Shelter Kit Manual Rev 2E.p65 TM Underground Kita
User Manual: TM-Underground-Shelter-Kita of /SteelBuildings
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The Bunker Book American Safe Room’s Underground Blast Resistant Bomb/Fallout Shelter System www.AmericanBombShelter.com File: TM-Underground-Shelter-Kit.pdf Revision: 2E Date: June 29, 2011 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Contact information Address: American Safe Room 868 Murdock Drive Oakland, OR 97462 Shelter questions and support: 541-315-0987 shelters@AmericanBombShelter.com Engineering: info@mailasr.com Main telephone: 541-459-1806 FAX: 503-212-6695 Websites: www.AmericanBombShelter.com www.AmericanSafeRoom.com www.AmericanIsolationRoom.com COPYRIGHT ©2011 LEONARD M. HENRIKSON, ALL RIGHTS RESERVED THE DRAWINGS AND TEXT IN THIS MANUAL ARE COPYRIGHTED MATERIAL Version notes June 22, 2011 This is the American Safe Room underground shelter kit manual, version 2D. It supersedes all previous versions. The revision 2 manuals are the first revision to incorporate the 200, 300, and 400 series shelters. Planned • • • additions: Horizontal “tunnel” kit to attach two or more shelters together or a shelter to a basement Stair kit to allow access to a vertical blast door Variable length shelter kits that allow the length to be adjusted in 32 inch increments Table of contents Section A Description, notes, and cautions ...................................................................... 5 Ordering a shelter kit ..................................................................................... 6 Shelter kit work sheet .................................................................................... 7 Choosing the shelter size and location .............................................................. 8 Section B Excavation Series 100 Series 200 Series 300 Series 400 overview ....................................................................................... 9 ............................................................................................. 10, 11 ............................................................................................. 12, 13 ............................................................................................. 14, 15 ............................................................................................. 16, 17 Section C Shelter floor overview .................................................................................. Floor slab size ............................................................................................. Floor slab horizontal rebar placement ............................................................. Floor slab vertical rebar placement ................................................................ Shelter grounding system ............................................................................. 18 19 20 21 22 Section D Constructing the walls .................................................................................. 23 Section E Ceiling truss overview .................................................................................. 24 Ceiling trusses — setting and centering .......................................................... 25 Section F Ceiling form boards Dimensions of form Ceiling form boards Ceiling form boards Ceiling form boards Ceiling form boards Ceiling form boards overview ........................................................................ boards ........................................................................... — dimension drawings and quantities ................................ — installing the long perimeter form boards ....................... — installing the short perimeter form boards ...................... — installing the bottom form boards .................................. — securing the perimeter boards ....................................... 26 26 27 28 29 30 31 Section G Ceiling penetration kits overview ................................................................... 32 Ceiling penetrations - electrical, water, and waste water ................................... 33 Ceiling penetrations - ventilation pipes and blast valves .................................... 34 Section H Ceiling — rebar layout .................................................................................. 35 Ceiling — installing the rebar ........................................................................ 36 Table of contents – continued Section I Riser hatch and ladder assemblies ................................................................. Mounting the riser on the ceiling trusses ......................................................... Mounting the riser over conventional concrete openings ................................... Ladder assembly — installation ..................................................................... 37 38 38 39 Section J Pouring the ceiling and wall concrete .............................................................. 40 Roof expansion groove detail ......................................................................... 40 Ceiling slab slope ......................................................................................... 41 Section K Exterior sealant ........................................................................................... 42 Back filling the excavation ............................................................................ 42 Section L NBC air filtration system overview ................................................................. 43 NBC air filtration system parts ....................................................................... 44 Section M Optional french drain system ......................................................................... 45 Optional vertical blast door ........................................................................... 46 Optional vertical blast door installation ........................................................... 47 Optional automatic ventilation system ............................................................ 48 Optional differential pressure gauge overview ................................................. 49 Optional differential pressure gauge installation ............................................... 50 Optional electrical connection kit overview ...................................................... 51 Optional electrical connection kit installation ................................................... 52 Optional electrical connection kit wiring instructions ......................................... 53 Optional toilet installation kit overview ........................................................... 54 Optional toilet installation kit parts ................................................................ 55 Optional toilet installation kit dimensions ........................................................ 56 Section N Reference - rebar cut and forming chart ......................................................... 57 Reference - certification of pressure rating ...................................................... 