Flexible Support System Guide

7/31/2019 Flexible Support System Guide

1/19

1

Introduction

Flexible support system also known as strut channel system is a unique engineered

system of components. It can be used for various applications, for example, in storageracks, construction of warehouses etc. It is not just limited to being a support system.

The system consists of vertical and horizontal support members. The individualmembers are manufactured accurately and carefully by cold rolling mild steel. The

vertical support members are complemented by cantilever arms also made of thesame channel and welded with a back plate- and a variety of clamps and brackets.Thestandard length of channels are 6m. These members are generally hot-dip galvanized.

These members can be assembled in a number of combinations. The assemblies canbe designed and erected at site.

The uniqueness of this system is that it isadjustable- demountable- reusable.

It does not require on site welding, thereby preserves the protective coating of thesystem . In environments, where there is a fire hazard, this property is a boon.


2/19

2

Components of Flexible Support Systems

The components are of four types:

Channels Spring nuts Cantilever arms Brackets and Clamps

Channels

Type Diagram Description

Single channel Used as main supportchannel. It is cold rollformed from 2.5mm thick

steel. Maximum length sixmeters.

Double Channel

Made from two single

channels welded back toback. Used as main

support channel for heavyloads.


3/19

3

Spring nut assembly


Spring nut Consists of a channel nutwith spring and a bolt.

Spring nut fits into thechannel making it easy toassemble brackets and

clamps. The spring holdsthe channel nut firmly in

Place. The system isadjustable, reusable anduser friendly.

Cantilever arm


Cantilever arm Channel welded with a

back plate. Fixedhorizontally on mainsupport channels.

Available in different sizesto accommodate the size ofthe equipment being

supported.


4/19

4

Brackets and Clamps


Base plate for single

channel

Used to fix main support

single channel to the flooror ceiling

Base plate for doublechannel

Used to fix main supportdouble channel to the floor

or ceiling

Channel Clamps Used to connect single

channel with horizontalmain support channel or toanchor main support

channel against the wall.

Clamp for double channel Used to connect doublechannel with horizontal

main support channel or to

anchor main supportchannel against the wall.

Right angle bracket Used as a connector

between vertical andhorizontal main support

channel.


5/19

5


90Angle fitting Used for connecting

horizontal and verticalmain support channels,where heavy loads are tobe supported.

Tray fixing clamp Used to fix horizontalladder type trays withcantilever arms.

Slotted Channels Used to support fitting

from the top.

Concrete Inserts Used to fix main supportchannels into the walls


6/19

6

Type Diagram DescriptionBeam clamp light duty Used to suspend single

channel from the beam.

Beam clamp heavy duty Used to suspend doublechannel from the beam.

Flat plate straight fitting Used to join two single

channel in series

Tee Clamp Used to connect two singlechannels perpendicular toeach other


7/19

7

Basic assembly of components

Spring nut assembly

The spring nut is assembled in four easy steps:

1. Insert the spring nut anywherealong the continuous slot in thechannel. Rounded nut endsmake insertion easy.

2. Turn the nut 90 clockwise. Theserrated grooves in the nut arenow positioned along theinturned edges of the channel.Brackets (or clamps) can be

placed anywhere along thechannel opening.

3. Insert the bolt through thebracket into the spring nut.

4. Tighten the bolt with a wrench.This locks the serrated teeth of

the spring nut with the inturnededges of the channel.


8/19

8

Assembling the cantilever arm with main support channel

1. Insert a spring nut in the main support channel and position it byturning 90 clockwise.

2. Hold the cantilever arm perpendicular to the main support channel with theback plate against the open slot of the channel. Take care that the slot in thecantilever arm align with the spring nut.

3. Insert the bolt into the nut through the cantilever arm.4. Tighten with a wrench to lock the bolt in place.

Figure 1

Main support channel

cantilever arm

Connecting vertical and horizontal main support channels

1. Right angle bracket is used to connect vertical and horizontal main supportchannels.

Note:The prescribed distance between two cantilever arms is 250mm.


