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This manual describes the components and design of the European HI280 Shelving System. The product is a construction system used primarily for building adjustable steel shelving. It is manufactured by the Aker Group within Scandinavia for distribution worldwide. The components have been designed and tested in accordance with the recommendations of “The Federation Europeenne de la Manutention� (FEM). The information contained within this manual relates solely to the HI280 product, it should not be used as the basis for designing any other product, either of the companies manufacture, or from another source. This manual is the property of the Aker Material Handling Group of Companies. It must not be copied or reproduced without written consent and must be returned upon request. The information contained within it must be regarded as confidential and must not be disclosed to any third party. Whilst the utmost care is taken to ensure the accuracy of the data and design details shown within, the company can in no circumstances be held liable for any injuries, expenses or loss incurred which could in any degree be attributed to the adoption of such data and design details.

Issue Status

September 2006

The following convention has been adopted to assist tracking changes since the previous release of the design manual (June 2005). Revised text within an existing page: Complete new page: Revised/new illustration:

Amendments are highlighted. New page appears in the top right hand corner of the page. Revised/new illustration appears beneath the illustration.

The following pages are either new, or have been revised:

Contents Section A Section C Section H Section K

Pages: 3. Pages: A.3. Pages: C.3, and 4. Pages: H.2, 4, 12 and 13. Pages: K.2, 4, 28, 29, 31, 33 and 38.

Issue: September 2006


MAIN CONTENTS Section A – Product Introduction.

Page

Basic system......................................................................................................................... A.1 Parameters of the system..................................................................................................... A.2 Rack dimensions .................................................................................................................. A.3 Shelving components, applications, illustrations .................................................................. A.4 Section B – Frame Components

Page

Introduction ........................................................................................................................... B.1 Frame codes......................................................................................................................... B.2 Upright types S, K and EK .................................................................................................... B.5 Standard baseplate and levelling plate................................................................................. B.7 Heavy duty levelling plate ..................................................................................................... B.8 High rise baseplates and levelling plates.............................................................................. B.9 Upright splice ...................................................................................................................... B.11 Frame batten ...................................................................................................................... B.12 Frame brace ....................................................................................................................... B.14 Solid frame cladding ........................................................................................................... B.15 Cladding trim....................................................................................................................... B.17 Mesh frame cladding .......................................................................................................... B.18 Mesh frame cladding – fixing bracket ................................................................................. B.20 End frame cladding – decorative chipboard ....................................................................... B.21 Assembly tool types K and EK............................................................................................ B.22 Ellipse tool types K and EK................................................................................................. B.23 Floor fixings – Hammer screw ............................................................................................ B.24 Floor fixings – Expander bolt .............................................................................................. B.25 Section C – Short Span Bay Components

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Introduction ........................................................................................................................... C.1 Shelf beam............................................................................................................................ C.2 Shelf...................................................................................................................................... C.3 Shelf reinforcement bar ........................................................................................................ C.5 Shelf reinforcement support.................................................................................................. C.6 Shelf divider – part height ..................................................................................................... C.7 Shelf divider – full height....................................................................................................... C.8 Bin front ................................................................................................................................ C.9 Base plinth .......................................................................................................................... C.10 Back cladding (introduction) ...............................................................................................C.11 Full width solid back cladding .............................................................................................C.12 Half width solid back cladding ............................................................................................ C.14 EK solid back cladding .......................................................................................................C.15 Mesh back cladding ............................................................................................................C.16 Back cladding clip ............................................................................................................... C.17 Cladding trim....................................................................................................................... C.18 Slotted back panel .............................................................................................................. C.19 Slotted side panel and clip..................................................................................................C.20 Back brace EK .................................................................................................................... C.21

Issue: September 2006

Section - Contents

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Section D – Medium Span Bay Components

Page

Introduction ........................................................................................................................... D.1 Medium span beam ..............................................................................................................D.2 Steel in-fill shelves ................................................................................................................ D.3 Cross beam .......................................................................................................................... D.5 Chipboard shelf..................................................................................................................... D.6 Bench top and lock ............................................................................................................... D.7 Tool panel ……..................................................................................................................... D.8 U Support.............................................................................................................................. D.9 Section E – Accessories

Page

Introduction ........................................................................................................................... E.1 Divider bar ............................................................................................................................ E.2 Bay divider ............................................................................................................................ E.3 Tube rail................................................................................................................................ E.4 Tube rail support................................................................................................................... E.5 S-Hook and S-Hook 90......................................................................................................... E.6 Sign holder, insert and cover ................................................................................................ E.7 Label holder and insert ......................................................................................................... E.8 Section F – Drawer and Tray Sets

Page

Introduction ........................................................................................................................... F.1 Pull out tray........................................................................................................................... F.2 Gasket tray ........................................................................................................................... F.3 Gasket tray pin...................................................................................................................... F.4 Pull out drawer...................................................................................................................... F.5 Pull out drawer – front to back partition ................................................................................ F.6 Pull out drawer – partition holder .......................................................................................... F.7 Expansion slide (100% pull out) ........................................................................................... F.8 Expansion slide – holder....................................................................................................... F.9 Shelf drawer........................................................................................................................ F.10 Drawer stop ........................................................................................................................ F.11 Drawer side guide and shelf lock........................................................................................ F.12 Shelf lock ............................................................................................................................ F.13 Section G – Door Sets

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Introduction ...........................................................................................................................G.1 Door left and door right .........................................................................................................G.2 Top and bottom pieces .........................................................................................................G.3 Handel and lock ....................................................................................................................G.4

Issue: September 2006

Section - Contents

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Section H – Low Rise Short Span Applications + Design

Page

Introduction ........................................................................................................................... H.1 Design process ..................................................................................................................... H.2 Design tables ........................................................................................................................ H.3 Baseplate and floor fixing requirement ............................................................................... H.11 Design example one ...........................................................................................................H.12 Design example two ...........................................................................................................H.13 Section J – Low Rise Medium Span Applications + Design

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Introduction ............................................................................................................................J.1 Design process ......................................................................................................................J.2 Design tables .........................................................................................................................J.3 Baseplate and floor fixing requirement ................................................................................J.23 Design example one ............................................................................................................J.24 Design example two ............................................................................................................J.25 Section K – High Rise Short Span Applications + Design

Page

Introduction ........................................................................................................................... K.1 Section K1 – Design process (racks 3100 to 5500mm)........................................................ K.2 Section K1 – Design tables................................................................................................... K.3 Section K1 – Back bracing / cladding ................................................................................. K.23 Section K1 – Baseplate and floor fixing requirement.......................................................... K.26 Section K1 – Top tie requirement ....................................................................................... K.27 Design example one ........................................................................................................... K.28 Design example two ........................................................................................................... K.29 Section K2 – Design process (racks 3100 to 12,000mm)................................................... K.31 Section K2 – Design tables................................................................................................. K.32 Section K2 – Back bracing / cladding ................................................................................. K.35 Section K2 – Baseplate and floor fixing requirement.......................................................... K.36 Section K2 – Top tie requirement ....................................................................................... K.37 Design example three......................................................................................................... K.38

Appendices

Page

Appendix A – Frame Assembly Schedule .....................................................................App A.1 Appendix B – Full Width Back Cladding Schedule ........................................................App B.1 Appendix C – Plastic Trays and Bins.............................................................................App C.1 Appendix D – Load Notices ...........................................................................................App D.1 Appendix E – EU Manual Handling Directive ................................................................App E.1 Appendix F – HI280 on Mobile Bases ........................................................................... App F.1

Issue: September 2006

Section - Contents

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SECTION A – PRODUCT INTRODUCTION BASIC SYSTEM The Dexion HI280 shelving system is a heavy duty, versatile product available in a wide choice of sizes to enable individual solutions to be tailored to client requirements. It is quick and easy to assemble with the main components simply hooking and locking together to provide a strong rigid structure.

With a full range of accessories, choice of upright styles, and flexibility to increase shelf capacities, the system is ideal for providing storage solutions ranging from simple low rise shelving accessed by pedestrian operatives through to high rise installations requiring access via raised walkways or mechanical order picking equipment. It is possible to enclose individual storage compartments with side and/or back cladding, and to enclose the front with lockable door sets. Small items can be accommodated in a range of bins, drawers and tray sets. It is principally a ‘bolt-free’ system with frame components either being swaged or riveted together, and shelf beam components hooking and locking together. However when the system is extended to provide either taller or heavier loaded structures the addition of such items as bracing or special baseplates will require the use of some nuts and bolts. Notation Where ever possible within this manual we have tried to keep to the following notation when describing the shelving components: ‘L’ Length, such as bay length, beam and shelf lengths etc. ‘W’ Width, such as frame width, shelf width etc. ‘H’ Height, such as frame height etc. ‘T’ Thickness, such as shelf thickness, material thickness etc. Issue: September 2006

Section A – Product Introduction

Page A.1


PARAMETERS OF THE SYSTEM

The Dexion HI280 product has been designed to operate within the following standard parameters. Consult product support if considering applications outside of this range. Hand Loaded

HI280 is a hand loaded shelving system, which is NOT suitable for loading by fork lift truck. (It is not a pallet racking system).

Loads

Loads should be stable and self supporting, with a maximum unit weight within the safe working recommendations of the EU manual handling directive.

Rack Height

Low rise, standard heights of, 1000, 1600, 2100, 2300, 2500, and 3000mm. High rise, heights 3100 to 12,000mm in 100mm increments.

Shelf Pitches

Short span bays, shelf pitches up to 800mm, in 25mm increments. Medium span bays, shelf pitches up to 1500mm, in 25mm increments.

Bay Lengths

Short span bay lengths of 900, 1000, and 1290mm. Medium span bay lengths of 1500, 1750, 2000, 2250 and 2500mm.

Frame Widths

Short span frame widths of 300, 400, 450, 500, 600, and 800mm. Medium span frame widths of 500, 600, 800, and 1000mm.

Warehouse Floor The floor which is the responsibility of the client should generally be of a solid CONCRETE construction designed to accept the point loads imposed by the shelving legs. Installations on other types of floor, such as timber, bitumen and tarmac, should be specifically designed to suit the strength of that floor. Dry Conditions

Components and load data are based on dry internal warehouse applications.

Temperature Range

+3°c to +35°c. Although the system principally has a pre-galvanised finish there are some painted components, and the medium span can incorporate chipboard shelving. Therefore applications in Chill and Cold stores with temperatures below +3°C, where moisture is likely to be present, need to have their material finish checked for suitability. Chipboard decking must not be allowed to become damp.

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Section A – Product Introduction

Page A.2


RACK DIMENSIONS

Frame Width ‘W’

Frame widths are expressed by their nominal dimension, i.e. either 300, 400, 450, 500, 600, 800 or 1000mm.

Rack Width ‘W+’

The actual rack dimensions are slightly greater than the frame dimensions: Single entry racks = nominal frame dimension + 7mm. Double entry racks = nominal combined frame dimension + 17mm. For racks with back bracing a further 3mm must be added for single racks and the same for double racks.

Bay Length ‘L’

The bay length is the actual ‘centre to centre’ dimension between the uprights.

Overall Rack Length The overall length of rack equals the total of the bay centres + 50mm. Shelf Height Adjustment

Adjustment is on a 25mm increment, within the following limits. Short span bays, shelf pitches up to 800mm. Medium span bays, shelf pitches up to 1500mm.

Shelf Heights

To save confusion over baseplate thickness and differing amounts of levelling due to uneven floors, all shelf heights are expressed from the top of the baseplate. This means shelves will have heights ending with 00, 25, 50, or 75mm

Tolerances

The above dimensions are the theoretical design dimensions and will be subject to normal production and assembly tolerances.