58 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Description The American Safe room Shelter System is comprised of a series of individual kits that can be supplied together to build a complete shelter or separately for use in your own shelter design. There are four series of shelters: 100, 200, 300, and 400. They correspond to different widths of shelters. The width is the span distance that the load rating is computed — side to side, not end to end. The ceiling trusses span the width and support the ceiling concrete while it is curing. After it cures, these trusses reinforce the concrete, adding a significant amount of steel right where it can be best used to resist the high pressures of a nearby detonation. All of the necessary penetrations can be through the ceiling — ingress/egress riser hatch, air ventilation pipes, electrical, plumbing, and communication. These penetrations can be installed before the ceiling pour and cast into place. The walls of the shelter can be built using the block construction shown in this manual or conventional steel reinforced concrete construction. Either construction method is made easier because of the lack of requiring the penetrations to be through the walls. As an option, an American Safe Room blast door can be installed in a wall of the shelter when one or more walls are exposed. Blast doors greatly increase the usability of a shelter by eliminating the need to get supplies, pets, or elderly and infirmed people up and down a ladder. Notes and cautions The construction techniques described in this manual are intended as a guide for experienced professionals. The ceiling trusses and riser assembly are heavy and require the use of heavy lifting equipment and qualified operators. The proper equipment should be used for every operation. This kit is designed to be easily installed by a licenced general contractor utilizing subcontractors as necessary. The skills and certifications necessary to build a complete underground shelter include excavation, concrete forms and pouring, masonry, electrical, plumbing, and structural skills. An experienced, licensed general contractor is highly recommended to oversee this project. All of the items in these kits have been designed to conform to the Uniform Building Code. Local building codes and ordinances do vary by location. It is the responsibility of the builder and owner to insure that all construction techniques and practices meet all building code requirements before construction begins. This includes all permits and inspections. Section A Page 5 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ordering a shelter kit Getting a quotation The first step is to determine exactly what shelter you need. See the worksheet on page 6 that shows all of the options available. Next, contact our shelter sales department for a quotation — see page 2 for contact information. You will need to give us the details from the worksheet, a shipping address, and an e-mail address so we can send you a quotation. Terms All items are shipped prepaid. Special order items require a 50% deposit at time of order and the balance due before shipping. When you order is complete, a proof picture will be e-mailed to you, you arrange payment for the balance due, and we ship your order right out by truck line and send you the tracking number. Most locations will see about one week shipping time. Payment options American Safe Room accepts checks (held until cleared), certified checks, and wire transfers. Availability The shelter kit is considered a special order item. We build them to order — first come, first serve. We can usually ship a shelter order in about five weeks. Custom engineering We can custom engineer shelter modifications if we have enough bandwith in our engineering department. At times, we may decide to not bid on custom jobs. Please contact our shelter sales department to find out if we are able to provide custom engineering and the costs involved. What is included with every kit Seven each steel trusses with brackets and fasteners (nuts, bolts, and washers) Complete cut and formed rebar kit One each riser hatch with ladder (other options available) One each complete blast protected NBC air filtration system that includes: one each ASR-100-AV-NBC Safe Cell NBC air filter one each ASR-50-BB emergency hand pump two each ASR-101-BV blast valves one each ASR-50-OP overpressure valve Two each 48 inch ceiling ventilation pipes — one each for air intake and outflow One each ceiling electrical penetration, water penetration, and waste water penetration kit Optional items French drain — see page 45 Blast door — see page 46 Automatic ventilation system — see page 48 Differential pressure gauge — see page 49 Electrical system — see page 51 Toilet installation kit — see page 54 What is not included Concrete blocks Form boards Concrete, mortar, and gravel Rebar safety caps External plumbing and wiring Anything else not explicitly listed above in the “included” list Section A Page 6 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Shelter kit order worksheet We will need the information below and a shipping address to accurately quote your kit. Please fill in the quantities below and return this information by e-mail to shelters@AmericanBombShelter.com or by FAX to 503-212-6695. Manuals referenced below are available at www.AmericanBombShelter.com Shelter size ___ 100 series, 8’8” x 20’ inside dimensions, total shielding: ___ feet, see page 11 ___ 200 series, 10’ x 20’ inside dimensions, total shielding: ___ feet, see page 13 ___ 300 series, 12’ x 20’ inside dimensions, total shielding: ___ feet, see page 15 ___ 400 series, 14’ x 20’ inside dimensions, total shielding: ___ feet, see page 17 Doors and hatches ___ Single leaf blast door, part number: _________________________, see pages 46 – 48 ___ Riser blast hatch, part number: _________________________, see pages 37 – 39 see the respective manuals for information how to generate the part number Ceiling penetration kits ___ Ventilation pipes — 48” ceiling penetration pipes without sleeve kit, see page 34 see the vent pipe manual for more information and options ___ Electrical penetration kit, see pages 32 and 33 ___ Water supply penetration kit, see pages 32 and 33 ___ Waste (septic) penetration kit, see pages 32 and 33 Filtration and ventilation — see the respective manuals for information about these parts ___ Complete blast protected NBC air filtration system, see pages 43 and 44 Includes: one ASR-100-AV-NBC Safe Cell NBC air filtration system one ASR-50-BB backup hand pump two ASR-101-BV blast valves one ASR-50-OP overpressure valve Or, choose your components individually: ___ ASR-100-AV-NBC — AC and DC Safe Cell NBC air filter ___ ASR-100-XX-NBC — DC only Safe Cell NBC air filter, please specify 12 or 24 volt ___ ASR-50-BB backup hand pump ___ ASR-101-BV blast valve ___ ASR-50-OP overpressure valve ___ ASR-50-FILTERS complete filter replacement for all Safe Cell models ___ ASR-100-AB automatic ventilation system, see page 49 ___ ASR-XX-DPG differential pressure gauge, specify range: ___, see pages 49 and 50 Optional kits ___ French drain system, see page 45 ___ Electrical connection kit, see pages 51 — 53 ___ Toilet installation kit, see pages 54 – 56 Section A Page 7 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Choosing the shelter size based on occupancy ratings There are two constraints to occupancy in a shelter: space and airflow. FEMA publication number 453, Safe Rooms and Shelters - Protecting People Against Terrorist Attacks. Here are some excerpts. For additional context, see this entire document: 1.6 Occupancy Duration, Toxic Free Area (TFA ) Floor Space, and Ventilation Requirements a. Less Than 24 Hours. An occupancy duration of less than 24 hours does not require sleeping areas. The occupant load will generally be a net 1.86 m2/person (20 square feet/person), depending upon the classification of occupancy. b. More Than 24 Hours. An occupancy duration greater than 24 hours requires sleeping areas. The minimum floor area, with the use of single size beds, is approximately 5.6 m2/person (60 square feet/person). With the use of bunked beds, the minimum floor area is approximately 2.8 m2/person (30 square feet/person). The recommended occupancy ratings based on floor space are: 100 200 300 400 series series series series — — — — 6 7 8 9 adults adults adults adults The recommended occupancy rating based on air supply is 12 occupants per Safe Cell air filtration system. This is using the ASHRE standard of 5 cubic feet of air per minute, per person. It is common practice to install more than one NBC air filter in a shelter to supply the required airflow. To ensure adequate airflow, each Safe Cell should have it’s own air intake and outflow ventilation pipe and blast valve. Choosing the location Careful planning should be given before an underground structure is started. The shelter should be accessible for quick entry while being hidden from view. There are some other considerations: 1. The shelter, or its foundation, may not be lower than the high water table. 