9/19

9

2. Insert a spring nut in the vertical main support channel and position it.3. Insert another spring nut in the horizontal main support channel and position

it.

4. Hold the channels as shown in the figure 2.5. Position a right angle bracket as a connector between the channels.6. Insert the bolts thr ough the bracket into the spring nuts.7. Tighten with a wrench to lock the nuts in position.

Figure 2Single channel

Right angle bracket main support channel

Connecting the 90 angle fitting (heavy duty) with main supportchannels

The 90 angle brackets are used to connect horizontal and vertical main supportchannels where heavy loads have to be supported.

Insert two spring nuts in the horizontal main support channel.

Insert two spring nuts in the vertical channel.

Hold the 90 angle fitting at the junction where the horizontal and vertical channels

meet. Take care that the spring nuts align with the slots in the 90

angle fitting.


10/19

10

Insert the bolts in the spring nuts and tighten with a wrench to lock them in position.

Figure 3

Main support channel single channel

90 bracket

Assembling flat plate straight fitting

These are used to connect two single channels in series.

Insert two spring nuts near the end of the first single channel.

Hold the flat plate straight fitting with the first two slots aligned with the spring nuts.

Insert the two bolts through the fitting and tighten with a wrench.

Insert two spring nuts at the beginning of the second single channel.

Hold the second channel in series after the first channel. Take care that its spring nutsalign with last two slots in the flat plate straight fitting.

Insert the two bolts through the fitting and tighten with a wrench.

Figure 4

Single channels flat plate straight fitting


11/19

11

Assembling Tee clamps

These clamps are used to connect single channels perpendicular to each other.

1. Insert three spring nuts in the horizontal channel and position them.2. Insert one spring nut in the vertical channel and position it.3. Hold the tee clamp at the meeting point of the two channels, taking care that

the spring nuts are aligned with the slots in the clamps.

4. Insert the bolt through the clamp into the center nut of the horizontal channeland tighten with a wrench to lock the nut into position.

5. Insert the bolt into the nut directly below the central nut, into the verticalchannel and tighten with a wrench.

6. Insert the bolts into the nuts on both sides of the central nut into the horizontalchannel and tighten with a wrench.

Figure 5

Horizontal channel

tee clampvertical channel


12/19

13

Trench wall

In places where cables run against the wall, the cable trays have to be anchoredagainst the wall. For that purpose , we need to anchor the main support channel to thewall. It can be single channel or a double channel, depending upon the weight to besupported.

The CC1 clamps are used, mainly, to anchor the main support channel against thewall. The clamps are available in different sizes for single and double channels.

Anchoring the main support channel against the wall

1. Select the channel of appropriate length to serve as the main support channel.2. Insert two spring nuts into the main support channel, one near the top and one

near the bottom , and position them.

3. Hold the channel against the wall with the open end of the channel facingyou.

4. At the top hold the channel clamp over the channel , aligned with the springnut. Make a mark on the wall through the slots in the clamp, on both sides.

5. Repeat the procedure with another clamp held at the bottom of the channel.6. Remove the channel and clamp and drill holes in the wall at the places

marked.

7. Hold the channel against the wall with the open end facing outward.8. Hold the clamp over the channel at the top with the spring nut aligned with the

slot in the clamp.

9. Insert the rawl bolts through the clamp into the wall at the sides of the channel.


13/19

14

10.Insert the bolt through the clamp into the spring nut and tighten it with awrench.

11.Repeat the steps 7-9 for fixing the clamp at the bottom of the channel.12.The cantilever arms can now be fixed to the channel.

Floor Support

Figure 6

Note:

To connect double channels follow the same procedure described above. Substitute the

single channel clamp with a double channel clamp.The prescribed distance between two channels is 1.5 meters.Select the cantilever arm as per the tray width.


