Introduction

Flexible support system also known as strut channel system is a unique engineered system of components. It can be used for various applications, for example, in storage racks, construction of warehouses etc. It is not just limited to being a support system. The system consists of vertical and horizontal support members. The individual members are manufactured accurately and carefully by cold rolling mild steel. The vertical support members are complemented by cantilever arms also made of the same channel and welded with a back plate- and a variety of clamps and brackets.The standard length of channels are 6m. These members are generally hot-dip galvanized. These members can be assembled in a number of combinations. The assemblies can be designed and erected at site. The uniqueness of this system is that it is - adjustable - demountable - reusable. It does not require on site welding, thereby preserves the protective coating of the system . In environments , where there is a fire hazard, this property is a boon.

Components of Flexible Support Systems

The components are of four types: Channels Spring nuts Cantilever arms Brackets and Clamps

Channels
Type Single channel Diagram Description Used as main support channel. It is cold roll formed from 2.5mm thick steel. Maximum length six meters. Made from two single channels welded back to back. Used as main support channel for heavy loads.

Double Channel

Spring nut assembly

Type Spring nut Diagram Description Consists of a channel nut with spring and a bolt. Spring nut fits into the channel making it easy to assemble brackets and clamps. The spring holds the channel nut firmly in Place. The system is adjustable, reusable and user friendly.

Cantilever arm
Type Cantilever arm Diagram Description Channel welded with a back plate. Fixed horizontally on main support channels. Available in different sizes to accommodate the size of the equipment being supported.

Brackets and Clamps

Type Base plate for single channel Diagram Description Used to fix main support single channel to the floor or ceiling Used to fix main support double channel to the floor or ceiling

Base plate for double channel

Channel Clamps

Used to connect single channel with horizontal main support channel or to anchor main support channel against the wall. Used to connect double channel with horizontal main support channel or to anchor main support channel against the wall. Used as a connector between vertical and horizontal main support channel.

Clamp for double channel

Right angle bracket

Type 90 Angle fitting

Diagram

Description Used for connecting horizontal and vertical main support channels, where heavy loads are to be supported. Used to fix horizontal ladder type trays with cantilever arms.

Tray fixing clamp

Slotted Channels

Used to support fitting from the top.

Concrete Inserts

Used to fix main support channels into the walls

Type Beam clamp light duty

Diagram

Description Used to suspend single channel from the beam.

Beam clamp heavy duty

Used to suspend double channel from the beam.

Flat plate straight fitting

Used to join two single channel in series

Tee Clamp

Used to connect two single channels perpendicular to each other

Basic assembly of components

Spring nut assembly
The spring nut is assembled in four easy steps:

1. Insert the spring nut anywhere along the continuous slot in the channel. Rounded nut ends make insertion easy.

2. Turn the nut 90 clockwise. The serrated grooves in the nut are now positioned along the inturned edges of the channel. Brackets (or clamps) can be placed anywhere along the channel opening.

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

4. Tighten the bolt with a wrench. This locks the serrated teeth of the spring nut with the inturned edges of the channel.

Assembling the cantilever arm with main support channel

1. Insert a spring nut in the main support channel and position it by turning 90 clockwise. 2. Hold the cantilever arm perpendicular to the main support channel with the back plate against the open slot of the channel. Take care that the slot in the cantilever arm align with the spring nut. 3. Insert the bolt into the nut through the cantilever arm. 4. Tighten with a wrench to lock the bolt in place. Figure 1 Main support channel

cantilever arm

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

Connecting vertical and horizontal main support channels

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

2. Insert a spring nut in the vertical main support channel and position it. 3. Insert another spring nut in the horizontal main support channel and position it. 4. Hold the channels as shown in the figure 2. 5. Position a right angle bracket as a connector between the channels. 6. Insert the bolts thr ough the bracket into the spring nuts. 7. Tighten with a wrench to lock the nuts in position. Figure 2 Single channel

Right angle bracket

main support channel

Connecting the 90 angle fitting (heavy duty) with main support channels

The 90 angle brackets are used to connect horizontal and vertical main support channels where heavy loads have to be supported. Insert two spring nuts in the horizontal main support channel. Insert two spring nuts in the vertical channel. Hold the 90 angle fitting at the junction where the horizontal and vertical channels meet. Take care that the spring nuts align with the slots in the 90 angle fitting.

Insert the bolts in the spring nuts and tighten with a wrench to lock them in position. Figure 3 Main support channel single channel

90 bracket

Assembling flat plate straight fitting

These are used to connect two single channels in series. Insert two spring nuts near the end of the first single channel. Hold the flat plate straight fitting with the first two slots aligned with the spring nuts. Insert the two bolts through the fitting and tighten with a wrench. Insert two spring nuts at the beginning of the second single channel. Hold the second channel in series after the first channel. Take care that its spring nuts align with last two slots in the flat plate straight fitting. Insert the two bolts through the fitting and tighten with a wrench. Figure 4

Single channels

flat plate straight fitting

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Assembling Tee clamps

These clamps are used to connect single channels perpendicular to each other. 1. Insert three spring nuts in the horizontal channel and position them. 2. Insert one spring nut in the vertical channel and position it. 3. Hold the tee clamp at the meeting point of the two channels, taking care that the spring nuts are aligned with the slots in the clamps. 4. Insert the bolt through the clamp into the center nut of the horizontal channel and tighten with a wrench to lock the nut into position. 5. Insert the bolt into the nut directly below the central nut, into the vertical channel and tighten with a wrench. 6. Insert the bolts into the nuts on both sides of the central nut into the horizontal channel and tighten with a wrench. Figure 5