2. The location should have sufficient slope to allow for surface water drainage. 3. The allowable compaction ratio of the soil at the footing should not be less than a 10,000 pounds per square foot — otherwise a thicker footing may be required. 4. location must comply with all required local building permits. 5. With fully or partially buried shelters make sure that you have sufficient space and access for needed construction equipment for excavating and lowering the pallets of loaded block into the finished excavation. Caution — do not attempt to construct your under ground shelter below the high water table. Be sure to consult with a local soil expert or drill appropriate test holes before excavation. Section A Page 8 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Excavation overview The following eight pages have the dimensions of the shelters and the required excavation. The drawings show the size for both a 3 foot and a 4 foot total shielding — ceiling slab plus back filled earth, with adequate slope to relieve surface water. Note that the ventilation pipes are shown at two feet off of the surface — as per the US Army Corps of Engineers guidelines. Be sure and read “Choosing the Location” on the previous page. To guard against cave-in of the excavation, American Safe Room drawings depicts a bench side wall slope of 45 degrees. This is considered sufficient slope for A and B soil types. The drawings show an end elevation of the shelter with the bench shown on the long side of the hole. The short sides (ends) of the holes also require this bench. The safe slope or bench for the banks of an excavation varies with different soil types, and must be determined on each individual project by the excavation contractor. If your excavating contractor is in doubt of your soil type, consult with OSHA regulations Safety and Health Regulations for Construction, part 1926, Subpart P sloping and benching and soil classifications in appendix A. Excavate the floor of the hole as level as possible without disturbing the compaction. Care must be taken not to disturb the soil compaction at the bottom of the excavation. At the recommended 10 to 11 foot depths, the soil is usually compacted sufficiently — unless it is disturbed in the excavation process. If it is disturbed, you must compact the soil with a vibra-plate compactor before constructing the floor slab forms and a footer may be required to carry the load. Caution — excavating a large hole can be dangerous. A qualified equipment operator with the proper equipment is recommended. Section B Page 9 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Series 100 shelter dimensions and quantities Maximum recommended occupancy: 6 persons Dimensions Inside dimensions: 8.7 feet wide x 20 feet long x 7.3 feet high Inside area: 173.2 square feet Inside volume: 1,264.4 cubic feet Outside square footage (walls and top) for sealant: 650 square feet Block count — local purchase 8 inch x 16 inch blocks Standard: 245 each Half: 22 each Bond: 245 each Total: 490 each Note: Be sure and order extra concrete. The truck may be short, the ground uneven below the floor slab, or the blocks you use may have larger cavities. It is standard practice to order 10% extra. Concrete requirement — local purchase 4000 PSI concrete Floor slab: 4.0 cubic yards Walls: 5.5 cubic yards Ceiling: 7.7 cubic yards Rebar requirement — see page 57 Figure B-1 Section B Page 10 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Series 100 Required excavation depth, riser, ladder and vent pipe lengths Top of riser hatch 10 inches above grade Excavation depth Ceiling beam height Floor to ceiling height Floor to opening height Riser height Vent pipe length Ladder length Ladder rungs 10-ft 10-in 88-in 134-in 36-in 60-in 128-in 11 Typical bench on all four sides of the hole Figure B-2 3 feet of total top shielding (ceiling plus backfill) Top of riser hatch 10 inches above grade Excavation depth Ceiling beam height Floor to ceiling height Floor to opening height Riser height Vent pipe length Ladder length Ladder rungs 11-ft 10-in 88-in 146-in 48-in 72-in 140-in 12 Typical bench on all four sides of the hole Figure B-3 4 feet of total top shielding (ceiling plus backfill) Section B Page 11 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Series 200 shelter dimensions and quantities Maximum recommended occupancy: 7 persons Dimensions Inside dimensions: 10 feet wide x 20 feet long x 7.3 feet high Inside area: 200 square feet Inside volume: 1,460 cubic feet Outside square footage (walls and top) for sealant: 700 square feet Block count — local purchase 8 inch x 16 inch blocks Standard: 265 each Half: 22 each Bond: 265 each Total: 530 each Note: Be sure and order extra concrete. The truck may be short, the ground uneven below the floor slab, or the blocks you use may have larger cavities. It is standard practice to order 10% extra. Concrete requirement — local purchase 4000 PSI concrete Floor slab: 6.0 cubic yards Walls: 5.6 cubic yards Ceiling: 10.4 cubic yards Rebar requirement — see page 57 Figure B-4 Section B Page 12 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Series 200 Required excavation depth, riser, ladder and vent pipe lengths Top of riser hatch 10 inches above grade Excavation depth Ceiling beam height Floor to ceiling height Floor to opening height Riser height Vent pipe length Ladder length Ladder rungs 10-ft 12-in 88-in 134-in 34-in 60-in 128-in 11 Typical bench on all four sides of the hole Figure B-5 3 feet of total top shielding (ceiling plus backfill) Top of riser hatch 10 inches above grade Excavation depth Ceiling beam height Floor to ceiling height Floor to opening height Riser height Vent pipe length Ladder length Ladder rungs 11-ft 12-in 88-in 146-in 46-in 72-in 140-in 12 Typical bench on all four sides of the hole Figure B-6 4 feet of total top shielding (ceiling plus backfill) Section B Page 13 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Series 300 dimensions and quantities Maximum recommended occupancy: 8 persons Dimensions Inside dimensions: 12 feet wide x 20 feet long x 7.3 feet high Inside area: 240 square feet Inside volume: 1,752 cubic feet Outside square footage (walls and top) for sealant: 775 square feet Block count — local purchase 8 inch x 16 inch blocks Standard: 287 each Half: 11 each Bond: 287 each Total: 574 each Note: Be sure and order extra concrete. The truck may be short, the ground uneven below the floor slab, or the blocks you use may have larger cavities. It is standard practice to order 10% extra. Concrete requirement — local purchase 4000 PSI concrete Floor slab: 7.1 cubic yards Walls: 5.9 cubic yards Ceiling: 14.0 cubic yards Rebar requirement — see page 57 Figure B-7 Section B Page 14 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Series 300 Required excavation depth, riser, ladder and vent pipe lengths Top of riser hatch 10 inches above grade Excavation depth Ceiling beam height Floor to ceiling height Floor to opening height Riser height Vent pipe length Ladder length Ladder rungs 10-ft 14-in 88-in 134-in 32-in 60-in 128-in 11 Typical bench on all four sides of the hole Figure B-8 3 feet of total top shielding (ceiling plus backfill) Top of riser hatch 10 inches above grade Excavation depth Ceiling beam height Floor to ceiling height Floor to opening height Riser height Vent pipe length Ladder length Ladder rungs 11-ft 14-in 88-in 146-in 44-in 72-in 140-in 12 Typical bench on all four sides of the hole Figure