MAX Compact Exterior - Podio balcony floor panel

MAX Compact Exterior

Balcony floor panels (Podio) with visible an concealed fasteners

Installation instructrions:

Before starting installation, all materials must be checked for completeness and possible damage. The qualified personnel of the executing company must obtain all required details for proper installation from the panel manufacturer.

The balcony flooring panel is fixed to a horizontal timber or steel substructure in accordance with the panel manufacturer's specifications, either visibly using head-painted screws incl. rosette or concealed using screw-in inserts. To ensure installation free of constraint, when using visible fastening the screw-in process must be stopped as soon as the screw head rests on the panel. Afterwards, back off by approx. 1/8 turn to avoid tension. No additional torque may be applied.

The substructure must be prepared in accordance with the structural requirements and the manufacturer's specifications. The centre-to-centre spacing of the support profiles is max. 500 mm for 16 mm and 18 mm panels, and max. 600 mm for 20 mm panels. The screw spacings must be observed accordingly. The distance between fastening points must not exceed the distance of the supports/beams and must always be ≤ 600.0 mm.

The specifications of the general building authority approval Z-50.4-337 must be complied with without exception. The number and arrangement of the screws must be taken from the structural verification and implemented accordingly. The substructure must have sufficient load-bearing capacity from a structural point of view.

The permissible live load of the balcony flooring panels must be considered in accordance with the technical information provided by the panel manufacturer. The design is carried out taking into account the panel thickness, the support spacing, and the maximum permissible deflection. The relevant values must be taken from the current technical documentation of the manufacturer and considered as part of the structural design

Width of the support profiles:
Metal substructure strips must have a width of at least 60.0 mm, and at least 80.0 mm in the joint area.
Timber substructure strips must have a width of at least 60.0 mm, and at least 100.0 mm in the joint area.
For timber substructures, pay attention to structural and/or chemical wood protection.
Use EPDM tape with a thickness of at least 1.2 mm.

For visible installation, fastening must be carried out using the following approved fasteners:
Timber substructure: EJOT JA3-S-6.5 with RAMPA rosette US 16x3.3 steel
Steel substructure: EJOT JZ-S-6.3 with RAMPA rosette US 16x3.3 steel
RAMPA rosettes type US according to DIN 7991 for accommodating countersunk screws

For concealed fastening, the RAMPA insert type SK12x12 M6 is used. The blind holes must be drilled with a diameter of 11.5 mm and countersunk with a countersink bit. The remaining wall thickness between the drilled hole and the front face of the panel must be at least 2.0 mm after deduction of all tolerances.

A metric screw can subsequently be screwed into the installed RAMPA insert as required, using a washer if necessary.
Fastening is carried out either directly through IPE beams or via metal brackets to the substructure.

The minimum edge distance is ≥ 20.0 mm, the maximum edge distance ≤ 100.0 mm.

During design and installation, ensure that the material is not exposed to standing moisture. The panels must be able to dry at all times. For balcony installations, a slope of 1.52 % must be maintained.

During installation, it must be ensured that no constraint is introduced into the HPL panel material by the installation or fastening of attached and built-in parts. Panel expansion is approx. 2 mm per running metre of panel material. To allow dimensional changes to occur unhindered, joints must be executed with a width of at least 8 mm. Joint filling is carried out using a permanently elastic sealant and backing rod/round cord in accordance with the state of the art.

The following tender texts (product descriptions) serve as templates for freely formulated specifications. They are not directly suitable for use in public tenders and must be adapted to comply with applicable national o regional procurement guidelines (e.g., by adding criteria regarding equivalence).