All dimensions within this manual are in millimetres (mm), unless stated otherwise. Issue: September 2006

Section A – Product Introduction

Page A.3


SHELVING COMPONENTS An HI280 shelving installation will be built using a combination of individual components carefully selected to provide the style of system required by each client. The three main groups of components that will be required are: frame components i.e. uprights, baseplates, frame cladding, bay components i.e. shelves, beams, back cladding, accessory components i.e. accessories, drawers, doors etc. With the HI280 shelving system a different set of bay components are required when building short span racks as opposed to building medium span racks. Therefore to aid selection and to make identification easier the components described within this manual have been split into the following sections: Section B – Frame Components Section C – Short Span Bay Components Section D – Medium Span Bay Components Section E – Accessories Section F – Drawer and Tray Sets Section G – Door Sets

SHELVING APPLICATIONS + DESIGN The following applications are covered within this manual: Section H – Low Rise Short Span Shelving (up to 3000mm high). Section J – Low Rise Medium Span Shelving (up to 3000mm high). Section K – High Rise Short Span Shelving (from 3100 to 12,000mm high).

ILLUSTRATIONS All illustrations within this manual are designed to be informative rather than necessarily to scale. If detailed dimensioning information is required, separate reference should be made to product drawings rather than estimating the information from an illustration.

Issue: September 2006

Section A – Product Introduction

Page A.4


SECTION B – FRAME COMPONENTS INTRODUCTION

Component Parts

A frame assembly comprises the following components. Three uprights (either type S (standard), K (heavy), or EK (extra heavy)). Connection pieces between the uprights (either battens, sheet cladding, or battens and diagonal braces). Baseplates and levelling plates. Fixings (either swaged or riveted).

Frame Heights

Standard heights of: 1000, 1600, 2100, 2300, 2500, 3000, and 4600mm.

Frame Widths

Standard frame widths of: 300, 400, 450, 500, 600, 800, and 1000mm.

Frame Types

The following styles of frame can be constructed. A. Battened frame (either 2, 3, 4 or 5 battens). B. Battened and braced frame. C. Fully braced frame. D. Solid clad frame.

Up to 5500mm. Up to 5500mm. 3100 – 12000mm. Up to 12000mm.

Individual frame bracing patterns (location of battens/braces etc.) are shown within Appendix A – Frame Assembly Schedule. Frame Assembly

Swage fixed frames can easily be assembled on site with the use of the hand held swaging tool.

Part Codes

Codes for the most common frames are listed on the following pages.

Issue: September 2006

Section B – Frame Components

Page B.1


FRAME CODES The following is a list of codes for some of the most common frames. These include frame heights up to 3000mm, either solid clad or with two battens, using the either the type ‘S’ or type ‘K’ uprights. Other frames need to be ordered in component form. 2 batten frame (knock down) Type ‘S’ Standard uprights. 300-600 deep - swaged battens 800-1000 deep - riveted battens Pre-galvanised uprights

Painted R7016 uprights

Solid clad frame (knock down). Type ‘S’ Standard uprights. Swaged connections.

Pre-galvanised uprights

Painted R7016 uprights

1000mm high frames x ???mm wide. 300mm 450751425 400mm 450751426 450mm 450751650 500mm 450751427 600mm 450751428 800mm 450751429 1000mm 450751430

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450751455 450751456 450751660 450751457 450751458 450751459 ---

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1600mm high frames x ???mm wide. 300mm 450751431 400mm 450751432 450mm 450751651 500mm 450751433 600mm 450751434 800mm 450751435 1000mm 450751436

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450751460 450751461 450751661 450751462 450751463 450751464 ---

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2100mm high frames x ???mm wide. 300mm 450751437 400mm 450751438 450mm 450751652 500mm 450751439 600mm 450751440 800mm 450751441 1000mm 450751442

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450751465 450751466 450751662 450751467 450751468 450751469 ---

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Continued on the next page.

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Section B – Frame Components

Page B.2


FRAME CODES (continued) 2 batten frame (knock down) Type ‘S’ Standard uprights. 300-600 deep - swaged battens 800-1000 deep - riveted battens Pre-galvanised uprights

Painted R7016 uprights

Solid clad frame (knock down). Type ‘S’ Standard uprights. Swaged connections.

Pre-galvanised uprights

Painted R7016 uprights

2300mm high frames x ???mm wide. 300mm 450751443 400mm 450751444 450mm 450751653 500mm 450751445 600mm 450751446 800mm 450751447 1000mm 450751448

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450751470 450751471 450751663 450751472 450751473 450751474 ---

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2500mm high frames x ???mm wide. 300mm 450751449 400mm 450751450 450mm 450751654 500mm 450751451 600mm 450751452 800mm 450751453 1000mm 450751454

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450751475 450751476 450751664 450751477 450751478 450751479 ---

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3 batten frame (knock down) Type ‘S’ Standard uprights. 300-600 deep - swaged battens 800-1000 deep - riveted battens Pre-galvanised uprights

Painted R7016 uprights

3000mm high frames x ???mm wide. 300mm 450751481 400mm 450751482 450mm 450751483 500mm 450751484 600mm 450751485 800mm 450751486 1000mm 450751487

Issue: September 2006

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Solid clad frame (knock down). Type ‘S’ Standard uprights. Swaged connections.

Pre-galvanised uprights

Painted R7016 uprights

450751488 450751489 450751490 450751491 450751492 450751493 ---

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Section B – Frame Components

Page B.3


FRAME CODES (continued) 2 batten frame (knock down) Type ‘K’ Heavy uprights. 300-600 deep - swaged battens 800-1000 deep - riveted battens Pre-galvanised uprights

Painted R7016 uprights

Solid clad frame (knock down). Type ‘K’ Heavy uprights. Swaged connections.

Pre-galvanised uprights

Painted R7016 uprights

2100mm high frames x ???mm wide. 300mm 450752437 400mm 450752438 450mm 450752652 500mm 450752439 600mm 450752440 800mm 450752441 1000mm 450752442

450791447 450791448 450791572 450791449 450791450 450791451 450791452

450752465 450752466 450752662 450752467 450752468 450752469 ---

450791453 450791454 450791562 450791455 450791456 450791457 ---

2300mm high frames x ???mm wide. 300mm 450752443 400mm 450752444 450mm 450752653 500mm 450752445 600mm 450752446 800mm 450752447 1000mm 450752448

450791498 450791499 450791573 450791500 450791501 450791502 450791503

450752470 450752471 450752663 450752472 450752473 450752474 ---

450791504 450791505 450791563 450791506 450791507 450791508 ---

2500mm high frames x ???mm wide. 300mm 450752449 400mm 450752450 450mm 450752654 500mm 450752451 600mm 450752452 800mm 450752453 1000mm 450752454

450791509 450791510 450791574 450791511 450791512 450791513 450791514

450752475 450752476 450752664 450752477 450752478 450752479 ---

450791515 450791516 450791564 450791517 450791518 450791519 ---

Issue: September 2006

Section B – Frame Components

Page B.4


UPRIGHT TYPES: S, K and EK

Section

T-shaped upright which is 50mm wide by 51mm front to back. The same section is used for both the front and rear uprights within a frame. The upright is formed to create a rectangle hollow section as part of the web, this gives the upright high load carrying capacity with respect to material thickness. The return lips of the section are clinched together at 100mm intervals.

Duty

There are three grades of upright section: Upright S (standard): rolled from 0.7mm thick material, Upright K (heavy): rolled from 0.9mm thick material, and Upright EK (extra heavy): rolled from 1.2mm thick material.

Upright S or K

These uprights can be identified by the grooves along the front face, and the absence of face holes, other than those at either end. Additional the upright type either S or K is punched at 300mm centres along the outside face of the longer return lip.

Upright EK

This upright can be identified by its smooth front face, and the pairs of face holes punched at regular 100mm increments along its length.

Web Holes

The upright web is provided with a series of holes / hooks: Integrated hooks at 25mm increments, to locate the shelves and beams. Oval holes at 100mm increments, for swage fixing frame battens and cladding. Smaller round holes also at 100mm increments, for riveting side braces and battens. continued over page.

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Section B – Frame Components

Page B.5


Face Holes

The upright face is also provided with a series of holes: Central 4.5mm hole at either end, to locate the baseplate fixing when required. A pair of 6.5mm holes spaced 26.4mm apart. One set positioned 19.5mm from the bottom of the upright, and another set 100mm from the top. These holes are used for fixing racks back to back to create double entries and to provide fixing holes for upright splices and back braces. (Use M6x20mm nuts and bolts for fixing uprights back to back). Additionally the EK upright has further pairs of 6.5mm holes punched at regular 100mm increments along its face. These are additional fixings holes for EK solid back cladding and back braces.

Length

Standard upright lengths of: Type S: 1000, 1600, 2100, 2300, 2500, and 3000mm. Type K: 2100, 2300, 2500, 3000, and 4600mm. Type EK: 2100, 2300, 2500, 3000, and 4600mm. Non-standard lengths can be produced in lengths of 1000 to 8000mm in 100mm increments.

Structural

The upright is a structural component.

Material

0.7, 0.9 and 1.2mm thick pre-galvanised steel.

Finish

The standard finish is pre-galvanised. Alternative finish for the K upright is pre-painted steel Anthracite RAL 7016 over the top of the pre-galvanised base.

Part Codes

One piece.

Length 1000mm 1600mm 2100mm 2300mm 2500mm 3000mm 4600mm

Issue: September 2006

Type S Pre-galv ZN 444046011 444046012 444046013 444046014 444046015 444046016 ---

Type K Pre-galv ZN ----444046003 444046004 444046005 444046006 444046007

Section B – Frame Components

Type K Painted RAL 7016 ----444027653 444027654 444027655 444027656 444027657

Type EK Pre-galv ZN ----444058301 444058302 444058303 444058304 444058305

Page B.6


STANDARD BASEPLATE and STANDARD LEVELLING PLATE

Use

A baseplate must be fitted to every upright to: -Provide a smooth bearing surface for the upright, -Spread the load of the upright over a reasonable area of the floor, -Provide a means of fixing the upright to the concrete floor, -Provide a means of levelling the upright when necessary.

Baseplate

50mm wide x 39mm front to back x 1.2mm thick. The baseplate extends approximately 2mm beyond the front face of the upright. The U profile upstand of the baseplate pushes into the rectangular hollow section in the web of the upright, and the tangs on the baseplate U profile clip into specific slot openings in the upright.

Maximum Load

Maximum load per baseplate is 1500kg, (i.e. 3000kg per frame). Assumes a floor of minimum grade C16/20 concrete (Eurocode 2).

Baseplate Fixing

When the design requires, the following fixings should be used: Baseplate to upright: a single 4.2 dia. x 15mm long screw per baseplate. Baseplate to floor: a single hammer screw or a single expander bolt.

Levelling Plate

1.2mm thick, but slightly larger than the baseplates at 50mm wide x 42mm front to back. Levelling plates should not be stacked higher than 20mm.

Material + Finish

1.2mm thick pre-galvanised steel.

Part Codes

Baseplate = 444030200, Levelling plate = 444031300, screw = 444046500.

Issue: September 2006

Section B – Frame Components

Page B.7


HEAVY DUTY LEVELLING PLATE

Use

The use of this levelling plate under the standard baseplate increases the capacity of the standard baseplate from 1500kg to 2500kg. The heavy duty levelling plate is 54mm wide x 41mm front to back x 3mm thick. The plate is provided with a single fixing hole and a raised dimple that locates into one of the holes in the baseplate above. When used, a levelling plate MUST be positioned under EVERY upright.

Levelling

The shelving can be levelled by either using additional heavy duty plates at 3mm thick, or standard plates at 1.2mm thick. When using the thin standard levelling plates they must be positioned in between the baseplate and the heavy duty levelling plate.

Maximum Load

Maximum load per upright is 2500kg. (i.e. 5000kg per frame). Assumes a floor of minimum grade C16/20 concrete (Eurocode 2).

Material

3mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

Heavy duty levelling plate = 444060205.

Issue: September 2006

Section B – Frame Components

Page B.8


HIGH RISE BASEPLATES and LEVELLING PLATES

Use

These baseplates provide the same function as the standard baseplates, but are designed to carry greater loads. There are two baseplates, the single and the double.

Single Baseplate

135mm wide x 100mm front to back x 5mm thick. The baseplate extends approximately 41mm beyond the front face of the upright, which is positioned inside the channel upstand. A single M6S 6x20 screw and nut is used to fix the upright to the baseplate.

