:
Chalk line:
Hand drill /driver:
Rotary hammer machine:
Wire snip:
Aviation snip:
Clamp:
Knife:
Pop Rivet:
Slitting shear machine:
21
Maintenance
Standard Maintenance
Armstrong Ceiling Systems require no more maintenance than painted drywall ceilings. However, when maintenance is
necessary, certain procedures should be followed to insure continued high performance and attractive appearance.
Dust and loose dirt may easily be removed by brushing or with a vacuum cleaner. Vacuum cleaner attachments such
as those designed for cleaning upholstery or walls do the best job. Be certain to clean in one direction only. This will
prevent rubbing dust into the surface of the ceiling. After loose dust has been removed, pencil marks, smudges, or clinging
dirt may easily be erased with an ordinary art gum eraser.
Armstrong metal ceilings may be cleaned with a moist cloth or a sponge dampened in water containing mild soap.
The sponge should contain as little water as possible. After washing, the soapy film should be wiped off with a cloth or
sponge slightly dampened in clean water.
22
Glossary
1. Plenum: The space between the main structural slab and suspended ceiling is called the plenum.
2. Tegular: A functional edge detail that allows a suspended ceiling tile to extend below the grid, making the grid less
noticeable.
3. Rout hole: A hole on main runner to insert and lock the cross tees on the main tee.
4. Plumb mark: Measuring either from the floor or roof level and marking the ceiling height is known as plumb mark.
From the plumb mark point, the entire ceiling level will be marked.
5. Plaster bulk heads: Plaster bulkhead is otherwise called Plaster board boxing. Plaster bulkhead is designed to
accommodate HVAC grilles vertically.
6. Flange: The visible area of the grid from below the ceiling i.e. the horizontal surface on the face on the main runner
or cross tee.
23
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