Calhas Chao HAGER Manual
Calhas Chao HAGER Manual
Calhas Chao HAGER Manual
Basic manual
Table of Contents
FAQs..............................................................................................................................................4
Basic knowledge........................................................................................................................18
Basic planning principles ....................................................................................................................................20
Requirements for installation technology .......................................................................................................20
Requirements from building conception ........................................................................................................20
Requirements for organisation ......................................................................................................................20
Requirements for security ..............................................................................................................................21
Installation requirements / construction requirements ...................................................................................21
Duct systems ........................................................................................................................................................22
Screed-covered duct system .........................................................................................................................22
Screed-flush duct systems ............................................................................................................................23
On-floor duct system .....................................................................................................................................24
Raised floor installation system .....................................................................................................................24
Cavity floor installation system ......................................................................................................................25
Basic principles of screed ...................................................................................................................................26
Screed structure ............................................................................................................................................26
Screed work ...................................................................................................................................................27
Screed types ..................................................................................................................................................27
Floor structure ......................................................................................................................................................29
Floor structure 50 mm ...................................................................................................................................29
Floor structure 75 mm ...................................................................................................................................30
Floor structure 105 mm .................................................................................................................................30
Information on the floor covering and for the floor layer .................................................................................31
Information on the floor covering ........................................................................................................................31
Information for the floor layer .............................................................................................................................31
Determining the cable volume ............................................................................................................................32
Bend radii ......................................................................................................................................................33
Cable volume of most common installation cables ........................................................................................34
Power supply and device installation units .......................................................................................................36
IP degree of protection .........................................................................................................................................42
IK degree of impact resistance ...........................................................................................................................43
Mechanical/thermal loads ....................................................................................................................................44
Standardisation and testing ................................................................................................................................45
Erector specifications ..........................................................................................................................................48
Protection against electric shock ...................................................................................................................48
Mechanical load of cables .............................................................................................................................48
Separation of different services .....................................................................................................................49
Fire protection ................................................................................................................................................49
Equipotential bonding ..........................................................................................................................................50
Inter-unit working .................................................................................................................................................51
Inter-unit working - Screed work ....................................................................................................................51
General information for screed layers ...........................................................................................................51
Inter-unit working - Floor covering work ........................................................................................................51
Inter-unit working - Building cleaning .............................................................................................................51
Sound protection and impact noise ....................................................................................................................52
Impact noise reduction for floor installation systems .....................................................................................52
Appendix ...............................................................................................................................................................54
Overview of floor installation systems - cable assignment .................................................................................54
Reference sources of standards and specifications ........................................................................................61
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FAQs
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7 questions - 7 answers
To meet all the requirements during the planning phase, you should get to grips with
these 7 questions. This ensures that you will obtain the right duct system solution for
your construction project.
The answers to your questions will provide you with the right solution for your con-
struction project. Starting with the right duct system, the screed height, the floor cov-
erings and their care through to the installation units.
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Using these aspects, it is possible to make a rough selection of the right duct system.
In addition, it should be noted that, in this calculation, no floor tanks or outlets which might inter-
rupt the cable path are taken into account.
In practice, power and data cables are routed separately in the duct. Separating webs divided
the duct up into multiple compartments. If this applies, then the space requirements must be cal-
culated for each compartment individually.
With stronger current loads of the cables, cable heating should be taken into account. In addi-
tion, all the relevant regulations, such as DIN VDE 0100, must also be taken into account.
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Ab 50 mm Ab 75 mm Ab 100 mm Ab 105 mm
P In general, the prescribed floor structure specifies the area available for the floor solution.
– Hinged cover with ultra-flat installation depth for a floor structure of 50 mm or more
– Standard supply units with floor covering recesses of 5 mm for a floor structure of 75 mm
or more
– Standard supply units with floor covering recess of 12 mm for a floor structure of 100 mm
or more
– Stainless steel cassettes for a floor structure of 105 mm or more
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1500 N Standard
7500 N drive-on
Basic knowledge
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Important note
This document explains the relevant principles for the installation of floor installation
systems and routing cables in these systems.