Double Baseplate

135mm wide x 120mm front to back x 5mm thick. One upright is positioned inside the channel upstand, and the second outside. A single MC6S 6x20 screw and nut is used to fix the uprights to the baseplate.

Maximum Load

Maximum load per baseplate is 3000kg, (i.e. 6000kg per frame). Assumes a floor of minimum grade C16/20 concrete (Eurocode 2).

Floor Fixing

When the design requires the following floor fixings should be used: Single baseplate: one M10 expander bolt per baseplate. Double baseplate: two M10 expander bolts per baseplate.

Levelling Plates

Single and double versions to the same dimensions as the baseplates. Levelling plates should not be stacked higher than 50mm. Stack heights between 20 and 50mm should be tack welded together.

Material

1mm, 3mm, thick steel.

Finish

1mm and 3mm plates are pre-galvanised.

Issue: September 2006

Section B – Frame Components

Page B.9


HIGH RISE BASEPLATES and LEVELLING PLATES (continued) Part Codes

Single baseplate = 444059701 new code. Single levelling plates: 1mm thick = 444060111 new code, 3mm thick = 444060112 new code. Double baseplate = 444059801 new code. Double levelling plates: 1mm thick = 444060211 new code, 3mm thick = 444060212 new code. M6S 6x20mm screw MC6S 6x20mm screw M6 Nut

Issue: September 2006

725237051. 725537151. 731231601.

Section B – Frame Components

Page B.10


UPRIGHT SPLICE

Use

When uprights greater than 8000mm long are required two uprights may be spliced together. Both uprights must be of the same section type.

Position

Each splice plate covers the pockets either side of the joint. Therefore the splice position is most important and must be decided on an application by application basis to ensure the splice doesn’t coincide with either: a shelf, a batten, or bracing diagonal. The ideal position would be at mid height so that each section is the same length, but if this is not possible the splice should be raised so that the bottom section is always larger than the top section. The closest a shelf / shelf beam can be positioned to the joint is 125mm below, or 150mm above the joint. The closest available hole to the joint for a batten / bracing fixing is 139mm below (oval hole), or 111mm above the joint (round hole).

Assembly

Each assembly comprises two plates and ten MC6S 6x20 screws and nuts. Eight of the screws pass through the upright face and two through the web. These fixings use the existing holes in the EK, but when using the S or K uprights six of the face fixings will require new 6.5mm dia. holes to be drilled on site. Alternatively these holes can be factory provided through the specials request / coding / pricing procedure.

Structural

The splice is a structural component.

Material + Finish

2mm thick pre-galvanised steel.

Part Codes

Splice (one piece)=444042000, MC6S screw=725537151, nut=731231601.

Issue: September 2006

Section B – Frame Components

Page B.11


FRAME BATTEN

Use

Frame battens are mounted between the front and back uprights and serve to strengthen the frame in that direction. There are three styles dependent upon the frame width. Light duty swaged batten, for frame widths 300, 400, 450, 500, 600mm. Light duty riveted batten, for frame widths of 300, 400, 450, 500, 600mm. Heavy duty riveted batten, for frame widths of 800, and 1000mm. Each style fits into the opening between the returns on the upright web.

Light Duty Swaged

A 120mm high batten formed from 0.9mm thick material. Each batten is swage fixed through the oval holes in each corner using the assembly tool.

Light Duty Riveted

The same batten as the short swaged, but with the swage holes in each corner being replaced by 5.1mm dia. holes to accept four rivets 4.8 dia. x 7mm long (two at either end).

Heavy Duty Riveted A 224mm high batten formed from 1.6mm thick material. Each batten is fixed with six rivets 4.8 dia. x 7mm long (three at either end) through the small round holes in the upright web. Structural

The battens are structural components.

Finish

Pre-galvanised.

Part Codes

Codes are listed on the following page.

Issue: September 2006

Section B – Frame Components

Page B.12


FRAME BATTEN (continued) Part Codes

One piece.

Frame width

Light Duty Swaged

Light Duty Riveted

Heavy Duty Riveted

300mm 400mm 450mm 500mm 600mm 800mm 1000mm

444028201 444028202 444028210 444028203 444028204 -

444028250 444028251 444028252 444028253 444028254 -

444046901 444046902

4.8 dia. x 7mm long rivet = 722786309.

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Section B – Frame Components

Page B.13


FRAME BRACE

Use

Used to provide additional strength in non solid clad frames. The braces are always used in pairs to form a cross.

Length

The length is always expressed by ‘hole centres’. The following lengths are for an 800mm high bracing panel. Frame width Hole centres Part Code 300mm 829mm 444046601 400mm 860.9mm 444046602 450mm 880.6mm 444046607 500mm 902.6mm 444046603 600mm 953mm 444046604 800mm 1075mm 444046605 1000mm 1217.7mm 444046606

Fixings

Two rivets 4.8 dia. x 7mm long (one either end) fixed through the corresponding round holes in the upright web.

Structural

These braces are structural components.

Material

1mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

Brace codes as shown above, 4.8 dia. x 7mm long rivet = 722786309.

Issue: September 2006

Section B – Frame Components

Page B.14


SOLID FRAME CLADDING

Use

Used as an alternative to battens or bracing to create solid clad frames enabling stock segregation between one bay of shelving and the next. The cladding fits into the opening between the returns on the upright web.

Frame Widths

To suit frame widths of 300, 400, 450, 500, 600, and 800mm.

Heights (H)

Standard panel heights of 900, 1000, 1600, 2100, 2300 and 2500mm. A combination of two or more panels can be used to clad other frame heights. Where a combination is used the gap between panels should be covered with a piece of cladding trim. See Appendix A for recommended panel combinations.

Fixings

12 swage fixings, (6 into each upright) positioned at the top, the bottom and the rest evenly distributed in between.

Structural

The solid frame cladding is a structural component.

Material

0.6mm thick pre-galvanised steel.

Finish

Either pre-galvanised or painted Grey White RAL 9002

Part Codes

Codes are listed on the follow page.

Issue: September 2006

Section B – Frame Components

Page B.15


SOLID FRAME CLADDING (continued) Part Codes

One piece.

Solid Frame Cladding Sheet – Pre-galvanised. Frame width ‘W’ Frame 300mm 400mm 450mm 500mm Height ‘H’ 900mm 444046326 444046327 444046340 444046328 1000mm 444046301 444046306 444046341 444046311 1600mm 444046302 444046307 444046342 444046312 2100mm 444046303 444046308 444046343 444046313 2300mm 444046304 444046309 444046344 444046314 2500mm 444046305 444046310 444046345 444046315

Solid Frame Cladding Sheet – Painted Grey White RAL9002. Frame width ‘W’ Frame 300mm 400mm 450mm 500mm Height ‘H’ 900mm 444029576 444029577 444029585 444029578 1000mm 444029551 444029556 444029586 444029561 1600mm 444029552 444029557 444029587 444029562 2100mm 444029553 444029558 444029588 444029563 2300mm 444029554 444029559 444029589 444029564 2500mm 444029555 444029560 444029590 444029565

Issue: September 2006

Section B – Frame Components

600mm

800mm

444046339 444046316 444046317 444046318 444046319 444046320

444046330 444046321 444046322 444046323 444046324 444046325

600mm

800mm

444029579 444029566 444029567 444029568 444029569 444029570

444029580 444029571 444029572 444029573 444029574 444029575

Page B.16


CLADDING TRIM

Use

Cladding trim is used to cover the gap between panels when two or more panels are used within the height. The same section is also used as a trim for the back cladding.

Section

An ‘H’ section nominally 24mm high by 4mm thick.

Length

The overall length (L) of the trim is the frame width (W) – 150mm.

Material

Plastic.

Finish

Grey White RAL 9002.

Part Codes

300mm frame width = 444201170 400mm frame width = 444201171 450mm frame width = 444201172

Issue: September 2006

500mm frame width = 444201173 600mm frame width = 444201174 800mm frame width = 444201175

Section B – Frame Components

Page B.17


MESH FRAME CLADDING

Use

Provides segregation between one bay and the next, whilst allowing good ventilation, and the transfer of light. Mesh can only be fitted to a frame that is already battened, or battened and braced.

Panel Widths

To suit frame widths of 400, 450, 500, and 600mm. The panel width is frame width (W) – 100mm.

Heights (H)

To suit standard frame heights of 2100, 2300 and 2500mm. The panel height is frame height (H) – 50mm.

Fixings

The mesh is secured to the frames with eight mesh brackets that are swage connected to the uprights.

Positioning

To allow the mesh to pass the batten, the mesh should be installed on the concave side of the batten (as shown above) with the horizontal bars touching the batten. This ensures the vertical bars are next to the shelf which eases installation.

Structural

The mesh frame cladding is NOT a structural component, and can not be used as a replacement to either battens or braces.

Material

50 x 50 x 3mm diameter wire mesh.

Finish

Painted Grey White RAL 9002

Part Codes

Codes are listed on the following page.

Issue: September 2006

Section B – Frame Components

Page B.18


MESH FRAME CLADDING (continued) Part Codes

Individual panels (one piece) Frame width 2100mm ‘W’ 400mm 444031658 450mm 444031671 500mm 444031663 600mm 444031668

Frame heights ‘H’ 2300mm

2500mm

444031659 444031672 444031664 444031669

444031660 444031673 444031665 444031670

Complete kits (panel and brackets) Frame heights ‘H’ Frame width 2100mm 2300mm ‘W’ 400mm 450791343 450791344 450mm 450791365 450791366 500mm 450791346 450791347 600mm 450791349 450791350

Issue: September 2006

Section B – Frame Components

2500mm 450791345 450791367 450791348 450791351

Page B.19


MESH FRAME CLADDING FIXING BRACKET

Use

Used to secure the mesh frame cladding to the frame uprights. One end of the bracket is bent around the vertical wire of the panel whilst the other is swaged into the oval hole on the upright web using the assembly tool.

Fixing

Eight brackets are used to fix each mesh panel (four to each upright).

Material

0.7mm thick steel.

Finish

Zinc plated.

Part Code

444033000.

Issue: September 2006

Section B – Frame Components

Page B.20


END FRAME CLADDING – DECORATIVE CHIPBOARD

Use

Used to provide a finish to the end frames on a row of shelving. As a minimum these panels must be used in conjunction with battened frames.

Availability

These chipboard panels are not a Dexion supplied item and need to be sourced independently from the shelving, either through the appropriate local purchasing department, or direct from a stockist.

Frame Widths

Chipboard widths of 298, 398, 448, 498, 598, and 798mm to suit frame widths of 300, 400, 450, 500, 600, and 800mm.

Heights (H)

Board heights should be 3mm less than the frame height.

Fixings

The board fits between the flanges of the upright and doesn’t require any additional fixings.

Structural

The end frame cladding is NOT a structural component, it is for decoration purposes only.

Material

12mm thick chipboard.

Finish

A range of standard finishes are available from various suppliers. The choice could be to blend in with the surrounding shelving, or to enhance the client’s corporate colours.

Issue: September 2006

Section B – Frame Components

Page B.21


ASSEMBLY TOOLS TYPES K and EK

Use

These tools are used to make the swage fixings on frame battens, cladding and brackets. The tool is inserted through the swage hole in the batten/cladding etc. and into an oval hole in the upright, and then turned through 180°. This rotation swages the steel of the batten/cladding into the upright hole thus creating the fixing.

Type

There are two types of tool, the K and EK designed to suit the steel upright thickness. The K tool is also used with the type S uprights. It is important that the correct tool is used for each upright. They can be identified by their colour, the EK tool also has a groove around its shaft.

Life

If the resultant hole through the swage measures less than 9.5mm diameter, the tool is worn and needs replacing. Each assembly tool will last approximately 1000 swages.

Material

Steel with case hardened surface treatment.

Finish

Tool type K: Tool type EK:

Silver appearance. Yellow chromate appearance.

Part Codes

Tool type K: Tool type EK:

444033200. 444060300.