14/19

16

Floor Support

In cases where the channel have to be supported from the floor, we use base plates.Base plates are of two types:

Base plate for single channel BP1 Base plate for double channel - BP2

The maximum channel length thatcan be supported by a base plate is 1 m.

Fixing base plate for single channel

1. Select the single channel of appropriate length.2. Choose the base plate for single channel.3. Fix the base plate to floor using cement. Take care that the cement does not

close the slots in the base plate.

4. For further support nail the base plate to the floor through the slot in the flatportion of the base plate.

5. Insert a spring nut into the single channel.6. Place the single channel vertically on the base plate with the spring nut aligned

with either of the slots.

7. Insert the bolt through the base plate into the spring nut. Tighten it with awrench to lock the nut in position.

8. The cantilever arm can now be fixed on to this single channel.


15/19

17

Fixing base plate for double channel

Select the double channel of required length.

Fix the base plate firmly with the floor using cement. Take care that the cement doesnot enter the slots in the flat portion of the base plate.

Nail the base plate firmly to the floor using the slots on either side of the plate.

Insert one spring nut each into the continuous slots on either sides of the doublechannel.

Hold the double channel vertically on the base plate. Take care that the spring nuts arealigned against the slots on the sides of the raised portion of the base plate.

Insert the bolt through the base plate into the spring nut. Tighten with a wrench tolock the nut into position. Insert the bolt on the other side also.

The cantilever arm can now be fixed on to this main support channel.

Figure 7

Single channel double channel

base plate for single channel base plate for double channel


16/19

19

Ceiling Support

Case 1: When I beam is present

To suspend a single channel from the I beam:

1. Select two light duty beam clamps.2. Fix the beam clamps on both sides of the I beam.3. Hold the beam clamp on the beam and tighten the set screws with a wrench.4. Insert the clamping nuts and tighten them with a wrench.5. Insert the horizontal single channel through the U bolts of the beam clamps.6. Fix the 90 angle bracket to the horizontal channel.7. Attach a vertical channel to the 90 angle bracket, perpendicular to the

horizontal channel.

8. The cantilever arms can now be attached to the vertical channel.

Figure 8I beam

beam clamp for single channel heavy duty beam clamp


17/19

20

Case 2: When the I beam is absent

Fix the 90 angle bracket to the ceiling by using a nut and bolt.

Attach a vertical channel to the 90 angle bracket, perpendicular to the horizontal

channel.

The cantilever arms can now be attached to the vertical channel.

Note:

The 90 angle bracket can also be welded to the ceiling or cemented to the

ceiling depending on the weight to be supported.

Note:

To suspend a double channel from the I beam, use the heavy duty beam clamp

and follow the instructions given in the case of the single channel.


18/19

21

Support at both ends

In situations where the verticals channels from the floor have to be of lengths greaterthat 1 m , the support has to be given from both ends.

1. Select the length of the channel suitable for the purpose.2. Fix a base plate to the floor by following the procedure given on pg 000.3. Fix another base plate to the ceiling, directly above the base plate on the floor.4. Insert two spring nuts into either ends of the channel.5. Insert the channel vertically between the two base plates.6. Insert the bolts into the spring nuts and tighten them with a wrench.7. The cantilever arms can now be attached to the vertical channel.


19/19

22

Vertical risers

When the cables have to be supported vertically against a wall, we make use ofvertical risers.

Vertical risers are single channels anchored on to a wall at a fixed distance from eachother. The cable tray is then fixed on these channels parallel to the wall.

Fixing vertical risers

Select the cable tray of required length.

Divide the length of the cable tray( in meters) by 1.5 to arrive at the number of single

channels needed.

Anchor the single channels horizontally on the wall by using clamps. (see pg )

The distance between the channels must be 1.5 metres.

The cable tray can now be fixed on to these single channels.

Flexible Support System Guide

Documents

Transcript of Flexible Support System Guide