The contents of this document are based on the currently applicable rules and regula-
tions as well as our own test findings. No generally applicable legal obligation shall be
derived from the contents of this document.
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Image 6: Planning
Duct systems
A distinction is made between 5 standard floor systems. The appropriate floor system sets
the course from the very start. Depending on the system, only certain products may be used.
Whether this is a screed-covered duct system, which is often used in new buildings, or an on-
floor duct system, which is often used during renovations, the rough direction is entirely differ-
ent. Specific solutions and combination options are available for each system.
The following points, defined in the planning phase, are of decisive importance for the correct
selection of the right duct system:
– Building type (office/administrative building, car showrooms, etc.)
– Building substance (new building, old building with/without protection)
– Building structure (single or open plan offices)
– Use practices (flexible for changes of use)
Screed-covered duct system
Image 7: electraplan.UK
The electraplan.UK floor installation system is quick and easy to install and is suitable for virtually
all types of screed. The underfloor duct and floor boxes made from galvanised sheet steel, which
offers optimal protection against corrosion, are secured to the bare floor. Since the upper sections
of the basic profile are detachable, the cables can be placed into the duct from above and do not
need to be pulled in. The screed is administered flush with the upper edge of the floor boxes such
that the underfloor duct is covered. See catalogue
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Image 9: electraplan.BK
This height-variable system is used anywhere where it is not clear how the “final installation” will
be and/or the highest level of flexibility is desired. Duct widths of up to 600 mm allow the duct to
be used wherever high volumes of cables occur. This screed-flush duct is used in a shiny version
in production halls, but also in office and administrative buildings with duct covers with floor cov-
ering stuck on. Its very low height means that the duct is also suitable for very flat screed heights
of 30 mm or more.
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The minimum nominal thickness1 is regulated according to the hardness class (DIN EN 13813)
for perpendicular loads ≤ 2 kN/m².
Under some circumstances, chemical or thermal loads may occur, which require additional
measures to protect the installed system.
The electraplan.BK screed-flush duct systems and the BKSA underfloor sockets only receive
their load capacity for correct use through being joined with the adjacent screed.
For this reason, the following points are important and must be observed:
– After the duct system has been permanently installed on the raw concrete, then the system
may no longer be walked on or subjected to similar loads
– The duct system must form a composite system with the adjacent screed
With electraplan.BK, the following points must be particularly observed:
– The side profiles need to be supported with screed, in order to achieve a good static support
in the screed. The screed is to be carefully worked and compacted
– The opened duct system may neither be walked on nor subjected to similar loads. Measured
for the necessary protection must be taken in agreement with the construction management
1) For increased use and surface loads, appropriately increased minimum nominal thicknesses shall apply
(6)
(5)
(3) (4)
(2)
(1)
Floor structure
A decisive criterion in the correct selection is the floor structure. The screed height specifies the
amount of play for the underfloor installation. Different products and solutions are used, depend-
ing on the height. It is ever often the case that the screed height is even thinner for reasons of
cost. Hager can offer a range of finished solutions for this. However, should the screed height
be extremely low, then special, project-related special solutions can be provide assistance here.
Ab 50 mm Ab 75 mm Ab 100 mm Ab 105 mm
Floor structure 50 mm
The two hinged covers KDQ08x and KDE04x were developed
specially for the requirements, in which only a screed height of 50
mm or more is available.
Thanks to their horizontally arranged socket outlets in the
GBES2x device casing, the hinged covers are suitable anywhere
where the screed height is only very low. Special solutions can
also be used to install data technology in the two hinged covers.