Issue: September 2006

Section B – Frame Components

Page B.22


ELLIPSE TOOLS TYPES K and EK

Use

The ellipse tool provides the same function as the assembly tool. It is intended for use when assembling larger quantities of frames, and consists of a handle with replaceable bits.

Type

There are two types of bit, the K and EK designed to suit the steel upright thickness. The K bit is also used with the type S uprights. It is important that the correct bit is used for each upright. They can be identified by their colour, the EK also has a groove around its shaft.

Life

If the resultant hole through the swage measures less than 9.5mm diameter, the tool is worn and needs replacing. Each ellipse bit will last approximately 1000 swages.

Material

Moulded plastic handle Steel bits with case hardened surface treatment.

Finish

Ellipse bit type K: Ellipse bit type EK:

Silver appearance. Yellow chromate appearance.

Part Codes

Ellipse handle Ellipse bit type K: Ellipse bit type EK:

444044400. 444034800. 444060400.

Issue: September 2006

Section B – Frame Components

Page B.23


FLOOR FIXING – HAMMER SCREW

Use

To securely fix the frames in position, to resist any lateral movement or uplift.

Type

Hammer Screw floor fixing. (Hilti HPS-1 8mm x 50mm) An 8mm diameter expanding fixing nominally 50mm long. This is a rapid expansion fixing that doesn’t require the use of a screw driver. The head of the fixing is struck with a hammer which forces the sides of the plastic sleeve outwards gripping the concrete floor. This fixing requires an 8mm diameter hole in the floor. Fixings can be removed by unscrewing with a screwdriver.

Location

The quantity and location of fixings will depend on each individual application, the rack design, and its height to width ratio. Refer to Application Section of the manual for detailed requirements.

Only use Constructor/Dexion Approved Fixings. Part Code

441099000.

Issue: September 2006

Section B – Frame Components

Page B.24


FLOOR FIXING – EXPANDER BOLT

Use

To securely fix the frames in position, to resist any lateral movement or uplift.

Type

Expander Bolt floor fixing. Two sizes are available dependent upon the baseplate they will be used with. Standard Baseplate. 6mm diameter expander bolt nominally 65mm long. Requires a 6mm diameter hole in the floor. High Rise Baseplates. 10mm diameter expander bolt either 68 or 90mm long. (Hilti HSA 10x68mm, or Hilti HSA 10x90mm). Requires a 10mm diameter hole in the floor.

Location

The quantity and location of fixings will depend on each individual application, the rack design, and its height to width ratio. Refer to Application Section of the manual for detailed requirements.

Only use Constructor/Dexion Approved Fixings. Part Codes

Expander bolt 6x65mm = 057975. Expander bolt 10x95mm = 057843 new code.

Issue: September 2006

Section B – Frame Components

Page B.25


SECTION C – SHORT SPAN BAY COMPONENTS INTRODUCTION

Bay Components

These are the components that give the rack its length, and basically consist of the shelf and its supporting beam. These two main components within short span differ from the shelf and beam used within the HI280 medium span system. Each system is largely unique with its own range of applications and accessories with only a few minor accessories being common across both systems. Therefore to save confusion this section of the manual only deals with the Short Span Bay Components, leaving medium span for the next section.

Bay Lengths

Short span is only available in bay lengths of 900, 1000 and 1290mm.

Frame Widths

Short span is only available in frame widths of 300, 400, 450, 500, 600, and 800mm. The larger 1000mm frame width is only available in medium span.

Issue: September 2006

Section C – Short Span Bay Components

Page C.1


SHELF BEAM

Use

Each storage level consists of two parts, a shelf and a shelf beam. The shelf beam is located between the rear uprights, the hooks on the ends of the beam corresponding with those on the web of the upright. At either end the beam is provided with recesses enabling it to fit around the return flanges on the upright. This connection provides good stability along the length of the rack. The beam web is provided with hooks that support the rear edge of the shelf. Oval holes in the top of the beam are to accommodate shelf dividers. The same beam is used for both the ‘standard’ and ‘heavy’ duty shelves.

Length

To suit the three standard bay lengths of 900, 1000, and 1290mm.

Structural

The shelf beam is a structural component.

Material

0.8mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

Shelf beam 900mm = 444027905. Shelf beam 1000mm = 444027902. Shelf beam 1290mm = 444027904.

Issue: September 2006

Section C – Short Span Bay Components

Page C.2


SHELF

Use

Each storage level consists of two parts, a shelf and a shelf beam. The shelf is made from profiled steel with a concave front face and folded rear and side faces. The steel is also clinched together adding to the strength of the shelf. At either end the front face of the shelf is provided with recesses enabling it to fit around the return flanges on the upright. This connection provides good stability along the length of the rack. Hooks at the front of the side faces locate with those on the upright web. The rear of the shelf is supported by the shelf beam. Holes on a 59.25mm pitch in the top of the shelf are to accommodate shelf dividers, the rear of the divider locates through similar holes in the top of the shelf beam.

Length

To suit bay lengths of 900, 1000, and 1290mm.

Width

To suit frame widths of 300, 400, 450, 500, 600 and 800mm.

Duty

There are three duties of shelf, ’N’ normal, ’S’ standard, and ‘H’ heavy duty offering different load carrying capacities which are listed within the design section. The duty is stamped on the front face of the shelf. Not all duties are available in each size, a list is contained on the next page. Some sizes are intended for the project market and subject to minimum order quantities.

Structural

The shelf is a structural component.

Issue: September 2006

Section C – Short Span Bay Components

Page C.3


New page SHELF (continued) Material + Finish

Normal duty shelves: Standard duty shelves: Heavy duty shelves:

Part Codes

One piece ‘Shelf Only’. Stock items shown Shelf size 300x900 300x1000 300x1290

400x900

400x1000

400x1290

450x900 450x1000 450X1290 500x900 500x1000 500x1290 600x900 600x1000 600x1290 800x900 800x1000 800x1290

Issue: September 2006

0.5mm thick pre-galvanised steel. 0.6mm thick pre-galvanised steel. 0.7mm thick pre-galvanised steel. . Project items shown P.

Part code

t mm

Duty

kg

444046255 444046225 444046256 444046206 444046254 444046216

0.5 0.7 0.5 0.7 0.5 0.7

N H N H N H

140 235 135 235 70 110

444046250 444046259 444046226 444046251 444046257 444046207 444046252 444046260 444046217

0.5 0.6 0.7 0.5 0.6 0.7 0.5 0.6 0.7

N S H N S H N S H

140 160 235 140 150 235 75 85 110

444046262 444046227 444046263 444046235 444046264 444046236

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

160 235 150 235 85 110

444046266 444046228 444046258 444046208 444046267 444046218

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

170 235 150 235 85 110

444046268 444046229 444046269 444046209 444046270 444046219

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

150 215 140 215 100 120

444046230 444046210 444046220

0.7 0.7 0.7

H H H

110 110 120

Section C – Short Span Bay Components

Stock/ Project

Min Qty

P

1000

P

1000

P P

2500 1000

P

2500

P P

1000 2500

P

1000

P

1000

P

1000

P

1000

P

1000

P

1000

P

1000

Page C.4


SHELF REINFORCEMENT BAR

Use

Only to be used with ‘H’ heavy duty shelves. Shelf reinforcement consists of two parts, the reinforcement bar/s and their supports at either end. The shelf can be reinforced with one or two longitudinal bars depending upon the required additional loading. There is no advantage using a third bar, it will not further increase the capacity. The longitudinal bars hook over recesses on the top edges of the supports. Shelves positioned below 100mm from the floor can not be reinforced. Shelves positioned at 100mm from the floor use a base support. Shelves positioned above 100mm from the floor use the normal support.

Length

To suit the standard bay lengths of 900, 1000, and 1290mm.

Fitting

The shelf reinforcement is fitted before the shelf is positioned.

Structural

The reinforcement bar is a structural component.

Material

0.9mm thick pre-galvanised steel for the 900 and 1000mm bars, and 1.2mm thick pre-galvanised steel for the 1290mm bar.

Finish

Pre-galvanised.

Part Codes

One piece: 900mm = 440839107, 1000mm = 440839104, and 1290mm = 440839106.

Issue: September 2006

Section C – Short Span Bay Components

Page C.5


SHELF REINFORCEMENT SUPPORT

Use

Shelf reinforcement consists of two parts, the reinforcement bar/s and their supports at either end. Shelves positioned below 100mm from the floor can not be reinforced. Shelves positioned at 100mm from the floor use a base support. Shelves positioned above 100mm from the floor use the normal support. The reinforcement bars hook over recesses on the top edges of these supports.

Base Support

This support rests on the baseplates.

Normal Support

This support is provided with hooks that locate into those on the upright.

Width

To suit standard frame widths of 300, 400, 450, 500, 600, and 800mm.

Fitting

The shelf reinforcement is fitted before the shelf is positioned.

Structural

The reinforcement bar is a structural component.

Material + Finish

1.5mm thick pre-galvanised steel.

Part Codes

One piece.

Normal support Base support

300mm 444046801 444050701

Issue: September 2006

400mm 444046802 444050702

Frame width ‘W’ 450mm 500mm 444046806 444046803 444050706 444050703

Section C – Short Span Bay Components

600mm 444046804 444050703

800mm 444046805 444050703 Page C.6


SHELF DIVIDER – PART HEIGHT

Use

Used to sub-divide the shelf into smaller compartments. The divider is secured by two pins that fit into the oval holes along the top of the shelf and shelf beam. One pin is shorter than the other, this shorter pin is located at the front of the divider and fits through the shelf. The use of the divider is independent of the shelf pitch as it only requires to be secured to the shelf below. Note: This accessory can only be used with short span shelving.

Adjustment

The divider location is adjustable on a 59.25mm pitch

Height

Either 90 or 140mm.

Length

To suit standard shelf widths of 300, 400, 450, and 500mm. This divider is NOT available to suit shelf widths of 600, and 800mm.

Material

1.5mm thick steel.

Finish

Painted Grey White RAL 9002

Part Codes

One piece.

90mm high 140mm high

Issue: September 2006

300mm 661400 661402

Frame width ‘W’ 400mm 450mm 661410 661414 661412 661416

Section C – Short Span Bay Components

500mm 661420 661422

Page C.7


SHELF DIVIDER – FULL HEIGHT

Use

Used to sub-divide the shelf into smaller compartments. The divider is secured by four pins that fit into the oval holes along the top and bottom of the shelf and shelf beam. One set of pins are shorter than the other, these shorter pins are located at the bottom of the divider and fit through the holes in the shelf/beam below. The divider height is fixed to the shelf pitch as it requires to be secured to both the shelf above and below. Note: This accessory can only be used with short span shelving.

Adjustment

The divider location is adjustable on a 59.25mm pitch

Sizes

As listed below, the height is the pitch between the top surfaces of the shelves, (i.e. the clear compartment height plus a 31mm shelf).

Material + Finish

Either 0.6 or 0.8mm thick pre-galvanised steel dependent upon divider size.

Part Codes

One piece.

Shelf pitch 200mm 250mm 300mm 400mm 500mm 600mm

300mm 444056601 444056602 444056603 -

Issue: September 2006

400mm 444056604 444056605 444056606 444056607 -

Frame width ‘W’ 450mm 500mm 444056625 444056608 444056626 444056609 444056627 444056610 444056628 444056611 444056629 444056612 444056613

Section C – Short Span Bay Components

600mm 444056614 444056615 444056616

800mm 444056617 444056618 Page C.8


BIN FRONT

Use

The bin front can be fitted to the front or the back of a shelf to prevent smaller items falling from the shelf. It fits inside the flanges on the uprights and is secured on the hooks on the upright web

Height

Standard height of 50mm.

Length

To suit the three standard bay lengths of 900, 1000, and 1290mm.

Structural

The bin front is NOT a structural component.

Material

1.0mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

900mm = 444032305, 1000mm = 444032302, and 1290mm = 444032304.