B-9 4 feet of total top shielding (ceiling plus backfill) Section B Page 15 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Series 400 shelter dimensions and quantities Maximum recommended occupancy: 9 persons Dimensions Inside dimensions: 14 feet wide x 20 feet long x 7.3 feet high Inside area: 280 square feet Inside volume: 2044 cubic feet Outside square footage (walls and top) for sealant: 850 square feet Block count — local purchase 8 inch x 16 inch blocks Standard: 305 each Half: 22 each Bond: 305 each Total: 610 each Note: Be sure and order extra concrete. The truck may be short, the ground uneven below the floor slab, or the blocks you use may have larger cavities. It is standard practice to order 10% extra. Concrete requirement — local purchase 4000 PSI concrete Floor slab: 10.1 cubic yards Walls: 6.3 cubic yards Ceiling: 18.2 cubic yards Rebar requirement — see page 57 Figure B-10 Section B Page 16 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Series 400 Required excavation depth, riser, ladder and vent pipe lengths Top of riser hatch 10 inches above grade Excavation depth Ceiling beam height Floor to ceiling height Floor to opening height Riser height Vent pipe length Ladder length Ladder rungs 10-ft 16-in 88-in 134-in 30-in 60-in 128-in 11 Typical bench on all four sides of the hole Figure B-11 3 feet of total top shielding (ceiling plus backfill) Top of riser hatch 10 inches above grade Excavation depth Ceiling beam height Floor to ceiling height Floor to opening height Riser height Vent pipe length Ladder length Ladder rungs 11-ft 16-in 88-in 146-in 42-in 72-in 128-in 12 Typical bench on all four sides of the hole Figure B-12 4 feet of total top shielding (ceiling plus backfill) Section B Page 17 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Shelter floor overview The floor constructed of 6 to 10 inches of 4,000 PSI minimum concrete with ¾ inch minus aggregate and a 5 to 6 inch slump. It should be poured at one time and allowed to cure for a minimum of seven to ten days. See pages 10, 12, 14, or 16 for the amount of concrete needed. Note - see page the Excavation Overview on page 9 for information on soil compaction and the need to not disturb the soil at the bottom of the excavation. Building the forms Construct the proper size forms as shown in figures C-3. Lay a 6 mil plastic vapor barrier down inside the forms. Trim the plastic so it lays flat inside the forms and does not curl up onto the form boards. When completed, the vapor barrier should not extend out past the floor slab or it will funnel water under the slab. Setting the rebar Lay the rebar in place as per the drawing C-2 on page 20. The horizontal rebar in the floor form should be set at a height of 3 inches off of the ground. Use dobies (small blocks of concrete with embedded wire) to hold the rebar at this height. Caution — because the rebar is at the bottom of a hole, all exposed ends should be capped as soon as they are laid in place or cut to length. Anyone who looses their balance in the hole is in danger of falling on an exposed rebar end. Installing the Ufer grounding system This is a special grounding system that complies with NEMA code and enhances the EMP resistance of the shelter. It needs to be installed before the floor is poured. See page 22 for more information. Pouring the concrete It is recommended to use a concrete pump to deliver the concrete down in the hole. After the form is full of concrete, rod it off, bull float it, and apply a trowel or broom finish. Note: Be sure and order extra concrete. The truck may be short, the ground uneven below the floor slab, or the blocks you use may have larger cavities. It is standard practice to order 10% extra. Section C Page 18 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Floor slab size Reference the drawing below when constructing the forms. The outside length at the bottom and the outside widths on the left side are the dimensions of the floor slab. The inside of the form boards should hold these dimensions. The ceiling trusses are shown for reference. Inside length Outside length Build form to this dimension Figure C-1 Floor slab dimensions Section C Page 19 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Floor slab horizontal rebar placement Lay the rebar in the floor forms as shown below. The perimeter rebar is doubled and placed 4 inches from the edge so it is centered under the walls. For rebar counts and lengths, see page 57. All rebar connections and intersections must be properly tied with two ties at least 12 inches apart. Figure C-2 Floor slab horizontal rebar placement Section C Page 20 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Floor slab vertical rebar placement Ensure that the exposed vertical rebar studs are properly located to extend up into the center of the blocks. F1A UFER ground F1D 2X8 board F2A Figure C-3 UFER ground, F1D See UFER ground details on the next page W L 6” to 10” thickness 12”-exposed rebar Figure C-4 Section C Page 21 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Shelter grounding system Wall UFER ground F1D F1A Figure C-5 This shelter kit utilizes the Ufer Ground. The Ufer Ground is an electrical earth grounding method named after Herbert Ufer. It is a concrete encased ground electrode. It is installed by connecting the ground wire to the rebar in foundation concrete. Proper grounding is essential to comply with NEMA code and mitigate the effects of electromagnetic pulses (EMP). A piece of bent rebar is attached to one of the F1A rebar pieces with wire ties. Place this Ufer ground rod in a location near where you plan on placing the electrical box — see pages 52 and 53. A grounding wire is connected to the box and this Ufer grounding rod. The National Electrical Code (NEC) Section 250.52(A) (3) requires the electrical service to be grounded to the footer reinforcing steel. This grounding is known as the Ufer Ground. This requirement only applies to footers having at least 20 feet continuous ½ inch diameter or larger reinforcing steel. This NEC requirement began January 1, 2005 for commercial buildings, and May 27, 2006 for residential buildings. 1) The contractor shall use a standard electrical ground rod or ½ inch or larger reinforcing steel rated for external use such as but not limited to (galvanized rod). Standard steel reinforcing rod wrapped with metallic tape will not be accepted. This ground rod or reinforcing steel shall be wire tied to the 20 ft of reinforcing steel in the footer with a minimum of two wire ties. This Ufer Ground can extend beyond the inside or the outside of the footer enough to make a future connection. The building inspectors shall mark the location of the Ufer Ground on the approved set of plans, and sign building card under UFER GROUND heading. 