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Art. number Art. designation Width Height Height Duct cross sec- Number of
[mm] min max tion cables (3 x 1.5
[mm] [mm] [cm²] 2 mm²) 3
AKU1500401 On-floor duct base 150 40 X 60 24
On-floor duct, screed-flush
BKF400105 416 105 150 540 223
with the film
On-floor duct, screed-flush
BKW200060 216 60 100 88 36
with the trough
On-floor duct, screed-flush
BKFD150065 170 65 110 121 50
with the film/sealing option
On-floor duct, screed-flush
BKWD200090 220 90 130 143 59
with the trough/sealing option
Screed-flush floor duct with
BKB25085 250 85 X 212 45
brush
BKG30060 Screed-flush floor duct, closed 300 60 X 154 16
Underfloor duct, 3-compart-
UK340483 340 48 X 163 65
ment, screed-covered
2) Values are rounded 3) Values are rounded / duct assignment of 50 %
IT data cables
P Further details on the duct area and cable volume can be found in the “Appendix”
Supply units
Forms
Supply units
Forms
IP degree of protection
The IP degree of protection of floor installation systems is tested and categorised according to
EN 50085-2-2 and the type of floor care according to EN 60529. Floor installation systems are
only intended for use in interior areas.
The supply unit is tested in its used and unused states to determine the degree of protection. All
the duct systems and supply units must fulfil at least the IP 20 degree of protection in the used
and unused states.
In addition to the categorisation of the IP degree of protection, with wet cleaning, it must be en-
sured that, in the used state, all the openings through which cables exit must be at least 10 mm
above the floor surface.
The floor covering cleaning type - dry, moist, wet - is the decisive factor in the selection of the
suitable supply unit.
Dry cleaning
Dry cleaned floors are primarily textile floor covers, which are cleaned by sucking up the dirt
(with small amounts of liquids or completely without). Should a cleaning solution be used, then
it must be dosed as low as possible, in order to prevent puddle formation or the floor covering
being soaked through.
Moist cleaning
Smooth floor coverings such as linoleum, PVC, laminate, parquet or polished stone floors fulfil
the requirements for moist care of the floor covering. The building cleaning trade defines this
type of floor covering as a manner of binding dust with moistened or prepared cleaning textiles.
Wet cleaning
Wet cleaning is primarily used with stone coverings, tiles, ceramic floors, linoleum and PVC.
This type of cleaning removes particularly tough and sticky contamination. In so doing, as much
cleaning liquid is applied in the first cleaning operation with cleaning textiles as is required to
soften contamination and release it. In a second operation, this liquid is wiped up again, togeth-
er with the contamination, using cleaning textiles.
IP 2 3
Code-Buchstaben
(International Protection)
Component Digits or letter Meaning for the protec- Meaning for the pro-
tion of the resource tection of people
Code letters IP - -
First code digit Against the ingress of sol- Against access to dan-
id foreign bodies gerous parts with
0 Not protected Not protected
1 ≥ 50 mm diameter Back of the hand
2 ≥ 12.5 mm diameter Finger
3 ≥ 2.5 mm diameter Tool
4 ≥ 1.0 mm diameter Wire
5 Dust-protected Wire
6 Dust-tight Wire
Mechanical/thermal loads
Mechanical and thermal loads (load) are forces impacting on the floor installation duct system
from outside. With improper installation and use, mechanical forces can cause deformations
and destruction. Thermal forces, cause by excessive sunlight and/or heated screeds, cause the
installed materials to expand. This can lead to crack formation.
Loads and their impacts on installation systems
Floor installation duct systems are exposed to the traffic loads typical for the building. They must
withstand the loads occurring at the place of use and, in so doing, maintain their function. The
loads can be triggered by different factors:
– Being walked over by people
– Stands of office furniture
– Loads from vehicles and means of transport
The load is applied directly to the floor or the entire ceiling construction. This means that the
load also has a direct influence on the installation floor installation systems.
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Standardisation
The EN 50085 series of standards specifies the general requirements for electrical installation
duct systems. In particular, Part 2-2 describes the requirements for floor installation systems
and took effect in July 2009.
The standard is divided up into two sections:
– Erector specifications
The electrical installation engineer is usually responsible for compliance with the require-
ments described in the erector specifications.