Issue: September 2006

Section C – Short Span Bay Components

Page C.9


BASE PLINTH

Use

A base plinth fits between the front uprights and is used to fill the gap between the floor and the underside of the first shelf. The first shelf fits above the plinth and needs to have a height above the floor of 100mm. The back of the first shelf is supported on a shelf beam in the usual manner.

Section

The base plinth is the same section as the medium span beam but without the holes in the top face or the hooks to support the medium span steel in-fill shelves.

Length

To suit standard bay lengths of 900, 1000, and 1290mm.

Structural

The base plinth is NOT a structural component.

Material

1.5mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

900mm = 444050805, 1000mm = 444050802, and 1290mm = 444050804.

Issue: September 2006

Section C – Short Span Bay Components

Page C.10


BACK CLADDING There are four different solutions for cladding the back of an HI280 bay of shelving. Each solution designed to meet varying requirements uses different components, fixing methods and cladding trim. These components are detailed on the following pages. These solutions can be summarised as follows:

1.

Full Width Solid Cladding This will be the main solution for cladding low rise racks. Height: one piece sheets up to 1300mm, taller bays use two or more sheets. Fixing: fixed to the upright with clips. Cladding trim: a single piece of plastic trim. Structural: this method of cladding is NOT structural.

2.

Half Width Solid Cladding Two half width sheets swaged together on site to form full width cladding. This will mainly be used when supplying pre-packed shelving kits in cartons through catalogue sales, E-business etc. Height: half width sheets up to 2500mm, taller bays use additional sheets. Fixing: fixed to the upright with clips. Cladding trim: two pieces of plastic trim. Structural: this method of cladding is NOT structural.

3.

EK Solid Cladding Bolted cladding which can replace back braces in taller heavier loaded racks that use the EK upright. Racks will be clad using a combination of 1000 and 1500mm high sheets. Height: individual sheets either 1000 or 1500mm. Fixing: fixed to the upright with nuts and bolts. Cladding trim: the sheets are overlapped therefore no trim is required. Structural: this method of cladding IS structural.

4.

Mesh Cladding Wire mesh cladding providing stock segregation whilst permitting the transfer of light and air circulation. Height: one piece sheets up to 2500mm, taller bays use two or more sheets. Fixing: fixed to the upright with clips. Cladding trim: no cladding trim is used. Structural: this method of cladding is NOT structural.

Issue: September 2006

Section C – Short Span Bay Components

Page C.11


FULL WIDTH SOLID BACK CLADDING

Use

The cladding is positioned between the back uprights within a bay to enclose the storage compartment. In double entry racks the cladding is common, being shared between both bays.

Bay Lengths

To suit standard bay lengths of 900, 1000, and 1290mm. The actual panel size is 51mm less the bay size.

Heights

Standard heights of 800, 1000, 1200, and 1300mm. A combination of two or more panels can be used to clad taller bays. Where a combination is used the gap between panels should be covered with a piece of cladding trim. Example of combinations: 2100mm bay height use 800 + 1300mm panels. 2500mm bay height use 1200 + 1300mm panels. 3000mm bay height use 3 x 1000mm panels. See Appendix B – Back Cladding Schedule for full details.

Fixings

Each panel is attached to the uprights with 6 back cladding clips. The hook on the clip passes through one of the rectangular hooks punched along either side of the panel.

Structural

This type of cladding is NOT structural.

Material

0.6mm thick steel.

Finish

Either pre-galvanised or painted Grey White RAL 9002.

Part Codes

Codes for individual panels and complete kits are shown on the next page.

Issue: September 2006

Section C – Short Span Bay Components

Page C.12


FULL WIDTH SOLID BACK CLADDING (continued)

Individual panels (one piece) Pre-galvanised Bay length ‘L’ Panel height 900mm 1000mm 1290mm 800mm 1000mm 1200mm 1300mm

444201021 444201022 444201023 444201024

444201029 444201006 444201030 444201007

444201031 444201016 444201032 444201017

Painted Grey White RAL9002 Bay length ‘L’ 900mm 1000mm 1290mm 444201080 444201081 444201082 444201083

444201089 444201056 444201090 444201057

444201091 444201066 444201092 444201057

Back cladding clip = 444033100.

Complete kits (panels, cladding trim and clips) Pre-galvanised Bay length ‘L’ Bay height 900mm 1000mm 1290mm 1000mm 1600mm 2100mm 2300mm 2500mm

450792000 450792001 450792002 450792003 450792004

Issue: September 2006

450792020 450792021 450792022 450792023 450792024

450792030 450792031 450792032 450792033 450792034

Painted Grey White RAL9002 Bay length ‘L’ 900mm 1000mm 1290mm 450792040 450792041 450792042 450792043 450792044

Section C – Short Span Bay Components

450792050 450792051 450792052 450792053 450792054

450792060 450792061 450792062 450792063 450792064

Page C.13


HALF WIDTH SOLID BACK CLADDING

Use

Two half width panels are linked together using the assembly tool to provide the same function as the full width cladding. This combined assembly is then clipped into position between the uprights.

Bay Lengths

To suit a standard bay length of 1000mm. The actual size of each half panel is 497mm.

Heights

Standard heights of 1000, 1600, and 2100mm.

Fixings

Attached to the uprights with back cladding clips. 1000mm panel uses 6 clips per panel. 1600, and 2100mm panels use 8 clips per panel. One edge of each half panel is alternately punched with swage and plain holes to allow the two sheets to be swaged together in 4 locations. The hooks on the cladding clips then pass through the rectangular hooks punched along the external side of the combined panel.

Structural

This type of cladding is NOT structural.

Material + Finish

0.6mm thick pre-galvanised steel.

Part Codes 1000mm 1600mm 2100mm Cladding clip

Issue: September 2006

Component code 444046406 444046407 444046408 444033100

Kit code 450791162 450791163 450791164

Section C – Short Span Bay Components

Page C.14


EK SOLID BACK CLADDING

Use

Can only be used in association with the EK upright. In high bay shelving this cladding sheet can be used to replace back bracing.

Bay Lengths

To suit standard bay lengths of 900, 1000, and 1290mm The actual panel size is 6.5mm less than the bay size.

Heights

Either 1000mm or 1500mm. A combination of two or more panels are used in the height to clad taller bays with the panels overlapped at least 50mm saving on the need for cladding trim. Remember to allow for this overlap when calculating the required combinations. For example a 3000mm bay can either use: a) 2x1000mm plus 1x1500mm panels with overlaps, or b) 2x1500mm panels with a 50mm overlap and a gap of 50mm between the bottom panel and the floor.

Fixings

Bolted to the uprights using MC6S 6x20mm fixings through the holes in the upright face. Positioned at top, bottom and evenly spaced in between. The 1000mm panel uses 6 nuts and bolts per panel (3 each side). The 1500mm panel uses 8 nuts and bolts per panel (4 each side).

Structural

This type of cladding is a part of the structure.

Material + Finish

0.9mm thick pre-galvanised steel.

Part Codes

Issue: September 2006

Bay length ‘L’ Panel height 900mm 1000mm 1290mm 1000mm 444059307 444059302 444059303 1500mm 444059308 444059305 MC6S 6x20mm screw = 725537151, M6M nut = 731231601. Section C – Short Span Bay Components

Page C.15


MESH BACK CLADDING

Use

Used to enclose the rear of the storage compartment, whilst allowing good ventilation, and the transfer of light.

Bay Lengths

To suit standard bay lengths of 900, 1000, and 1290mm The actual panel size is 98mm less than the bay length.

Heights

Standard heights of 2100, 2300, and 2500mm.

Fixings

Each panel is attached to the uprights with 8 back cladding clips.

Structural

This type of cladding is NOT structural.

Material + Finish

50 x 50 x 3mm diameter wire mesh. Painted Grey White RAL 9002.

Part Codes

Individual panels (one piece) Bay height 900mm 2100mm 444031857 2300mm 444031858 2500mm 444031859

Bay length ‘L’ 1000mm 444031851 444031852 444031853

1290mm 444031854 444031855 444031856

Complete kits (panel and clips) Bay height 900mm 2100mm 450791358 2300mm 450791359 2500mm 450791360

Bay length ‘L’ 1000mm 450791352 450791353 450791354

1290mm 450791355 450791356 450791357

Issue: September 2006

Section C – Short Span Bay Components

Page C.16


BACK CLADDING CLIP

Use

Clips are used to secure both types of solid back cladding as well as the mesh back cladding to the uprights. One end of the clip has a hook that grips either the vertical wires of the mesh or one of the receiving hooks on the solid back cladding. The channel in the middle of the clip rests against the indented flange on the upright, whilst the other end fits into the groove inside the upright flange.

Fixing Quantity

Each cladding panel requires the following number of clips: Full width panels: 800, 1000, 1200, and 1300mm use 6 clips. Half width panels: 900, and 1000mm use 6 clips. Half width panels: 1600, 2100, 2300, and 2500mm use 8 clips. Wire mesh panels: 2100, 2300, and 2500mm use 8 clips.

Material

0.5mm thick stainless steel.

Finish

Natural.

Part Code

Back cladding clip = 444033100.

Issue: September 2006

Section C – Short Span Bay Components

Page C.17


CLADDING TRIM

Use

Cladding trim is used to cover the gap between panels when two or more panels are used within the height. The same section is also used as a trim for the frame cladding.

Section

An ‘H’ section nominally 24mm high by 4mm thick.

Length

When used with ‘Full Width Cladding’ the overall length of the trim is the bay length less 140mm. 900mm bay length uses one trim 760mm long. 1000mm bay length uses one trim 860mm long. 1290mm bay length uses one trim 1150mm long.

Material

Plastic.

Finish

Grey White RAL 9002.

Part Codes

900mm bay = 444201155, 1000mm = 444201156, 1290mm = 444201157.

Issue: September 2006

Section C – Short Span Bay Components

Page C.18


SLOTTED BACK PANEL

Use

The shelving bay can be equipped with slotted panels for the storage of tools etc. The back panel must always be used in association with side panels, as the side panels lock the back panel in position. The panels are perforated with 9 x 9mm square holes on a 34mm square grid.

Length

To suit a standard bay length of 1000mm.

Height

Standard height of 1000mm.

Design

When designing a bay incorporating these panels use the bay loads for the 800mm shelf pitch, multiplied by half.

Material

1.5mm thick steel.

Finish

Painted Grey White RAL 9002.

Part Code

Slotted back panel 1000mm bay length = 444047402.

Issue: September 2006

Section C – Short Span Bay Components

Page C.19


SLOTTED SIDE PANEL and CLIP

Use

The shelving bay can be equipped with slotted panels for the storage of tools etc. The side panels must always be used in association with a back panel. The panel is perforated with 9 x 9mm square holes on a 34mm square grid.

Length

One standard length to suit a frame width of 500mm.

Height

Standard height of 1000mm.

Fixings

The side panels are locked against the back panel in the corners, and secured at the front with 2 clips, i.e. each bay requires 4 clips (2 left hand and 2 right hand).

Material

1.5mm thick steel.

Finish

Painted Grey White RAL 9002.

Clips

1.0mm thick pre-galvanised steel clip, available in left and right hand versions.

Part Code

Slotted side panel 500mm frame width = 444071303. Slotted side panel clip. Left = 444056201, right = 444056202.

Issue: September 2006

Section C – Short Span Bay Components

Page C.20


BACK BRACE EK

Use

Back braces are used within tall and heavily loaded racks to resist longitudinal forces. The back brace EK only covers a single bay width and does not need a vernier. These braces should always be used in pairs to form a cross, which requires 1000mm in the height.

Length

Bay length 900mm 1000mm 1290mm

Hole centres ‘X’ 1328.0mm 1395.5mm 1611.5mm

Overall length ‘L’ 1353.0mm 1420.5mm 1636.5mm

Fixings

2No M6x20mm long screws and nuts. This bracing is intended for use with the EK upright and utilises the holes in the upright face for its fixings. If used with the K upright, the upright will need to be drilled on site to accept the fixings.

Material

25mm wide x 3mm thick pre-galvanised steel strip.

Finish

Pre-galvanised.