2) Ufer Ground extensions installed toward the inside of the footer shall be long enough to go above the finished floor. Section C Page 22 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Constructing the walls After the floor slab has cured for at least seven days, the walls are built from industry standard concrete 8 x 8 x 16 inch 1,000 PSI two hole blocks using a 3/8 inch mortar bead. The completed wall assembly is 88-inches and 11 courses high. See section B for the block counts. Horizontal rebar is laid in every other layer. Course 1 (shown below) is standard block. Course 2 (shown below) is the horizontal rebar bond course, see fig D-3 below. All rebar connections and intersections must be properly tied with two ties at least 12 inches apart. Vertical rebar pieces are placed in the wall at the time of the ceiling kit assembly. See the rebar cut and forming chart in the reference section at the end of this manual for dimensions of the rebar shown below. The corner blocks on course 2 (the rebar courses) are made from regular blocks so the ends of the rebar channels are not exposed. W1C To be installed with ceiling kit 1 1 1 1 1 1 2 2 2 2 2 Figure D-1 W1A W1B W1B Bond block Standard block W1A Bond block Floor Standard block Figure D-2 Figure D-3 Section D Page 23 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling truss overview The ceiling trusses are set on the tops of the walls. There are standard trusses and riser trusses which are shipped assembled as shown below. The standard trusses are shipped and installed individually. The riser trusses are shipped and installed as a pair (shown below). They are designed to reinforce the structure under the riser hatch. If no riser hatch is installed, standard trusses are used for the entire ceiling. Place and center the riser truss pair (T-2) as shown below and on the next page. Place and center the remaining five standard trusses (T-1) as shown below and on the next page. All trusses are centered over block pairs as shown in figures E-2 and GE-3 and centered between the walls as shown in figure E-4, leaving room for the ceiling perimeter form boards. Caution — The ceiling trusses and riser assembly are heavy and require the use of heavy lifting equipment and qualified operators. The proper equipment should be used for every operation. T-2 T-1 Figure E-1 Section E Page 24 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling trusses — setting and centering Truss Wall Figure E-2 Side (elevation) view — all trusses are located on 32” centers Open Column Truss Figure E-3 Top (plan) view — all truss centers fall between the vertical columns in the block as per series width Form board Angle bracket Wall Figure E-4 Truss/wall centering bracket End view — all trusses are centered on their long axis as shown above Section E Page 25 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling form boards overview Dimensions of form boards Once the trusses are set, the perimeter form boards for the ceiling are cut and placed around the trusses. 100 Series 10’-0” X 21’-4” Side perimeter group, see figure F-1 Low side h=12”, high side h=14.1/2” Then the bottom form boards are cut and placed between the bottom flanges of the trusses. The form boards are to be supplied by the concrete contractor and made up onsite from 1.1/ 8 thick CDX plywood. All finished form boards should be painted with a weather proof primer before the concrete pour. Caution — the form system is designed to carry the wet pour load, if the pour thicknesses in this manual are exceeded, the forms may fail, allowing the ceiling concrete drop down onto the floor slab. There are 3 types of form boards. 1. The long side form boards are cut in two different heights to accommodate the required roof drainage slope of ¼” per foot. The high side is placed on the hatch-riser side of the roof. 2. The short end forms are taper cut to properly fit the side forms difference of ¼” per ft. The end boards are not installed until placement of the longitudinal rebar. 3. The bottom form boards are cut to 30.3/4” widths to nest between the trusses, and made up in rows in sufficient lengths to be 4-inches longer than the inside shelter width, as not to cover the block openings. If the block openings are covered, the walls cannot be filled with concrete during the ceiling pour. See figure F-8 on page 30. End perimeter group, see figure F-2 h1=12”, h2=14.1/2” End bottom group, see figure F-3 h= 25.1/2”, L=108” Center bottom group, see figure F-4 h=30.3/4”, L=108” 200 Series 11’-0” X 21’-4” Side perimeter group, see figure F-1 Low side h=14”, high side h=17” End perimeter group, see figure F-2 h1=14”, h2=17” End bottom group, see figure F-3. h= 25.1/2”, L=124” Center bottom group, see figure F-4 h=30.3/4”, L=124” 300 Series 13’-4” X 21’-4” Side perimeter group, see figure F-1 Low side h=16”, high side h=19.1/4” End perimeter group, see figure F-2 h1=16”, h2=19.1/4” End bottom group, see figure F-3 h= 25.1/2”, L=148” Center bottom group, see figure F-4 h=30.3/4”, L=148” 400 Series 15’-4” X 21’-4” Side perimeter group, see figure F-1 Low side h=17.3/4”, high side h=21.1/2” End perimeter group, see figure F-2 h1=17.3/4”, h2=21.1/2” End bottom group, see figure F-3 h= 25.1/2”, L=172” Center bottom group, see figure F-4 h=30.3/4”, L=172” Section F Page 26 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling form boards — dimension drawings and quantities Reference the dimensions on the previous page (h) 2 required different (h) (L) Figure F-1 Side perimeter form boards Figure F-2 End perimeter form boards (h-2) (h-1) 2 required (L) (L) Figure F-3 End bottom form boards (h) 2 required Figure F-4 Center bottom form boards (h) 6 required Section F Page 27 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling form boards — installing the long perimeter form boards The perimeter side boards serve two functions, first to secure the trusses from movement along the long axis of the shelter and secondly to provide the perimeter form for the poured concrete ceiling. Caution — it is critical that the distance between the truss centers on both ends of the trusses is correct as per figures E-3 and E-4. Using the fasteners provided with your truss kit: 1. Install all board brackets to the ends of the centered trusses as shown in fig. F-6, and F-7 but do not yet tighten the board bracket securely to the truss. 2. Set the long form boards on top of the wall and against the face of the board brackets as shown in figure F-7. 3. Using the board brackets as a template, mark and drill the 3/8-inch holes for the perimeter long form board bolts, and fasten the long form boards to the brackets. 4. Adjust the long perimeter form boards so that the outside face of the board is flush with the outside face of the wall, and tighten the board bracket truss bolts, as per figure F-7. End board place after rebar Side board End board place after rebar Figure F-5 Section F Page 28 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling form boards — installing the short perimeter form boards 1. Install the two short form boards over the end walls with the outside face of the board flush with the outside face of the wall just as the long form boards. 2. Use the corner board brackets as a drill template and fasten the corners with the provided bolts. angle bracket nut washer corner board bracket washer 2½” angle bracket bolt short form board long form boards connection plate Figure F-6 long form boards truss 1¼” board bracket/truss bolts 2½” perimeter form board bolts 1¼” truss/wall centering brackets bolts Figure F-7 Section F Page 29 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling form boards — installing the bottom form boards Openings in wall blocks Wall End form board Truss Center form board Truss Figure F-8 top view Ceiling form board being rotated into place Truss Truss Ceiling form board in place Figure F-9 side view Section F Page 30 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling form boards — securing the perimeter boards It is necessary to secure the perimeter side boards to the bottom boards to insure that they do not bulge or bow during the pour. Using the form brace as a template, mark and drill bolt locations for fasteners 1 and 2, and then install fasteners. Using a power screwdriver mark and drill bolt locations for fasteners 3, and then install fasteners. Using a good caulking compound, seal any gaps or openings around the trusses and wall edges. Form braces Bottom form boards Form braces 2 3 1 1. 2½” form brace bolt through perimeter form board 2. Form brace nut 3. 2½” form brace bolt through bottom form board Figure F-10 Section F Page 31 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling penetration kits overview There are four individual penetration kits. They are designed for quick and simple installation through the bottom concrete form board before the pouring of the concrete. 1. 2. 3. 