– Device testing specifications
The device test specifications specify the testing criteria of the products/devices. The manu-
facturer of the products/device is responsible for compliance with it.
Device testing specifications
– Define the function of the product/device
– Define the load capacity of the product/device
– Define the area of use of the product/device
– Are primarily responsible for the safety of the product/device (e.g. protection against
electric shocks)
Classification of floor installation systems
EN 50085-1, as a general section for electrical installation duct systems, and EN 50085-2-2, as
a system-specific section for floor installation systems, prescribe a classification of the products.
This standardises product properties across Europe. For the first time, a standard for installa-
tion systems has also been given an optional load test for vertical loads that impact over a large
area (heavy duty).
Testing
Load testing of electrical installation duct systems
Electrical installation duct systems for electrical installations must conform with the standard
(DIN) EN 50085-2-2.
The standard states that electrical installation duct systems must possess sufficient mechanical
stability.
Load capacity for screed-flush duct systems (BK) and their installation units
(DIN) EN 50085-2-2 defines load classes for two applications.
Tests are carried out according to:
– 6.102 with a stamp (Ø 13 mm) for standard applications (Image 18, left)
– 6.103 with a plate (Ø 130 mm) for high loads (Image 18, right)
6.103.1 2000 N
6.103.2 3000 N
High load (tested with a test plate Ø
6.103.3 5000 N
130 mm)
6.103.4 10000 N
6.103.5 15000 N
Erector specifications
The erector specifications according to DIN VDE describe a wide range of points, which the
electrician must observe and comply with during the construction and installation of the floor
installation systems.
The erector specifications are particularly important for:
– Safety (protection against electric shock)
– Maintenance of function - function maintenance
– Electromagnetic compatibility
– Fire protection
The following section explains some of the key points from the erector specifications:
Protection against electric shock
For the erection of a cable system with electrical installation duct systems, multiple standards
from the VDE 0100 series are important, in particular:
– DIN VDE 0100-410:2018-10, which describes the protection measures for protection against
electric shock, as well as
– DIN VDE 0100-520:2013-06, which describes the selection and erection of cable systems.
Electrical installation duct systems are a component part of the cable system (Section 520.3.1 in
DIN VDE 0100-520) and thus of the electrical installation. They are thus not covered by Section
411.3.1.2 of DIN VDE 0100-410.
In Section 410, DIN VDE 0100-410 refers to DIN EN 61140 (VDE 0140-1), which, as a basic
safety standard, describes the shared requirements for protection against electric shock for
electrical systems and resources. Accordingly, the basic rule of protection against electric shock
is that dangerous active parts may not be touchable and touchable, electrically conductive parts,
may not become dangerous active parts, neither under normal conditions, nor under conditions
of individual errors.
In addition, it describes that safety measures against electric shocks must consist of a suitable
combination of two independent protective measures - of a basic protection measure and an
error protection measure.
In a cable system, a basic protection measure would typically be basic insulation (e.g. wire insu-
lation) or a protective housing.
An error protection measure is frequently the automatic switch-off of the power supply (Section
411) or double insulation (Section 412).
Table A.52.1 of DIN VDE 0100-520 defines that insulated cables (wire cables) may only be used
in the electrical installation duct systems to be opened (including underfloor systems) if the duct
system offers at least the protection rating IP4x and can only be opened with a tool. Jacketed
cables can be used without restrictions.
In addition, Section 526.5 of DIN VDE 0100-520 defines that electrical connections must be
made in suitable jacketing (e.g. boxes or in resources, if planned).
Metallic duct systems must be included in the safety measures and the equipotential bonding.
This guarantees protection against electric shock according to DIN VDE 0100-410 and electro-
magnetic compatibility (EMC) according to EN 50310, EN 50173, EN 50174-2.
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Equipotential bonding
The certified floor installation system must offer the option of being included in the equipotential
bonding.
All the Hager underfloor cable duct systems are constructed in such a way that the connection
and inclusion in the equipotential bonding is possible without major work.