Horizontal channel

tee clamp vertical channel

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Trench wall
In places where cables run against the wall, the cable trays have to be anchored against the wall. For that purpose , we need to anchor the main support channel to the wall. It can be single channel or a double channel, depending upon the weight to be supported. The CC1 clamps are used, mainly, to anchor the main support channel against the wall. The clamps are available in different sizes for single and double channels. Anchoring the main support channel against the wall 1. Select the channel of appropriate length to serve as the main support channel. 2. Insert two spring nuts into the main support channel, one near the top and one near the bottom , and position them. 3. Hold the channel against the wall with the open end of the channel facing you. 4. At the top hold the channel clamp over the channel , aligned with the spring nut. Make a mark on the wall through the slots in the clamp, on both sides. 5. Repeat the procedure with another clamp held at the bottom of the channel. 6. Remove the channel and clamp and drill holes in the wall at the places marked. 7. Hold the channel against the wall with the open end facing outward. 8. Hold the clamp over the channel at the top with the spring nut aligned with the slot in the clamp. 9. Insert the rawl bolts through the clamp into the wall at the sides of the channel.

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10. Insert the bolt through the clamp into the spring nut and tighten it with a wrench. 11. Repeat the steps 7-9 for fixing the clamp at the bottom of the channel. 12. The cantilever arms can now be fixed to the channel.

Note: To connect double channels follow the same procedure described above. Substitute the single channel clamp with a double channel clamp. The prescribed distance between two channels is 1.5 meters. Floorthe cantilever arm as per the tray width. Select Support

Figure 6

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Floor Support
In cases where the channel have to be supported from the floor, we use base plates. Base plates are of two types: Base plate for single channel BP1 Base plate for double channel - BP2

The maximum channel length that can be supported by a base plate is 1 m. Fixing base plate for single channel 1. Select the single channel of appropriate length. 2. Choose the base plate for single channel. 3. Fix the base plate to floor using cement. Take care that the cement does not close the slots in the base plate. 4. For further support nail the base plate to the floor through the slot in the flat portion of the base plate. 5. Insert a spring nut into the single channel. 6. Place the single channel vertically on the base plate with the spring nut aligned with either of the slots. 7. Insert the bolt through the base plate into the spring nut. Tighten it with a wrench to lock the nut in position. 8. The cantilever arm can now be fixed on to this single channel.

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Fixing base plate for double channel Select the double channel of required length. Fix the base plate firmly with the floor using cement. Take care that the cement does not enter the slots in the flat portion of the base plate. Nail the base plate firmly to the floor using the slots on either side of the plate. Insert one spring nut each into the continuous slots on either sides of the double channel. Hold the double channel vertically on the base plate. Take care that the spring nuts are aligned against the slots on the sides of the raised portion of the base plate. Insert the bolt through the base plate into the spring nut. Tighten with a wrench to lock the nut into position. Insert the bolt on the other side also. The cantilever arm can now be fixed on to this main support channel. Figure 7 Single channel double channel

base plate for single channel

base plate for double channel

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Ceiling Support
Case 1: When I beam is present
To suspend a single channel from the I beam: 1. Select two light duty beam clamps. 2. Fix the beam clamps on both sides of the I beam. 3. Hold the beam clamp on the beam and tighten the set screws with a wrench. 4. Insert the clamping nuts and tighten them with a wrench. 5. Insert the horizontal single channel through the U bolts of the beam clamps. 6. Fix the 90 angle bracket to the horizontal channel. 7. Attach a vertical channel to the 90 angle bracket, perpendicular to the horizontal channel. 8. The cantilever arms can now be attached to the vertical channel.

Figure 8 I beam

beam clamp for single channel

heavy duty beam clamp

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Case 2: When the I beam is absent

Fix the 90 angle bracket to the ceiling by using a nut and bolt. Attach a vertical channel to the 90 angle bracket, perpendicular to the horizontal channel. The cantilever arms can now be attached to the vertical channel.

Note: The 90 angle bracket can also be welded to the ceiling or cemented to the ceiling depending on the weight to be supported.

Note: To suspend a double channel from the I beam, use the heavy duty beam clamp and follow the instructions given in the case of the single channel.

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Support at both ends

In situations where the verticals channels from the floor have to be of lengths greater that 1 m , the support has to be given from both ends. 1. Select the length of the channel suitable for the purpose. 2. Fix a base plate to the floor by following the procedure given on pg 000. 3. Fix another base plate to the ceiling, directly above the base plate on the floor. 4. Insert two spring nuts into either ends of the channel. 5. Insert the channel vertically between the two base plates. 6. Insert the bolts into the spring nuts and tighten them with a wrench. 7. The cantilever arms can now be attached to the vertical channel.

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Vertical risers
When the cables have to be supported vertically against a wall, we make use of vertical risers. Vertical risers are single channels anchored on to a wall at a fixed distance from each other. The cable tray is then fixed on these channels parallel to the wall. Fixing vertical risers Select the cable tray of required length. Divide the length of the cable tray( in meters) by 1.5 to arrive at the number of single channels needed. Anchor the single channels horizontally on the wall by using clamps. (see pg ) The distance between the channels must be 1.5 metres. The cable tray can now be fixed on to these single channels.

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