Part Codes

Bay length 900mm = 444060500, 1000mm = 444060501, Bay length 1290mm = 444060502. MC6S 6x20mm screw = 725537151, M6M nut = 731231601.

Issue: September 2006

Section C – Short Span Bay Components

Page C.21


SECTION D – MEDIUM SPAN BAY COMPONENTS INTRODUCTION

Bay Components

These are the components that give the rack its length, and basically consist of the medium span beam and in-fill shelves. These two main components within medium span differ from the shelf and beam used within the HI280 short span system. Each system is largely unique with its own range of applications and accessories with only a few minor accessories being common across both systems. Therefore to save confusion this section of the manual only deals with the Medium Span Bay Components, with the short span components being described within the previous section.

Bay Lengths

Medium span is available in bay lengths of 1500, 1750, 2000, 2250, and 2500mm.

Frame Widths

Medium span is only available in frame widths of 500, 600, 800, and 1000mm. The narrower frame widths are only available in short span.

Issue: September 2006

Section D – Medium Span Bay Components

Page D.1


MEDIUM SPAN BEAM

Use

Used in pairs the beams are located either between the rear or front uprights via hooks on the ends of the beam corresponding with those on the web of the upright. The ends of the beam are provided with recesses enabling them to fit around the return flanges on the upright. This connection provides good stability along the length of the rack. The beam web is provided with hooks that can support either the in-fill shelves or cross beams. Oval holes in the top of the beam are to accommodate accessories.

Section

The medium span beam is the same section as the short span base plinth but with the addition of the holes in the top face and the hooks to support the medium span steel in-fill shelves.

Length

To suit bay lengths of 1500, 1750, 2000, 2250, and 2500mm.

Structural

The medium span beam is a structural component.

Material

1.5mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

One piece. 1500mm = 444028101, 1750mm = 444028102, 2000mm = 444028103, 2250mm = 444028104, 2500mm = 444028105.

Issue: September 2006

Section D – Medium Span Bay Components

Page D.2


STEEL IN-FILL SHELVES

Use

A combination of shelves positioned side by side is used to create each storage level. The shelves are supported on the hooks along the rear face of the beam. The shelves are provided with holes to accommodate various accessories.

Width

To suit frame widths of 500, 600, 800, and 1000mm.

Length

Standard lengths of 129, 246, and 258mm. The following bay lengths require the following combinations of shelves: 1500mm bay: use 6x246mm shelves. 1750mm bay: use 1x129 + 6x246 + 1x129mm shelves. 2000mm bay: use 8x246mm shelves. 2250mm bay: use 1x129 + 8x246 + 1x129mm shelves. 2500mm bay: use 1x258 + 8x246 + 1x258mm shelves.

Structural

The in-fill shelves are structural components.

Material + Finish

0.8mm thick pre-galvanised steel.

Part Codes

Codes for individual shelves and complete kits are shown on the following page.

Issue: September 2006

Section D – Medium Span Bay Components

Page D.3


STEEL IN-FILL SHELVES (continued)

Individual shelves (one piece) Panel length ‘L’ 500mm 129mm 246mm 258mm

444030301 444030305 444030309

Frame width ‘W’ 600mm 800mm 444030302 444030306 444030310

444030303 444030307 444030311

1000mm 444030304 444030308 444030312

Complete kits (shelves and two beams) Bay length ‘L’ 1500mm 1750mm 2000mm 2250mm 2500mm

Issue: September 2006

500mm 450752200 450752201 450752202 450752203 450752204

Frame width ‘W’ 600mm 800mm 450752205 450752206 450752207 450752208 450752209

450752210 450752211 450752212 450752213 450752214

Section D – Medium Span Bay Components

1000mm 450752215 450752216 450752217 450752218 450752219

Page D.4


CROSS BEAM

Use

Used to support chipboard shelves within medium span bays. These supports fit over the hooks on the rear of the beam web, and are used at a maximum of 500mm spacing.

Size

To suit frame widths of 500, 600, 800, and 1000mm.

Quantity

The number of cross beams required for each level is: 1500mm bay: use 4 cross beams per level. 1750mm bay: use 5 cross beams per level. 2000mm bay: use 5 cross beams per level. 2250mm bay: use 6 cross beams per level. 2500mm bay: use 6 cross beams per level.

Structural

The cross beam is a structural component.

Material

0.7mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

Cross beam 500mm = 444029701, 600mm = 444029702, Cross beam 800mm = 444029703, 1000mm = 444029704.

Issue: September 2006

Section D – Medium Span Bay Components

Page D.5


CHIPBOARD SHELF

Description

Chipboard Grade P3 to European standard EN312-3. To achieve the load data contained within this manual it is important that all shelves are supplied to the above standard. Chipboard is not a Dexion supplied item and needs to be sourced independently, either through the appropriate local purchasing department, or direct from a stockist.

Length

To suit bay lengths of 1500, 1750, 2000, 2250, and 2500mm.

Width

To suit frame widths of 500, 600, 800, and 1000mm.

Supports

The chipboard shelf rests between the beams, supported on the cross beams which span front to back.

Material

18mm thick chipboard.

Finish

Natural.

Issue: September 2006

Section D – Medium Span Bay Components

Page D.6


BENCH TOP and LOCK

Use

To provide a work surface within a standard 1500x500mm bay of shelving. The bench top is 600mm front to back, thus extending beyond the front uprights by 100mm. Grooves on the short ends fit around the upright flanges.

Length

To suit a single bay length of 1500mm.

Width

To suit a single frame width of 500mm.

Fixings

Supported on two beams the top is secured at the back in each corner with a shelf lock and 4.8x7 SST rivet into the upright.

Load

Maximum uniformly distributed load of 180kg per bench top.

Material

30mm thick chipboard with a laminated top.

Finish

Oak Light Brown.

Note

Do not fit a bench top within a bay of shelving that is adjacent to a door set. The overhang of the bench top prevents the doors from being fully opened.

Part Code

Bench top complete with locks and fixings = 450752197.

Issue: September 2006

Section D – Medium Span Bay Components

Page D.7


TOOL PANEL

Use

A formed perforated panel that can accommodate standard tool hooks. The panel is perforated with 9 x 9mm square holes on a 34mm square grid.

Length

One size to suit a bay length of 1500mm.

Height

One height of 425mm.

Fixings

One tool panel will need two medium span beams for support, each additional panel requires an additional beam. The panels locate onto the hooks on the inside of the support beams. When additional panels are used they should be bolted together prior to hanging on the beams. Each fixing is an M5x16mm bolt with an M5 9mm square nut.

Material

1.5mm thick steel.

Finish

Painted Grey White RAL 9002

Part Codes

Tool panel = 440619600. M5x16mm bolt = 058076, and M5 9mm square nut = 058078.

Issue: September 2006

Section D – Medium Span Bay Components

Page D.8


U-SUPPORT

Use

To sub-divide a medium span bay into suitable compartments. The support spans between the front and rear beams with the legs fitting through the holes in the top surface of the medium span beams. Note: This accessory can only be used with medium span beams

Size

To suit frame widths of 500, 600, 800, and 1000mm.

Material

6mm diameter steel bar.

Finish

Zinc plated.

Part Codes

500mm = 444031901, 600mm = 444031902, 800mm = 444031903, 1000mm = 444031904.

Issue: September 2006

Section D – Medium Span Bay Components

Page D.9


SECTION E – ACCESSORIES INTRODUCTION Some HI280 shelving accessories are unique to either Short Span or Medium Span bays and some are common to both bay styles. To save confusion those that are unique have been included within the bay components section of the manual that relates to that bay style. The other accessories that are common are described within this section. Further sections of the manual are dedicated to Drawer and Tray Sets and another to Door Sets.

Issue: September 2006

Section E – Accessories

Page E.1


DIVIDER BAR

Use

The vertical bar divides the bay into suitable compartments. The bar passes through the holes in either beam or panel from above and down to the floor beneath. Any number of bars can be used, providing there are sufficient holes. In Short Span the bars pass through the shelf and shelf beam. In Medium Span they only pass through the holes in the in-fill panels.

Size

Standard sizes of 2105, 2305, and 2505mm.

Material

6mm diameter steel bar.

Finish

Zinc plated.

Part Codes

2105mm = 444032101, 2305mm = 444032102, 2505mm = 444032103.

Issue: September 2006

Section E – Accessories

Page E.2


BAY DIVIDER

Use

Used to segregate standing stock, the divider hooks over either the short span shelf beam, or the medium span beam.

Size

Two sizes either 350, or 470mm.

Material

19 x 1mm steel tube, 2.5mm steel bracket, and PVC end plug.

Finish

Bright Zinc Plated

Part Codes

350mm = 444047601, 470mm = 444047602.

Issue: September 2006

Section E – Accessories

Page E.3


TUBE RAIL

Use

Can be used on its own as a clothing rail, or in pairs to support tyres etc. Items can be hung from the rail by using hooks.

Length

A steel tube with flattened ends bent over to locate over the tube rail supports. Lengths to suit bay sizes of 900, 1000, 1290, and 1500mm.

Load

Load capacity of a single rail is 60kg. Load capacity on a pair of rails is 80kg per pair.

Design

The frame design should be based on the shelf spacing between the restraints above and below the tube rails. Short Span 900, 1000, and 1290mm rails. For a spacing greater than 800mm but less than 2000mm use the value for the 800mm spacing (for the 600-800 frame width), divided by 15. Medium Span 1500mm rails. For spacing up to 1500mm use the value shown. For a spacing greater than 1500mm but less than 2000mm use the value for the 800mm spacing divided by 15.

Material + Finish

32 x 2mm pre-galvanised steel tube.

Part Codes

900mm = 444032206, 1000mm = 444032202, 1290mm = 444032204,1500mm = 444032205.

Issue: September 2006

Section E – Accessories

Page E.4


TUBE RAIL SUPPORT

Use

These supports clip into the hooks on the upright web, and support either end of the tube rail. The support is provided with recesses for exact placement of the rails. A pair of supports will accommodate either one or two tubes.

Size

To suit frame widths of 300, 400, 450, 500, 600, 800, and 1000mm.

Rail Centres

When supporting one rail, the rail will be at mid-span. When supporting two rails their centres (#) will be: 300mm frame 110mm centres 400mm frame 190mm centres 450mm frame 210mm centres 500mm frame 220mm centres 600mm frame 260mm centres 800mm frame 340mm centres 1000mm frame 440mm centres

Load

Load capacity per pair of supports is 80kg.

Material

1.2mm thick pre-galvanised steel.

Finish

Zinc plated.

Part Codes

One piece, 300mm = 444030401, 400mm = 444030402, 450mm = 444030407, 500mm = 444030403, 600mm = 444030404, 800mm = 444030405, 1000mm = 444030406.

Issue: September 2006

Section E – Accessories

Page E.5


S–HOOK and S–HOOK 90

Use

Used to hang light items from a tube rail above.

S-Hook

130mm in length.

S-Hook 90

Similar to the S-Hook but only 120mm long and with one shank at an angle of 90° to the first.

Material

5mm diameter steel.

Finish

Galvanised

Part Codes

S-Hook = 441031900, S-Hook 90 = 441032000.

Issue: September 2006

Section E – Accessories

Page E.6


SIGN HOLDER, INSERT and COVER

Use

A sign that can be put up at the ends of rows of shelving to assist identification and orientation of the installation. A label can be inserted on either side of the holder. The signs clip into the hooks on the web of the upright.

Sign Holder (A)

1.6mm thick pre-galvanised steel holder.

Sign Insert (B)

A6 white cardboard insert measuring 148 x 105mm.

Sign Cover (C)

A6 clear celluloid cover measuring 148 x 105mm.

Part Codes

Sign holder = 444033600, insert = 18218800, and cover = 18218900.

Issue: September 2006

Section E – Accessories

Page E.7


LABEL HOLDER and INSERT

Use

A label holder with self adhesive tape on the reverse face for fixing to bins, shelves, beams etc..

Label Holder (A)

Clear plastic label holder measuring 75mm long x 23mm high.

Label Insert (B)

White cardboard inserts measuring 75 x 22mm.

