Assembly Guide

PART NUMBER: BXLAI. ISSUE 2 / MAY2010

ADJUSTABLE-BEAM PALLET RACKING

Standard Components and Accessories
READ THIS GUIDE THOROUGHLY BEFORE COMMENCING ASSEMBLY AND RETAIN FOR FUTURE REFERENCE

ESSENTIAL INFORMATION: KEY TO SYMBOLS USED IN THIS ASSEMBLY GUIDE

FAILURE TO FOLLOW INSTRUCTION MAY RENDER RACKING UNSAFE!

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Where dimension is LESS than figure shown

Where dimension is GREATER than figure shown

Tighten all bolts to their specified torque loading

Where dimension is EQUAL TO or GREATER THAN figure shown

Identifies fixing required

>

Dimension NOT TO EXCEED figure shown

The information contained in this booklet was accepted as correct at the date of publication. However, the manufacturer reserves the right to make any necessary changes, in line with product development and improvement. No liability can be accepted for any inaccuracies or omissions, although every reasonable care has been taken to make this publication as complete and accurate as possible. PRODUCT DESIGNED & MANUFACTURED IN THE UK TO QUALITY MANAGEMENT SYSTEMS CONFORMING TO THE INTERNATIONAL STANDARD BS EN ISO 9001:2000.

PLEASE READ FIRST: Safety & Operational Rules

Read this Guide thoroughly before commencing assembly and retain for future reference. Installation plans and design drawings should be strictly adhered to. If in doubt on any aspect of design, installation or usage, contact the racking supplier. Where racking is to be installed or directed to be installed by the client/user or an agent acting on their behalf, then installation work must be carried out in accordance with the Storage Equipment Manufacturers Association (SEMA) Guide to Method Statements for the Installation of Storage Equipment. It is RECOMMENDED that racking installation work is undertaken by experienced, trained personnel ONLY, and under the supervision of SEIRS Registered Installers (SEIRS is the Storage Equipment Installers Registration Scheme, operated by SEMA - see below). This document is available from: SEMA Mclaren House, 35 Dale End, Birmingham B4 7LN, UK Telephone: +44 (0) 121 200 2100 Fax: +44 (0) 121 200 1306 E-mail: [email protected] Web site: www.sema.org.uk

Safety & Load information signs MUST ALWAYS BE FITTED and clearly displayed - refer to page 11. Loading and performance information should be made available by the racking supplier. Racking MUST NOT BE DISMANTLED OR THE ADVISED CONFIGURATION CHANGED without prior consultation with the racking supplier - unauthorised removal or re-positioning of beams in particular can seriously compromise the stability and safety of the racking structure.
Clearly display all user and safety signs

Unless otherwise stated, load performance information provided assumes MAXIMUM STATIC UNIFORMLY DISTRIBUTED SAFE WORKING LOADS. Under no circumstances should quoted capacities be exceeded or varied.

kg

kg

3
kg

kg

kg

8
kg

kg

kg

kg

kg

kg

kg

During installation, check verticals and levels to ensure the racking is within the recommended parameters, shown right. The extent of undulation, slopes, steps, ridges, etc. in the concrete floor slab surface affect both racking and handling equipment. Advice on the effects of floor surface level variations on particular handling equipment should be obtained from the supplier. The supporting floor slab for pallet racking should be of suitable construction and thickness and level to within 1:1000. Note: general parameters only are shown refer to SEMA Guideline No.2 Guide to Erection Tolerances for Static Racking for other applications.

H/500

H/500

Installation Tolerances for Standard Adjustable Pallet Racking

use shims to level within tolerances

Component Identification
Installation of the following components (illustrated left) is described: J
A B C Component Frame Upright Frame Bracing Tie (horizontal) Frame Bracing Tie (diagonal) Bolted Frame Joining Unit Frame Foot Plates & Anchors Stepped Beam (in pairs) Box Beam (in pairs) Beam Locking Pin (2 per beam) Rack Run Spacer (fixed) Rack Run Spacer (adjustable) Upright Protectors & Anchors Chipboard Shelving Shelf Cladding Support, for Box Beams Cladding Location Bracket Shelf Cladding Support, for Stepped Beams Steel Shelf Panel Pallet Support Bar Page 3 4 4 5 5, 7 6 6 6 7 7 8 9 9 9 9

D E F G H I

A B

J K L M N

O P

Wire Beam Tie for Stepped Beams 9 9 9

C D

Q R

L O P Q F

Installation of the following additional accessory components (not illustrated) is also described:
Component Coil Cradle Pallet Foot Support Drum Chock Fork Spacer Safety Sign Page 10 10 10 10 11

N Q

Type B4 Type B3 Type B2

Type B1

Upright & Frame Identification and Orientation

1.1 Upright Duties - identification
MEDIUM DUTY Upright section HEAVY DUTY Upright section

1.1 Identify upright and frame duty from stamp. 1.2 Note frame type and orientation. 1.3 Note frame position relative to aisle.
84mm nominal 84mm nominal 65mm

1.1a Upright duty I.D. stamp

M H E S = = = = Medium duty Heavy duty Extra heavy duty Super heavy duty 55mm

EXTRA HEAVY DUTY Upright section

SUPER HEAVY DUTY Upright section

61mm

86mm nominal

61mm

1.2 Typical frame type configurations

300mm 300mm A* 600mm *Note: Dimension A on Normal Standard and Top Joining frames is variable but must not exceed 450mm. All dimensions are taken from bracing (tie) centres.