4. Electrical 1-inch, figure G-2. Water 1-inch, figure G-3. Waste (septic) water 2-inch, figure G-4. Air ventilation 4-inch, figure G-5. The bulkhead connection kits work by capturing both sides of the bottom form board by sandwiching or clamping the board between the upper and lower elements of the kit. Place the kit gasket at the desired penetration location and use as hole template for drilling through the form board. Air exhaust Air intake Figure G-1 Section G Page 32 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling penetrations - electrical, water, and waste water A B 3 1 2 Bottom form board 1. 2. 3. 4. A. B. C. D. E. Mounting plate Gasket ¼”-20 x 2-inch length bolt – 4 each Hex nut ¼”-20 – 4 each Conduit 90 – 1 each Close nipple 1” x 3” – 1 each Close nipple 1” x 1” – 1 each Coupling 1” female/female – 1 each Adaptor – 1 each C D 4 E Figure G-2 Electrical penetration 1 4 2 1 3 3 Bottom form board 2 Bottom form board 5 Figure G-3 Water penetration 1. 2. 3. 4. 5. 1½” x 20” pipe nipple Mounting plate Gasket ¼”-20 bolts – 4 each ¼”-20 nuts – 4 each 4 Figure G-4 Waste water penetration 1. 2. 3. 4. 2” x 20” pipe nipple Gasket ¼”-20 bolts – 4 each ¼”-20 nuts – 4 each Section G Page 33 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling penetrations - ventilation pipes and blast valves The ventilation pipes are bolted down to the bottom form boards before the ceiling pour. The mounting flange for the ventilation pipes exactly matches the mounting flange for the blast valve. These two mounting flanges sandwich a gasket, the bottom form board, and then another gasket as shown below. Note: this part list is for one ventilation pipe. Two ventilation pipes are required for each shelter for the air intake and the air outflow. Included with this installation A. 1 eachceiling style ventilation pipe G. 1 eachrubber gasket 1. 8 eachHHCS ½”-13 x 3” 2. 16 each flat washer ½” 3. 8 eachhex nut ½”-13 Note: this installation can also be used for steel shelters with flat ceilings. Ventilation pipe Mounting bolt Ceiling form board Gasket Installation steps: 1. After the bottom form board of the ceiling is in place, locate and cut a 4½ inch hole where the vent pipe is to be mounted. 2. Using the blast valve as template, locate and drill bolt circle for valve, ½ inch holes in all 8 locations. 3. Using the 8 each ½ inch X 3-in length bolts, sandwich the assembly together as shown in figure G-5. Gasket Blast valve Washer Flanged hex nut Figure G-5 Detail of pipe system Figure G-6 Mounting bolt pattern and dimensions Section G Page 34 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling — rebar layout The rebar is laid down as shown below. For length information see the rebar cut and forming chart on page 57. Note — all rebar connections and intersections must be properly tied with at least two ties at least 12 inches apart. Figure H-1 Section H Page 35 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling — installing the rebar R1B W1B W1B R1B R2B W1B Figure G-22 R2B R1B Figure H-2 R1B Note — letters refer to the rebar cut and form chart on page 57 R2B Figure H-3 Section H Page 36 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Riser hatch and ladder assemblies The riser hatch should be installed prior to the ceiling pour. Caution — the riser hatch and ladder assembly weighs several hundred pounds. It is the responsibility of the installer that proper lifting equipment be used for these procedures and that the installer has sufficient experience skill and knowledge to accomplish these tasks safely. Hatch riser assembly Ladder assembly Figure I-1 A B Hatch riser installation See figures I-3 Ladder installation See figures I-5, I-6 C Figure I-2 Section I Page 37 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Mounting the riser on the ceiling trusses This installation is for the special riser truss kit, provided with this shelter. A C 1. Apply a liberal coat of weather resistant silicone sealant over the edges of the openings surface face where the riser mounting flange bottom face will mate. 2. Install and tighten the provided hex bolts, washers and nuts as shown. A. 12.ea. Bolt 3/8-16 X 1.3/4” lg. B. 12. ea. Hex nut 3/8-16. C. Riser mounting flange. D. Truss mounting flange. B D Figure I-3 Mounting the riser over conventional concrete openings This procedure will require the concrete stud anchor kit provided with your concrete style riser and ladder kit order. A C 1. Using the riser base as a temple, locate the drill hole locations for the anchors of the provided stud anchor kit. B 2. Remove the riser and drill the holes for the stud anchors. Figure I-4 A. 12.ea. Concrete anchor studs 1/2” X 6” lg. B. 12. ea. 1/2” drilled hole w/provided drill bit. C. Riser mounting flange. Note: Concrete opening may not exceed 32” X 38” 3. Apply a liberal coat of weather resistant silicone sealant over the edges of the openings surface face where the riser mounting flange bottom face will mate. 4. Replace the riser assembly squarely over the opening and insert the stud anchor assemblies through the riser bottom flange into the drilled hole in the concrete. 5. Tighten all anchor stud nuts to (60 ft-lbs) in a cross pattern. Section I Page 38 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ladder assembly — installation 1. Pass the ladder down through the riser opening and rest the second rung on the top support brackets as shown. B 2. Insert the provided U-bolts over the ladder rung into and through the support bracket holes and install and tighten provided hex nuts. A 3. With the ladder hanging straight loosen the bottom foot locking bolt and lower the mounting foot to the floor and retighten the locking bolt, repeat this procedure for the opposite side. C Figure I-5 4. Insure that the ladder is positioned in a true vertical attitude and using the foot as a drill template install the provided anchor stud kit using the same procedure as described above. D E A. 2 ea. Support bracket F B. 2 ea. U-bolt G C. 4 ea. Hex nuts D. 2 ea. Locking bolt Figure I-6 E. 2 ea. Concrete anchor stud F. 2 ea. Drilled hole w/provided bit Section I Page 39 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Pouring the ceiling and wall concrete The block wall cavities and the ceiling are poured as single “pour.” More than one truck load of concrete may be required. See the concrete requirements on pages 10, 12, 14, and 16. Add the requirements for the walls and ceiling together when ordering the concrete. All concrete is minimum 4,000 psi strength, ¾-inch minus aggregate, and a 5-inch to 6-inch slump. A concrete pump is required. Fill the block cavities first, then the ceiling slab. Tamp the concrete down into the block cavities and finish the ceiling slab with a trowel or broom using the proper slope and expansion grooves shown below and on the following page. Note: Be sure and order extra concrete. The truck may be short, the ground uneven below the floor slab, or the blocks you use may have larger cavities. It is standard practice to order 10% extra. Roof expansion groove detail Figure J-1 Truss flange Support board Cement fill To avoid excessive fractures in the roof slab, the installation of an expansion groove is recommended. Section J Page 40 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Ceiling slab slope These drawings show the end elevation view Series 100 Taper per/ft. Figure J-2 Series 200 Figure J-3 Series 300 Figure J-4 Series 400 Figure J-5 Section J Page 41 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Exterior sealant The recommended sealant is Ames Blue Max Liquid Rubber Coating. It can be purchased at this website: www.AmesResearch.com/bluemax.htm The manufacturer’s recommended application: “Apply Ames' Blue Max to the surface. We recommend two gallons per 100 sq. ft. or two coats as needed for walls, and three gallons per 100 sq. ft. or three coats for cisterns and tanks, or as needed.” See the outside square footage dimensions listed on pages 10, 12, 14, and 16 to determine how much sealant you need to