Part Codes

Label holder = 441952601, and insert = 441954101.

Issue: September 2006

Section E – Accessories

Page E.8


SECTION F - DRAWER and TRAY SETS INTRODUCTION Drawer and tray sets are only available within short span shelving. Individual drawers and trays are not necessarily available in each of the bay length and frame width options. Care should be taken to ensure the items selected are available. All shelving that includes either drawers and or trays must have all perimeter baseplates securely fixed to the floor to prevent the units overturning. The baseplates must also be screwed to the upright through the hole provided.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.1


PULL OUT TRAY

Use

Used for the storage of flat items such as drawings.

Size

Two standard sizes to suit bay dimensions of: 1000x400, and 1000x500mm. All trays are 24mm high, providing an internal storage height of 23mm.

Fixings

Supported on a pair of expansion slides which are attached via the rectangular holes on the short sides of the tray.

Load

Maximum load 60kg evenly distributed.

Material

1.0mm thick steel.

Finish

Pre-galvanised.

Part Codes

1000x400mm tray = 444017652, new code. 1000x500mm tray = 444017651, new code.

Special Request

The following sizes are also available through the “special request” process. 1290x400, and 1290x500mm trays.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.2


GASKET TRAY

Use

A tray with a perforated base permitting the use of divider pins. The front edge of the tray incorporates a hand grip.

Size

One standard size to suit a bay dimension of 1000x500mm. The tray is 30mm high, providing an internal storage height of 29mm. 5mm diameter holes on a 20 x 20mm grid.

Fixings

Supported on a pair of expansion slides which are attached via the rectangular holes on the short sides of the tray.

Load

Maximum load 60kg evenly distributed.

Material

1.0mm thick steel.

Finish

Painted Grey White RAL 9002.

Part Codes

1000x500mm tray = 444035801.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.3


GASKET TRAY PIN

Use

Used to divide the gasket tray and to provide location for storing washers, gaskets, gear wheels etc.

Size

41mm long pin with one end threaded. The pin is fastened from the underside of the tray with a 5mm nut.

Material

6mm diameter bar.

Finish

Zinc plated.

Part Codes

Pin = 18175600, M5 nut = 731231401.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.4


PULL OUT DRAWER

Use

A drawer with raised sides for the storage of small parts. Each drawer can be sub divided using front to back partitions that locate into the grooves within the partition holders which are placed along the front and rear edges of the drawer. The front edge of the tray incorporates a hand grip.

Size

Two standard sizes to suit bay dimensions of: 1000x400, and 1000x500mm. Each tray is available in two height options either 75 or 150mm high, providing internal storage heights of 63 or 138mm.

Fixings

Supported on a pair of expansion slides which are attached via the rectangular holes on the short sides of the tray.

Load

Maximum load 60kg evenly distributed.

Material

0.8mm thick steel.

Finish

Painted Grey White RAL 9002.

Part Codes

1000x400x75mm = 4440338541, and 1000x400x150mm = 4440338542. 1000x500x75mm = 4440338551, and 1000x500x150mm = 4440338552.

Special Request

The following sizes are also available through the “special request” process. 1290x400x75, and 1290x400x150mm drawers. 1290x500x75, and 1290x500x150mm drawers.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.5


PULL OUT DRAWER – FRONT to BACK PARTITION

Use

Used to sub divide the drawer into full depth compartments. The upper and lower edges of the partition have been rolled for safety. The ends of these partitions fit into the grooves in the partition holder.

Size

Two sizes to suit either the 400 or 500mm drawer, and two heights to suit either 75 or 150mm drawers.

Material

0.7mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

400x75mm = 444034041, 400x150mm = 444034042. 500x75mm = 444034051, 500x150mm = 444034052.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.6


PULL OUT DRAWER – PARTITION HOLDER

Use

Profiled section placed against both the inside front and rear faces of the drawer to accommodate the front to back partition. Holders for the 1000mm drawer have 11 grooves at 77.6mm centres (#) allowing up to 12 compartments. Holders for the 1290mm drawer have 14 grooves at 82mm centres (#) allowing up to 15 compartments.

Size

One size to suit the 1000mm drawer, and two heights to suit either 75 or 150mm high drawers.

Material

0.7mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

1000x75mm = 444034111, 1000x150mm = 444034112.

Special Request

The following sizes are also available through the “special request” process. 1290x75mm, and 1290x150mm holders.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.7


EXPANSION SLIDE (100% PULL OUT)

Use

Used in pairs to support drawers and trays. Each slide consists of profiled sections containing bearings. These slides offer 100% pull out giving either 374 or 472mm extension.

Size

Left and Right hand options to suit either 400 or 500mm drawer / tray sets.

Load

Maximum load per pair of slides is 60kg evenly distributed

Finish

Zinc plated.

Part Codes

400mm slide: left hand = 444029404, right hand = 444029403. 500mm slide: left hand = 444029402, right hand = 444029401.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.8


EXPANSION SLIDE HOLDER

Use

The holder is used for fixing the expansion slides to the shelving uprights. It hooks into the hooks in the upright web and is secured with a single M5x16 screw and locking nut through one of the round holes in the holder into a corresponding hole in the upright web. Two left and two right hand holders are required for one pair of expander slides. Where trays are located close together it is possible for a set of holders to support two pairs of expanders.

Size

Left and Right hand options.

Material

1.25mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

Holder complete with fixings: left = 450752329, right = 450752328.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.9


SHELF DRAWER

Use

‘Shelf drawers’ are designed to be positioned directly on the HI280 shelves.

Sizes

Two sizes of drawer are available, with nominal dimensions of: 500 x 313 x 99mm high, (3 drawers side by side on a 1000mm shelf) 500 x 156 x 99mm high, (6 drawers side by side on a 1000mm shelf)

Dividers

If required the items being stored can be segregated with the use of dividers. These dividers are 97mm high and available for each size of drawer. Their position is adjustable front to back on a 33mm pitch.

Material

0.5mm and 0.7mm thick steel.

Finish

Painted Grey White RAL 9002.

Part Codes

Drawer 500 x 313 x 99mm high = 635680 (drawer only). Drawer 500 x 156 x 99mm high = 635681 (drawer only). Drawer divider 313 = 636616 (one piece). Drawer divider 156 = 636618 (one piece).

Design Note

It is important that when drawers are supported directly on a shelf that the shelf immediately above is secured in position with either two guides/locks or four shelf locks. This is to ensure that the shelf is not dislodged by the drawers when they are cantilevered out in front of the bay. These guides / locks must be riveted in position.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.10


DRAWER STOP

Use

A drawer stop can be fitted to the front of a shelf that supports drawers. The small upstand on the section helps locate the drawers within the confines of the shelf. This is particularly useful in applications such a ‘ship shelving and cabinets’ or within ‘mobile shelving’.

Description

A ‘Z’ section with cut outs at either end that enables the section to locate behind the uprights.

Size

Available in a single size to suit a 1000mm shelf.

Material

1.5mm thick steel.

Finish

Painted Grey White RAL 9002.

Part Code

444034152.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.11


DRAWER SIDE GUIDE AND SHELF LOCK

Use

This component provides two functions; firstly it acts as a side guide for the shelf drawers so that they don’t get stuck behind the uprights, and secondly they can be used to lock the shelf in position should it be necessary, such as within ‘ship shelving’. Two guides are used per shelf.

Description

A folded steel strip 95mm high, 436mm long and 20mm wide, with two holes at both ends. The spacing of these holes ensures that one hole at either end will always line up with a corresponding hole in the upright web.

Sizes

Available to suit a frame width of 500mm.

Fixings

It is not necessary to fix the guide within normal static applications, however within ship shelving two 4.8x7 SST rivets should be used, one at either end of the section.

Material

0.7mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

Guide / lock = 444034150. Rivet = 722786309 (one piece).

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.12


SHELF LOCK

Use

Used to secure the corner of the shelf in position to prevent it lifting. Each shelf is fitted with 4 locks. By locking the back corners of the shelf, the beams are also locked into position. Used on shelves that are directly above a shelf supporting drawers.

Description

A steel strip folded to form a 75 x 15mm hook with two holes spaced 25mm apart on the long leg. The spacing of these holes ensures that one hole will always line up with a corresponding hole in the upright web.

Fixings

One 4.8x7 SST rivet through either of the holes.

Material

1.25mm thick pre-galvanised steel.

Finish

Pre-galvanised.

Part Codes

Shelf lock = 444034151. Rivet = 722786309.

Issue: September 2006

Section F – Drawer and Tray Sets

Page F.13


SECTION G - DOOR SETS INTRODUCTION

Availability

Door sets are only available within short span shelving.

Use

An existing fully clad bay of shelving can be fitted with lockable double doors thus providing a secure environment for the goods being stored. Doors can be either full height or part height. Part height doors may be positioned at the bottom of a shelving unit, or at mid-height as desired.

Door Sizes + Codes Available in the following sizes: Size Different locking 2100 high x 900mm 444050950 1000 high x 1000mm 444050980 1600 high x 1000mm 444050990 2100 high x 1000mm 444050960 2100 high x 1290mm 444050970

Similar locking 444050952 444050982 444050992 444050962 444050972

Handle + Lock

Each door set is complete with a combined handle and locking system. Rotation of the inner handle extends or retracts the locking rods that secure the doors. The lock styles are described on the lock page.

Components

The above part codes contain all the necessary components required to install the doors. The right hand door that contains the locking arrangement is supplied pre-assembled with handle, lock, locking rods etc. The main items are described in the following pages.

Note

Don’t fit door sets in bays adjacent to bench tops, the bench top prevents the door being opened fully. Bays with doors should be fully fixed down.

Issue: September 2006

Section G – Door Sets

Page G.1


DOOR LEFT and DOOR RIGHT

Use

Always used as a pair.

Door Left

The two short edges and the long free edge of the door are 20mm deep, whilst the hinged edge is extended at an angle to 32mm. A reinforcing panel is welded into the reverse of the door to provide strength and rigidity. Two pin hinges are provided in the top and bottom corners of the door, these locate into the loops provided on the top and bottom pieces.

Door Right

Similar to the Door Left but with hinges on the opposite corners. This door also accommodates the combined door handle and lock. This arrangement is supplied pre-assembled for ease of installation on site.

Door Dimension

The doors when hung on the top and bottom pieces extend approximately 35mm in front of the front face of the uprights. The combined handle and lock then extend beyond this by a further 13mm.

Material

0.8mm thick steel.

Finish

Painted Grey White RAL 9002.

Issue: September 2006

Section G – Door Sets

Page G.2


TOP and BOTTOM PIECES

Use

The top and bottom pieces accommodate the pin hinges located on each door, and provide a location for the ends of the locking rods that are contained within the door right. There is also a rubber pad for the door left to close against. The pieces slide over the front face of the top and bottom shelves. The angle bracket for the locking rods is always on the right hand side as shown.

Length ‘L’

To suit the three standard bay lengths of 900, 1000, and 1290mm.

Fixings

2 No black plastic expanding fixings per piece. These fixings are pushed through the holes in either the top or bottom piece and into the corner holes on the top face of the shelf. Once through both pieces of material the stem of the fixing is hit with a soft hammer to expand the fingers, thus securing the top or bottom piece in position.

Material

1.5mm thick steel.

Finish

Painted Grey White RAL 9002.

Issue: September 2006

Section G – Door Sets

Page G.3


HANDLE and LOCK

Use

This a combined handle and lock arrangement. Rotation of the wedge shaped handle through 90° within the surrounding housing, either extends or retracts the locking rods that are attached to mechanism.

Flush Mounted

Unlike conventional handles this is a flush mounted arrangement only extending in front of the door leaf by 13mm. This leaves the operating aisle free from obstruction eliminating hazards and the risk of damage and injury.

Pre-assembled

The handle, lock and mechanism are supplied pre-assemble for ease of installation on site.

Lock Style

As standard door sets are supplied with ‘different locking’, which means every door has its own different key. As an alternative ‘similar locking’ can be supplied, this is where all doors within a system can be opened by the same common key.