1.3 Frame positioning

600mm

600mm 150mm

600mm 150mm

Normal MASTER Frame

Normal STANDARD Frame

87mm nominal

3
300mm 300mm 300mm 600mm 600mm 600mm 600mm 150mm 300mm 300mm 600mm 600mm A*

First (lowest) diagonal bracing node faces into the aisle.

BASE Joining Frame

CENTRE Joining Frame

TOP Joining Frame

K.D. Frame Assembly

Note: * For cold store applications use 8.8 grade fixings for all frame types

2.2 Connecting Bracing Ties

2.2a Single Bracing Ties

2.1 Undertake assembly with components laid flat or supported on suitable trestle frames. When assembling a series of frames build a template frame first to use as guide for remaining frames. 2.2 Fit horizontal and diagonal ties to paired uprights. Work from base upwards. Fits nuts & bolts loosely. 2.3 Check that the frame is fully square (measure diagonally from corner to corner). Tighten all bolts to the specified torque loading.

Fixings per connection point for Upright Duty: (standard finish*) M & H (4.6 grade) 1 x 3/8" x 60mm 1 x self-lock nut E & S (8.8 grade) 1 x 3/8" x 60mm 1 x self-lock nut

For Upright Duty: (standard finish*) M & H (4.6 grade) 2 x 3/8" x 60mm 2 x spacer 2 x self-lock nut E & S (8.8 grade) 2 x 3/8" x 60mm 2 x spacer 2 x self-lock nut

20Nm

20Nm

2.2 Frame Assembly

2.3 Frame Assembly

Diagonal Tie

Horizontal ties

Frame Joining
l Undertake assembly with components laid flat. l When joining on to master frames, discard the top horizontal tie. l Locate Joining Units within uprights of lower frame, bolt in place. l Locate upper frame in place. l Assemble diagonal ties.
Top Joining Frame Top Joining Frame

(8.8 grade) 6 x 3/8" x 60mm 6 x self-lock nuts

20Nm

Horizontal Tie is discarded

Normal Frame - Master Height

Base Joining Frame

Foot Plate Location

Note: * For cold store applications use 8.8 grade fixings for all frame types

B1 Foot Plate
For Upright Duty: (standard finish*) M (4.6 grade) 1 x 3/8" x 60mm 1 x self-lock nut

B2/R2 Foot Plate

For Upright Duty: (standard finish*) M & H (4.6 grade) 1 x 3/8" x 60mm 1 x self-lock nut

20Nm

B2 R2

E & S (8.8 grade) 1 x 3/8" x 60mm 1 x self-lock nut

20Nm

B3 Foot Plate
For Upright Duty: (standard finish*) M & H (4.6 grade) 2 x 3/8" x 60mm 2 x self-lock nut E & S (8.8 grade) 2 x 3/8" x 60mm 2 x self-lock nut

B4 Foot Plate - height adjustable

For Upright Duty: M, H, E & S (8.8 grade) 4 x 3/8" x 25mm 4 x self-lock nuts 4 x stepped locating washers

20Nm 20Nm

Bay Assembly
NOTE: Where racking is to be installed or directed to be installed by the client/user or an agent acting on their behalf, then bay assembly must be carried out in accordance with the Storage Equipment Manufacturers Association (SEMA) Guide to Method Statements for the Installation of Storage Equipment. To obtain this guide, refer to page 1 for contact details. Assemble starter bays first, then build out with extension bays.

Starter bay
Raise frames in compliance with SEMA method statements

Locate beams in compliance with SEMA method statements and instruction below

Frame positioning

3
Extension bay

First (lowest) diagonal bracing node faces into the aisle.

Beam Location - requires 2 safety locking pins per beam 1

Locate beam connectors to both uprights. Engage beam locking tabs into slots in the upright.

Press down and tap into place, ensuring all locking tabs are seated. Note: to prevent damage, use only a soft face mallet to tap beams into place.

Insert locking pins at BOTH ends of the beam. Pin goes in upper slot. Note: if pin does not easily pass through the slot, the beam locking tabs are not engaged correctly. Remove pin and tap until tabs are fully seated. Replace pin.