order. Follow the manufacturer’s recommendation for application. Back filling the excavation The shelter is back filled as shown below. F-2 Vapor barrier A 6-mil vapor barrier is laid over the top and extends down the sides. The optional french drains system must be installed before backfilling. F-2 Vapor barrier Perforated pipe F-1 Vapor barrier F-1 Vapor barrier Wrap F-1 vapor barrier up side under F-2 vapor barrier Figure K-1 Backfill Drain rock Figure K-2 Section K Page 42 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 NBC air filtration system overview The shelter air filtration system is divided into two groups, the intake group for drawing outside air into the NBC filtration unit, and the outflow group for expelling the CO2 laden air out. This arrangement provides for true positive pressure air filtration. AC electrical power Connect the power cord to the control panel power socket and plug into a working power source (electrical outlet). Switch on the lighted main power switch on the front control panel. Automatic battery back up Connect the 12-VDC cable connector to the control panel socket and connect the clip leads (jumper cable style clips) to a user supplied 12-volt DC automotive or marine type battery — ensure that the polarity is correct; red is positive, black is negative. For more detailed information regarding the components comprising this system, you may refer to the individual technical manuals available at www.AmericanBombShelter.com: 1. 2. 3. 4. 5. 6. 7. TM-50-VP, blast resistant ventilation pipes. TM-101-BV, blast valve TM-100-AV-NBC, air filtration system TM-50-BB, emergency hand pump TM-50-OP, overpressure valve ASR-100-AB auxiliary ventilation system TM-05-DPG, differential pressure gauge Section L Page 43 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 NBC air filtration system parts 1 1 2 2 3 A 3 Form board 4 1 4 Form board 5 5 5 5 6 6 9 11 B B 12 C C Battery 12-V user supplied Figure L-2 Output group 7 10 8 Figure L-1 Intake group 1. 2. 3. 4. 5. 6. Heavy steel rain cap EMP/insect screen Locking lug Heavy steel vent pipe Gasket Heavy steel blast valve 7. 8. 9. 10. 11. 12. Intake hose Filtration unit Emergency backup hand pump Power cord Battery jumpers Over pressure valve A. Hex bolt ½-13 X 3” B. Flat washer C. Hex nut ½-13 Section L Page 44 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional french drain system D, 10 inch PVC Culvert Pipe Cap C, Sump Pump A, 10 inch PVC Culvert Pipe B, perforated drain pipe Figure M-1 F2 Vapor Seal D A B C F1 Vapor Seal Figure M-2 Section M Page 45 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional vertical blast door ASR-50-BD Blast Door is a pre-hung, explosion resistant blast door that offers excellent protection from extremely high pressure blast waves like those produced by a large conventional or nuclear device detonated in relatively close proximity. This door is rated to withstand high pressure waves up to 7,200 pounds per square foot — that is 50 pounds per square inch (PSI). Additionally, the step over threshold option (page 8, blast door manual) offers a compression seal between the door and the frame allowing for the use of a positive pressure NBC filtration system inside the shelter. See the complete manual available at www.AmericanBombShelter.com Lift the door into place Lift door frame assembly into the wall opening and push the door so that the frame lip is fully captured inside the boundaries of the opening. Brace or otherwise secure the door frame assembly so that it can not fall out of the opening. Caution — take care to not pinch body parts between the door and any obstructions as a severe pinch injury will occur. When swinging the door closed use only the provided door handles. Read and understand these instructions thoroughly before attempting to hang this blast door. American Safe Room strongly recommends that this door be installed by a qualified installer with the proper tools and equipment. A licenced general contractor should be able to follow these directions and complete the installation properly. Strapping at lift points Figure M-3 Section M Page 46 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional vertical blast door installation If the wall is not perfectly straight, the door frame will bend when the nuts are tightened on the wedge anchors, so it is imperative that the wall be grouted to the frame, not the frame tightened to the wall. In order for the door to close, latch and seal correctly it is necessary for the outer door frame flange to nest flat against the wall surface (C). In cases where the wall is not square or flat with the door frame it will be necessary to use cement grout to create a flat surface between the frame and well. This is accomplished by creating a ½-inch wide void between the door frame and wall surface and filling it with wet cement grout. Using the door frame and wall surface as a vice evenly clamp a number of ½-inch thick shims or spacers between the door frame and wall surface by lightly tightening the anchor bolts. When the cement grout is dry remove the shims and tighten the anchor bolts to full torque, this will provide the door frame with a flat mounting surface. Fill w/concrete A B C Figure M-4 Figure M-5 Section M Page 47 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional automatic ventilation system The ASR-100-AB auxiliary ventilation blower system provides 100 CFM of fresh unfiltered air into your shelter. It may be used in ventilation mode only during non threat times when no outside toxins are present to purge your shelter of unwanted stale air, relieve moisture, and prevent anaerobic mold spores from growing. Emergency hand blower Plug Output Parts included in this kit 110 AC 12 V Battery Outside air Power supply Timer 110 AC Wall bkt Intake Plug Hose port Air intake hose Connection 1 Air intake hose Connection 2 Figure M-6 Section M Page 48 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional differential pressure gauge overview The American Safe Room Differential Pressure Gauge displays the difference in air pressure between the inside and outside of a shelter to constantly verify that you have positive pressure inside your shelter. It has a sampling tube that goes through the wall or ceiling in order to read the outside air pressure. Another sampling tube is inside the housing and the difference in air pressure is displayed by a needle on a dial gauge. When you do not have the Safe Cell NBC overpressure air filter on, a properly installed differential pressure gauge will read zero because there is no difference in the air pressure inside, and outside of the shelter. When you start the Safe Cell, the gauge will read a higher pressure. The unit of measure displayed is inches of water column (wc). There are 27.67 inches of water in one pound per square inch (PSI). Air flow and air pressure are two properties of forced air that are linked together. As a general rule, the more air pressure, the less air flow. An airflow of 5 cubic feet per minute per person at 0.3-inch (7.62-mm) of water column is recommended by the United States Army Corps of Engineers in the technical letter ETL 1110-3-498. See www.AmericanSafeRoom.com to view this document. There are three ranges of gauges available that displays positive overpressures: 1. zero to 0.5-inches of water column — part number ASR-05-DPG 2. zero to 1-inch of water column — part number ASR-10-DPG (special order item) 3. zero to 25-mm of water column — part number ASR-25-DPG (special order item) The Differential Pressure Gauge is designed for easy installation into any protected space. The kit includes all of the required components for installation inside of the protected space. Please see the manual for the Adjustable Overpressure Relief Valve to set up your shelter at the proper pressure. It is available at www.AmericanSafeRoom.com. Specifications Range: 0 to .5-inches/wc (12.7 mm/wc) or 0 to 1-inch/wc (25.4 mm/wc) Accuracy: +/- 5% of full scale Absolute pressure limit: 30 psi g (2.067 bar) Temperature limits: 20-120 F (-6.67-48.9 C) Figure M-7 Figure M-8 Section M Page 49 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional differential pressure gauge installation differential pressure gauge outside pressure port wall mounting screws sampling pipe - see note below washer hex nut coupler inside pressure port coupler hex nut washer seal 90 degree fitting seal Figure M-9 Installation 1. Choose a mounting location on an outside wall with smooth flat surfaces to insure proper sealing of the bulkhead compression seals. 