Installation Guide - Load Support _v2021.3a

Replacing Sections
Replacing Damaged Cells & Sections
Should the need arise a localized Neoloy section or group of cells can be easily replaced.

1.    Remove cover layers, overfill and infill materials so that the localized to-be-cut area is fully exposed and can be
      removed and replaced.

2.    Cut out the localized cells in the perimeter using a utility knife (preferably in a rectangular shape), leaving a border
      of undamaged cells on each of the four sides.

3.    Place a new Neoloy section over the ‘hole’ of cut area – it must
      be larger to enable strip overlapping at the perimeter. Make sure
      the section is in the same orientation and open it fully, so that
      the cells expand to their optimal size (see Table A-1 below).

4.    Cut the new replacement section exactly to the required size
      including overlapping, using the utility knife.

5.    Position the replacement section into place and anchor the walls
      and ends if necessary, so that the cells are opened fully (see
      Table A-1 below). Overlap the strips with the perimeter of the cut
      area.                                                                             FIGURE A-22. REPLACING DAMAGED SECTIONS


      NOTE: All cells in the replacement section must be fully open for the system to function properly.

6.    Fasten the new replacement with the existing Neoloy mattress. Make sure to use sufficient staples:
      • < PRS 075 mm – 3 staples (minimum)
      • < PRS 100 mm – 4 staples
      • < PRS 120 mm – 4 staples
      • < PRS 150 mm – 5 staples
      • < PRS 200 mm – 6 staples

      Note that the replacement will be fastened to the adjoining undamaged section on 4 sides:
      end to end of adjacent ‘strips’ as well as face to face along the cell walls of the adjacent sections.

                                                 TABLE A-3. CELL OTPIMAL OPENING SIZE

      Distance
                                    330 mm              356 mm              445 mm               660 mm               712 mm
      between         ±2.5%
                                     (13 in)             (14 in)            (17.5 in)             (26 in)              (28 in)
     Weld Seams
 Cell Dimension                   245 x 210 mm        260 x 224 mm         340 x 290 mm         490 x 421 mm         520 x 448 mm
                        ±3%
 (Optimal opening)                (9.65 x 8.27 in)   (10.24 x 8.82 in)   (13.39 x 11.42 in)   (19.29 x 16.53 in)   (20.40 x 17.64 in)


7.    Fill the new replacement section using the same of one grade higher quality infill material than the removed infill
      material.
8.    Compact to required levels of density.

      NOTE: Full compaction of the replacement section is required for the system to function properly.




PRS-EN-TD-LS-3000                                                16/21                                                        Ver. 2021.3