Foot Plate Anchoring

l All foot plates must be fixed to the floor using the required number of anchor bolts. l Before fixing, check verticals and levels to ensure racking is within recommended tolerances for the installation. l Shim as necessary then floor fix. l Tighten all bolts to the specified torque loading.
M10 Expansion floor fixing bolt

17mm 12mm

85mm Min

55mm Min

B1

B2

Anchor all uprights! 22Nm x1 x1

B3

B4
9mm max. foot plate & shim depth for M10 fixing

x2

x2

Rack Run Spacers

l Fitted to each pair of backing frames. l Fit in pairs for rack spacing of 800mm and over.
Locate spacers within 225mm of bracing node points

7.1 Run Spacer (fixed)

nominal rack spacing

7.2 Run Spacer (adjustable)

nominal rack spacing

adjustable +/-20mm

>300mm

x1 <800mm

x2 ~ >800mm

x1 <800mm

x2 ~ >800mm

>2.5m Between spacers >2.5m First spacer (8.8 grade) 2 x 3/8" x 45mm 2 x self-lock nuts (8.8 grade) 2 x 3/8" x 45mm 2 x self-lock nuts (8.8 grade) 2 x M8*16mm 2 x self-lock nuts 2 x washers

20Nm Rack Spacing

20Nm

Upright Protectors
8.1 8.2 8.3 l U-Type Protector. L-Type Protector. Column Protectors. Types U & L must be anchored to the floor at all fixing positions.
17mm M8/12 Expansion floor fixing bolt. Part Number FAS1515

15mm 50Nm

120mm Min

80mm Min

8.1 U-Type Upright Protector - Square

8.2 L-Type Upright Protector

8.3 Column Protectors

4 x 3/8" x 45mm (8.8) 4 x self-lock nut 4 x stepped locating washers 20Nm

400/555mm

x4

x4

400mm

425/650/950mm

>525mm

Recommended >450mm

550mm high recommended >600mm 400mm high recommended >450mm

First Beam Clearance 425mm High Protector

First Beam Clearance (on 3T connector)

First Beam Clearance (on 3T connector)

>750mm

>1050mm

B1/B2 47mm min. B3 40mm min.

40mm B1/B2 47mm min. B3 40mm min.

Recommended Clearance (plan view)

Recommended Clearance (plan view)

First Beam Clearance 650mm High Protector

First Beam Clearance 950mm High Protector

Shelving
STEPPED BEAMS 9.1 Chipboard with wire beam ties. 9.2 Chipboard with shelf cladding supports. 9.3 Steel profile shelf panels.

9.1 Chipboard: Wire Beam Tie/s

9.2 Shelf Cladding Support & Tie/s

Locate beam tie/s then place chipboard.

Locate beam tie/s, then cladding supports then place chipboard. L

x1 ~ L = >1800mm, > 2700 L

9.3 Profile Shelf Panels & Tie/s

Locate beam tie/s then place panels.

x2 L = > 2700 X L Y Y X

Y = L (number of supports - 0.5) X = Y x 25% e.g. Y = 2700 (3 - 0.5) = 1080mm X = 1080 x 25% = 270mm

BOX BEAMS 9.4 Chipboard with cladding location brackets. 9.5 Chipboard with shelf cladding supports. 9.6 Steel shelf panels.

9.4 Chipboard: Cladding Bracket 9.5 Shelf Cladding Support

Cladding bracket x4

Locate cladding supports, then cladding brackets then place chipboard L

9.6 Steel Shelf Panels

Y = L (number of supports - 0.5) X = Y x 25%

10

10

Support Accessories
10.1 10.2 10.3 10.4 10.5 Pallet Support Bar. Coil Cradle. Pallet Foot Support. Drum Chock. Fork Spacer.

10.1 Pallet Support Bar

Steel pallets which have feet must be supported on pallet foot supports. Non-palletised loads such as drums, coils, barrels etc must be supported by the correct accessory.

Usually fitted 3 bars per pallet, but this may be varied to suit the requirements of the pallet type. Secured using 2-off self tapping screws (Type TC25) per bar.

10.2 Coil Cradle

10.3 Pallet Foot Support

Fitted in pairs. Secured using 2-off self tapping screws (Type TC25) per pallet foot support.

10.4 Drum Chock

10.5 Fork spacer

Fitted in pairs. Secured using 2-off self tapping screws (Type TC25) per fork spacer.

One chock required per drum or barrel, placed on the front beam.

11

11

Racking (maintenance & safety) Signs

l Means of clearly displaying essential safety information for pallet racking. l Signs are 297mm high x 420mm wide. Material is rigid styrene sheet or laminated paper. l Signs are supported on 2 x horizontal bracing ties and fitted using a sign fixing kit. l Position signs centrally.
LINK 51

SIGN FIXING KIT 4 x plastic plugs to fit Horizontal Bracing Ties. 4 x 3/8" x 60mm long frame bracing bolts and Nyloc nuts. 4 x spacers. Four TEK fixings (Type TC25) for fixing sign to horizontal ties.

420mm

1725mm 297mm

Example Sign Template

LINK 51

LINK 51

LINK 51

LINK 51

LINK 51

LINK 51

LINK 51

Recommended positioning of Horizontal Ties for sign support

Racking Safety Inspection

In accordance with current guidelines and workplace health & safety regulations, it is essential that pallet racking is inspected for actual or potential safety hazards. These may be caused by impact damage to the racking or result from missing components. Inspections should be conducted on a regular, scheduled basis by suitably competent personnel. If in doubt when and now to conduct racking safety inspections, contact the racking supplier.

12

1425mm