The earthing clamp BKZSAK00 is used to include the duct system in the equipotential bonding.
The earthing clamp is inserted in the existing grooves and screwed tight. The terminal area is
designed for a conductor cross-section of up to 4 mm².
Touchable, electrically conductive electrical installation duct systems are not included in the
protective equipotential bonding (see Section 411.3.1.2 of DIN VDE 0100-410) and thus are not
to be used as an error protection measure. However, they can, for example, for EMC reasons,
be included in the functional equipotential bonding or in the additional protective equipotential
bonding and in the lightning protection equipotential bonding.
Conversely, this means that the resources installed within the electrical installation duct system
must automatically fulfil the requirements for basic protection and error protection. This also
includes the cable systems according to DIN VDE 410 Section 412.2.4.
The floor installation system is an electrical installation duct system and does not fulfil the
requirements for double insulation (VDE 0100-410 Section 412). This means that the use of
conductors with basic protection (e.g. H07V-K) is not permitted. At least jacketed cables (e.g.
NYM-J) must be used, which end or are connected in suitable jackets (e.g. in boxes or in re-
sources). Strain relief must always be provided.
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Inter-unit working
On today’s construction sites, inter-unit working is a matter of course and the associated inten-
sive communication with the neighbouring units essential.
For this reason, we at Hager recommend, at the beginning of the construction phase and in
agreement with the construction management, co-ordination between electricians and the con-
terminous inter-unit working, in order to guarantee a flawless procedure for installing the floor
installation system and the quality of the entire construction section.
Inter-unit working - Screed work
Screed-flush cable duct systems and the connector boxes of the screed-covered duct system
are a binding draw-off gauge for the screed. The levelling height of the system components is
aligned to the structural specifications of the construction management (observe the cutting
check).
The screed layer must work, compact and draw off the screed carefully in the area of the con-
nector boxes and cable trunking. Screed can be destroyed through crack formation. Screed-
flush systems and system components may not be subjected to loads before the screed has
finally hardened, in order to avoid crack formation in the screed.
General information for screed layers
The duct system levelled to the target screed height and the levelled floor boxes may not be
subject to a load, walked on or opened before the target screed stability is reached. With cov-
ers with snap fastenings, the transport lock screws of the cover may only be removed when
the screed has hardened. Screed-flush ducts and floor boxes must be levelled to the intended
height before screed laying (construction side height line). The screed layer should check the
levelling height. Smooth and compress screed well on the screed-flush ducts and floor boxes.
Only this achieves the required load capacity. All the duct openings larger than the grain size
used must be sealed.
Inter-unit working - Floor covering work
The company responsible for the floor covering work is also responsible for the exact routing
and adaptation of the floor covering to the connector boxes and cable outlets.
The exact joint dimensions must be clarified in advance with the construction management.
The covers of the screed-flush connector boxes must also be covered with floor covering.
Any carpet used must be permanently laid and must be resistant to cutting.
Inter-unit working - Building cleaning
In particular during the initial cleaning of the floor surfaces, building installation units and instal-
lation spaces must be carefully cleaned of construction dust and other impurities, so that their
function does not lead to impairments later.
P During the use phase, building installation units must be checked for their intended use and
possible damage, in order to avoid later damage (Facility Management / Electricians).
P In particular, device installation units for wet cleaned floors are to be maintained regularly
and the seals checked for their function. For this, it is necessary to relubricate the seal regu-
larly (Facility Management / Electricians).
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Standard DIN 4109 specifies noise limits Ln,w that must not be exceeded in certain areas of
application.
Examples of segment-related noise limits:
– Office buildings: Residential dividing ceilings and ceilings between third-party office rooms
Ln,w ≤ 53 dB
– Recreation rooms and hotels (increased sound protection requirements):
Ln,w ≤ 46 dB
The following always applies: The lower the values, the better the impact noise insulation is. The
value can be reduced, for instance, by laying a floor covering (such as carpet). The transfer of
impact noise can also be reduced by laying the screed on an insulation layer (“floating screed”).