2. Drill a 13/32-inch diameter hole through the bulkhead wall. 3. Insert the hollow threaded rod through the hole and assemble the seals and threaded fasteners as shown in Figure M-6. Note: two 6-inch sampling pipes are included with a coupler to connect them. Maximum wall thickness is 5-inches per sampling pipe. Please order additional sampling pipes for thicker walls. Figure M-10 Section M Page 50 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional electrical connection kit overview This optional kit brings 110 volt AC electrical service from the included ceiling penetration down to a breaker box and then out to two outlets on the bottom of that box. The basic load center kit is a 60 amp service installed in a NEMA 2, UL approved enclosure having two each 20 amp ground fault protected three prong outlets factory mounted at the bottom of the enclosure. The unit comes completely pre-wired except for the 4 wire connection to the grid or generator and accompanying UFER ground installed with the floor rebar kit. The kit is full expandable with eight additional breaker slots. The kit also includes all connection hardware such as conduit, fittings, UFER ground rod and clamp and mounting hardware. Conduit group C Conduit group B Bulkhead Ceiling Conduit group A Enclosure UFER ground NOTE Be sure to place UFER ground in proper location to connect the enclosure ground Figure M-11 Figure M-11 Section M Page 51 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional electrical connection kit installation The components are listed in the order of installation A. B. C. D. E. F. G. 1 2 1 1 1 1 1 each each each each each each each NEMA 2 enclosure and door concrete anchors bulkhead kit, w/ gasket and fasteners conduit group A, w/ fittings conduit group B, w/ fittings conduit group C, w/ fittings UFER ground kit F E C D A B AA G BB UFER ground rod Figure M-12 Section M Page 52 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Wiring instructions All internal wiring of the load center from the main breaker on is done at the factory. The minimum gage size of hook up wire shall be #6. All conduits and fittings from conduit group C, to the source is to be provided by the installer. All connection wire from the load center to the source is provided by the installer. There are only four on site wire connections and a ground required by the installing electrician as per the figure M-13 below. L1 L2 Neutral Ground Ground clamp UFER ground rod Figure M-13 Caution — The final hook up wiring to the power source and commissioning of the load center should be done by a licensed electrician. Section Page 53 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional toilet installation kit overview This kit will allow a Zoeller Qwik Jon to be installed in a shelter. It uses the air outflow vent pipe to vent the toilet by connecting between the overpressure valve and the blast valve. The overpressure valve is a one way check valve so septic odors will not be released into the shelter. This kit contains parts R-6 through R-14 referenced below and shown on the next page. Parts R-1 through R-5 (all items shown on the next page) are furnished with the ventilation kit hardware. Please specify that you want this optional item at time of ordering — there is an additional charge for this kit. Parts R-A through R-H are furnished by the end user. Note — the installation of the items in this section must be carried out BEFORE the ceiling/wall pour of concrete. Some of these parts are poured in place. The Zoeller Qwik Jon, catalog sheet can be downloaded here: http://www.zoeller.com/zcopump/zcopdfdocs/FM0692.pdf The Zoeller Qwik Jon, installation instructions can be downloaded here: http://www.zoeller.com/zcopump/zcopdfdocs/FM1469.pdf The contact information for the factory is: Zoller Pump Company 3649 Cane Run Road Louisville, Kentucky. 40200-1961 Telephone: 800-928-7867 502-778-2731 Item index for the drawing on the next page: R-1 ............ exhaust ventilation pipe R-2 ............ blast valve R-3 ............ fastener bolts, 8 each R-4 ............ fastener nuts, 8 each R-5 ............ overpressure valve R-6 ............ Y-connection R-7 ............ flanged trough the ceiling drain pipe R-8 ............ fastener screws, 4 each R-9 ............ fastener nuts, 4 each R-10 ........... threaded 2-inch pipe coupling pipe to 2” PVC pipe R-11 ........... flanged through the ceiling water pipe R-12 ........... fastener screws R-13 ........... threaded 3/4-inch pipe coupling pipe to 3/4-inch PVC pipe R-14 ........... 3/4-inch mail to 1/2-inch female PVC nipple reducer R-A ............ R-B ............ R-C ............ R-D ............ R-E ............ R-F ............. R-G ............ R-H ............ ½” shut off valve ½” toilet connection pipe toilet Zoller, “Qwick Jon®” Model number 100 with sewage pump — part number WM264 vent pipe 3-inch PVC 2-inch shut off valve 2-inch PVC pipe anti-backflow device This system is recommended because of its cost effectiveness and this system allows for the addition of a sink and shower. See the Zoeller Qwik Jon installation manual pages 6 and 7 for plumbing of additional fixtures such as showers and sinks. R Section M Page 54 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional toilet installation kit parts R-1 R-11 R-3 R-12 R-7 Ceiling form board R-8 R-13 R-4 R-2 R-14 R-9 R-A R-6 R-B R-5 R-10 R-F R-E R-G R-H R-D R-XX R-C Figure M-14 Section M Page 55 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Optional toilet installation kit dimensions Figure M-15 Figure M-16 Figure M-17 R Section M Page 56 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Reference - rebar cut and forming chart Figure N-1 A Figure N-2 B D C Figure N-3 Rebar naming convention 1st. character = destination, floor, walls, roof. 2ed. character = location at destination. 3rd. character = cut and forming detail. (NOTE) bar size R2B (NOTE) all rebar connections and intersections must be properly tied Series 100 Series 300 F1A = 34 pcs. #4 bar x 112” lg. F2A = 17 pcs. #4 bar x 248” lg. F1D = 01 pcs. #4 bar x 16” lg W1A = 10 pcs. #4 bar x 112” lg. W1B = 10 pcs. #4 bar x 248” lg W1C = 86 pcs. #4 bar x 92 “ lg. R1B = 13 pcs. #4 bar x 248” lg. R2B = 30 pcs. #7 bar x 112” lg. F1A = 34 pcs. #4 bar X 152” lg. F2A = 24 pcs. #4 bar X 248” lg. F1D = 01 pcs. #4 bar x 16” lg. W1A = 10 pcs. #4 bar x 152” lg. W1B = 10 pcs. #4 bar x 248” lg. W1C = 94 pcs. #4 bar x 92” lg. R1B = 16 pcs. #4 bar x 248” lg. R2B = 30 pcs. #8 bar x 152” lg. Series 200 Series 400 F1A = 34 pcs. #4 bar x 128” lg. F2A = 20 pcs. #4 bar X 248” lg. F1D = 01 pcs. #4 bar x 16” lg. W1A = 10 pcs. #4 bar x 128” lg. W1B = 10 pcs. #4 bar x 248” lg. W1C = 90 pcs. #4 bar x 92” lg. R1B = 14 pcs. #4 bar x 248” lg. R2B = 30 pcs. #7 bar x 128” lg. F1A = 34 pcs. #4 bar x 176” lg. F2A = 29 pcs. #4 bar x 248” lg. F1D = 01 pcs. #4 bar x 16” lg. W1A = 10 pcs. #4 bar x 176” lg. W1B = 10 pcs. #4 bar x 248” lg. W1C = 98 pcs. #4 bar x 92” lg. R1B = 18 pcs. #4 bar x 248” lg. R2B = 30 pcs. #9 bar x 176” lg. All series H dimension = 16-in Section N Page 57 TM-Underground-Shelter-Kit.pdf Revision: 2E — Date: June 29, 2011 Reference - certification of pressure rating Section N Page 58
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