Müller-BBM GmbH measured the impact noise reduction in the ceiling test station in accordance
with the DIN EN ISO 10140 standard and evaluated the findings in accordance with the ISO
717-2 standard.
The results of the measurement of the impact noise reduction are summarised below for the
floor duct and the stainless steel cassette.
The installation of the floor duct has no significant influence on the impact noise re-
duction of the screed.
The installation of the stainless steel cassette has no significant influence on the im-
pact noise reduction of the screed.
► You can find detailed information and an evaluation of the impact noise at www.hager.de.
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Appendix
b
513
565
48
75
b
134
Max. cable
Usable
Nominal Drawing Levelling assignment
External cross-sec-
Ducts dimen- height range Ø 11 mm
width [mm] tion
sion [mm] [mm] Filling level
[cm2]
0.5
BKW150040 150 166 28 40 - 60 37,5 15
BKW150050 150 166 38 50 - 70 50,9 21
BKW150060 150 166 48 60 - 100 64,3 26
BKW150070 150 166 58 70 - 110 77,7 32
BKW200060 200 216 48 60 - 100 88,3 36
BKW200070 200 216 58 70 - 110 106,7 44
BKW200080 200 216 68 80 - 120 125,1 51
BKW200090 200 216 78 90 - 130 143,5 59
BKW250060 250 266 48 60 - 100 112,3 46
BKW250070 250 266 58 70 - 110 135,7 56
BKW250080 250 266 68 80 - 120 159,1 65
BKW250090 250 266 78 90 - 130 182,5 75
BKW300060 300 316 48 60 - 100 136,3 56
BKW300070 300 316 58 70 - 110 164,7 68
BKW300080 300 316 68 80 - 120 193,1 79
BKW300090 300 316 78 90 - 130 221,5 91
BKW350060 350 366 48 60 - 100 160,3 66
BKW350070 350 366 58 70 - 110 193,7 80
BKW350080 350 366 68 80 - 120 227,1 93
BKW350090 350 366 78 90 - 130 260,5 107
BKW400060 400 416 48 60 - 100 184,3 76
BKW400070 400 416 58 70 - 110 222,7 92
BKW400080 400 416 68 80 - 120 261,1 107
BKW400090 400 416 78 90 - 130 299,5 123
BKW500060 500 516 48 60 - 100 232,3 96
BKW500070 500 516 58 70 - 110 280,7 116
BKW500080 500 516 68 80 - 120 329,1 136
BKW500090 500 516 78 90 - 130 377,5 156
BKW600060 600 616 48 60 - 100 280,3 115
BKW600070 600 616 58 70 - 110 338,7 139
BKW600080 600 616 68 80 - 120 397,1 164
BKW600090 600 616 78 90 - 130 455,5 188
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b
63
115
48
63
b
111
85
Max. cable as-
Usable
Duct width Duct height signment Ø 11
Ducts Version cross-section
[mm] [mm] mm
[cm²]
Filling level 0.5
BKB15085 150 85 2-compartment 10000 28
BKB25085 250 85 2-compartment 21250 45
60
Max. cable
Usable
assign-
Nomi- cross-section
Duct height Usable ment
nal di- External [cm²]
without lev- cross-sec- Ø 11 mm
Ducts men- width Duct height Version
elling screw tion Filling
sion [mm] incl.
[mm] [cm²] level 0.5
[mm] levelling
Internal
screw [mm]
levelling
BKG20060 2-compart-
200 200 60,3 73 104.7 8
ment
BKG30060 3-compart-
300 300 60,3 73 154.2 16
ment
BKG40060 3-compart-
400 400 60,3 73 214.2 37
ment
BKG50060 4-compart-
500 500 60,3 73 263.7 50
ment
BKG30080 3-compart-
300 300 80,3 93 205.6 28
ment
BKG40080 3-compart-
400 400 80,3 93 285.6 60
ment
BKG50080 4-compart-
500 500 80,3 93 351.6 77
ment
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60
190
40
150
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