Finish

Black plastic housing.

Issue: September 2006

Section G – Door Sets

Page G.4


SECTION H - LOW RISE SHORT SPAN APPLICATIONS and DESIGN INTRODUCTION This section of the manual covers the design of ‘Low Rise Short Span Shelving’ i.e. Low Rise : shelving heights between 1000 and 3000mm. Short Span : bay lengths of 900, 1000, and 1290mm. Shelving outside of this range will be covered in a separate section of the manual. The components for this type of shelving are described within: Section B : Frame Components. Section C : Short Span Bay Components. Design Data The design data contained within this manual is in accordance with the recommendations of “The Federation Europeenne de la Manutention” (FEM) Code 10.2.06. Frame/Upright Types All types of upright are permitted within ‘Low Rise Short Span Shelving’. Erection Tolerance For the design data to remain accurate it is important that the shelving is installed within a tolerance of 1/350 both across and down the aisle. (i.e. a 3500mm frame must be installed within 10mm of plumb). Minimum Number of Bays The design tables are based on a minimum of 3 consecutive bays per rack. If a rack contains fewer bays, then the allowable bay load from the design tables needs to be reduced by multiplying by the following factors. Single bay racks (or sections of rack): multiply by 0.8 Two bay racks (or sections of rack): multiply by 0.9 Different Bay Styles within the same Rack – Bay Load When designing racks that contain bays of the same height, but different bay loads. Design the highest loaded bay according to the total number of bays of this type (i.e. applying the 0.8 or 0.9 factors for short racks). Design each type of lower loaded bay according to the total number of bays of this type including bays of the higher load. Therefore a single low loaded bay may be designed as a multi-bay rack if it is with at least two other higher loaded bays. Different Bay Styles within the same Rack – Bay Height When designing racks that contain bays of different height, each section should be designed for the actual number of bays together of that height. Apply the 0.8 and 0.9 factors as appropriate.

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.1


DESIGN PROCESS

Sketch the desired rack. Indicate bay length, width, and height. Show the number of shelf levels, the desired load per shelf and the pitch between these shelves.

Check the shelf design. The most cost effective design will be to use a N normal duty shelf if available in the size you require, followed by a S standard and then a non-reinforced H heavy duty shelf. After that a reinforced H heavy duty shelf with either one or two reinforcement bars.

Check the bay design. Select the preference for either an open frame or a clad frame. The most cost effective open frame will have S uprights with the least allowable number of battens. Check the design of that frame first, and if it fails progress through to an increased number of battens or the use of the K or EK upright.

Check the baseplate and floor fixing requirements. This involves checking the load through the baseplate, and the height to width ratio of the bay. If a bay contains drawer or tray sets it MUST be fixed down regardless of its ratio.

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.2


DESIGN TABLES The following tables are provided. Table H1:

Shelf Capacity Capacity of the shelf and beam using, none, one, or two reinforcing bars.

Table H2:

Bay Capacity Rack heights up to 2100mm. All uprights, 900 and 1000mm bay lengths.

Table H3:

Bay Capacity Rack heights up to 2100mm. All uprights, 1290mm bay lengths.

Table H4:

Bay Capacity Rack heights of 2300 and 2500mm. All uprights, 900 and 1000mm bay lengths.

Table H5:

Bay Capacity Rack heights of 2300 and 2500mm. All uprights, 1290mm bay lengths.

Table H6:

Bay Capacity Rack heights of 3000mm. All uprights, 900 and 1000mm bay lengths.

Table H7:

Bay Capacity Rack heights of 3000mm. All uprights, 1290mm bay lengths.

------------------------------------------------------------------------------------------

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.3


New table Table H1:

Shelf Capacity in kg. Capacity of the shelf and beam using either none, one, or two reinforcing bars.

Shelf size

300x900 300x1000 300x1290

400x900

400x1000

400x1290

450x900 450x1000 450X1290 500x900 500x1000 500x1290 600x900 600x1000 600x1290 800x900 800x1000 800x1290

Issue: Sept 2006

Shelf t mm

Shelf Duty

Without bars. kg

0.5 0.7 0.5 0.7 0.5 0.7

N H N H N H

0.5 0.6 0.7 0.5 0.6 0.7 0.5 0.6 0.7

With 1 bar.

With 2 bars.

kg

kg

140 235 135 235 70 110

260 260 235

300 300 350

N S H N S H N S H

140 160 235 140 150 235 75 85 110

260 260 235

300 300 350

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

160 235 150 235 85 110

260 260 235

300 300 350

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

170 235 150 235 85 110

260 260 235

300 300 350

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

150 215 140 215 100 120

290 290 215

380 380 310

0.7 0.7 0.7

H H H

110 110 120

290 290 215

380 380 310

Section H – Low Rise Short Span Applications + Design

Page H.4


Table H2:

Bay Capacity in kg. Rack heights up to 2100mm. All uprights types, 900 and 1000mm bay lengths. Minimum 3 bays per rack.

Upright type ‘S’ 2 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 1057 300mm 1057 400mm 1057 500mm 1057 600mm 1057 700mm 1057 800mm 1057

Frame widths 600-800mm 1163 1163 1163 1163 1163 1163 1163

3 Batten Frames or Fully Clad Frames Frame Shelf Frame widths spacing widths 300-500mm 600-800mm 200mm 1609 1757 300mm 1609 1757 400mm 1609 1757 500mm 1609 1643 600mm 1592 1592 700mm 1533 1533 800mm 1478 1478

Upright type ‘K’

Upright type ‘EK’

Frame widths 300-500mm 1774 1774 1774 1774 1774 1774 1774

Frame widths 600-800mm 2034 2034 2034 2034 2034 2034 2027

Frame widths 300-500mm 1774 1774 1774 1774 1774 1774 1774

Frame widths 600-800mm 2034 2034 2034 2034 2034 2034 2027

Frame widths 300-500mm 2813 2813 2813 2540 2254 2042 2027

Frame widths 600-800mm 3071 3071 3028 2540 2254 2042 2027

Frame widths 300-500mm 2813 2813 2813 2540 2254 2042 2027

Frame widths 600-800mm 3071 3071 3028 2540 2254 2042 2027

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.5


Table H3:

Bay Capacity in kg. Rack heights up to 2100mm. All uprights types, 1290mm bay lengths. Minimum 3 bays per rack. Upright type ‘S’

2 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 1057 300mm 1057 400mm 1057 500mm 1057 600mm 1057 700mm 1057 800mm 1057

Frame widths 600-800mm 1163 1163 1163 1163 1163 1163 1163

3 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing widths widths 300-500mm 600-800mm 200mm 1609 1757 300mm 1609 1757 400mm 1609 1737 500mm 1609 1615 600mm 1587 1587 700mm 1523 1523 800mm 1447 1447

Upright type ‘K’

Upright type ‘EK’

Frame widths 300-500mm 1774 1774 1774 1774 1774 1774 1774

Frame widths 600-800mm 2034 2034 2034 2034 2034 2004 1988

Frame widths 300-500mm 1774 1774 1774 1774 1774 1774 1774

Frame widths 600-800mm 2034 2034 2034 2034 2034 2004 1988

Frame widths 300-500mm 2813 2813 2813 2622 2326 2004 1988

Frame widths 600-800mm 3071 3071 3071 2622 2326 2004 1988

Frame widths 300-500mm 2813 2813 2813 2622 2326 2004 1988

Frame widths 600-800mm 3071 3071 3071 2622 2326 2004 1988

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.6


Table H4:

Bay Capacity in kg. Rack heights 2300 and 2500mm. All uprights types, 900 and 1000mm bay lengths. Minimum 3 bays per rack. Upright type ‘S’

Upright type ‘K’

Upright type ‘EK’

2 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 728 300mm 728 400mm 728 500mm 728 600mm 728 700mm 728 800mm 728

Frame widths 600-800mm 810 810 810 810 810 810 810

Frame widths 300-500mm 1218 1218 1218 1218 1218 1218 1218

Frame widths 600-800mm 1416 1416 1416 1416 1416 1416 1416

Frame widths 300-500mm 1262 1262 1262 1262 1262 1262 1262

Frame widths 600-800mm 2484 2484 2484 2484 2484 2207 2005

3 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 1542 300mm 1542 400mm 1542 500mm 1406 600mm 1338 700mm 1306 800mm 1208

Frame widths 600-800mm 1723 1723 1576 1406 1338 1306 1208

Frame widths 300-500mm 2696 2696 2667 2182 1890 1709 1553

Frame widths 600-800mm 2997 2997 2667 2182 1890 1709 1553

Frame widths 300-500mm 2802 2802 2802 2802 2555 2207 2005

Frame widths 600-800mm 3886 3886 3444 2954 2555 2207 2005

Frame widths 300-500mm 2997 2997 2667 2182 1890 1709 1553

Frame widths 600-800mm 2997 2997 2667 2182 1890 1709 1553

Frame widths 300-500mm 3886 3886 3444 2954 2555 2207 2005

Frame widths 600-800mm 3886 3886 3444 2954 2555 2207 2005

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing widths widths 300-500mm 600-800mm 200mm 1741 1741 300mm 1741 1741 400mm 1576 1576 500mm 1406 1406 600mm 1338 1338 700mm 1306 1306 800mm 1208 1208

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.7


Table H5:

Bay Capacity in kg. Rack heights 2300 and 2500mm. All uprights types, 1290mm bay lengths. Minimum 3 bays per rack. Upright type ‘S’

Upright type ‘K’

Upright type ‘EK’

2 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 728 300mm 728 400mm 728 500mm 728 600mm 728 700mm 728 800mm 728

Frame widths 600-800mm 810 810 810 810 810 810 810

Frame widths 300-500mm 1218 1218 1218 1218 1218 1218 1218

Frame widths 600-800mm 1416 1416 1416 1416 1416 1416 1416

Frame widths 300-500mm 1262 1262 1262 1262 1262 1262 1262

Frame widths 600-800mm 2484 2484 2484 2484 2484 2315 1975

3 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 1542 300mm 1542 400mm 1528 500mm 1379 600mm 1368 700mm 1286 800mm 1181

Frame widths 600-800mm 1714 1714 1528 1379 1368 1286 1181

Frame widths 300-500mm 2696 2696 2686 2254 2092 1673 1520

Frame widths 600-800mm 3012 3012 2686 2254 2092 1673 1520

Frame widths 300-500mm 2802 2802 2802 2802 2746 2315 1975

Frame widths 600-800mm 4180 4180 3637 3160 2746 2315 1975

Frame widths 300-500mm 3044 3044 2686 2254 2092 1673 1520

Frame widths 600-800mm 3044 3044 2686 2254 2092 1673 1520

Frame widths 300-500mm 4180 4180 3637 3160 2746 2315 1975

Frame widths 600-800mm 4180 4180 3637 3160 2746 2315 1975

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing widths widths 300-500mm 600-800mm 200mm 1714 1714 300mm 1714 1714 400mm 1528 1528 500mm 1379 1379 600mm 1368 1368 700mm 1286 1286 800mm 1181 1181

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.8


Table H6:

Bay Capacity in kg. Rack heights 3000mm. All uprights types, 900 and 1000mm bay lengths. Minimum 3 bays per rack. Upright type ‘S’

Upright type ‘K’

Upright type ‘EK’

3 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 1302 300mm 1302 400mm 1302 500mm 1208 600mm 1177 700mm 1027 800mm 1027

Frame widths 600-800mm 1388 1388 1388 1208 1177 1027 1027

Frame widths 300-500mm 2002 2002 2002 1847 1535 1320 1320

Frame widths 600-800mm 2426 2426 2098 1847 1535 1320 1320

Frame widths 300-500mm 2074 2074 2074 2074 2074 1728 1638

Frame widths 600-800mm 3344 3344 2704 2538 2182 1728 1638

4 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 1478 300mm 1478 400mm 1433 500mm 1208 600mm 1177 700mm 1027 800mm 1027

Frame widths 600-800mm 1533 1533 1433 1208 1177 1027 1027

Frame widths 300-500mm 2584 2584 2098 1847 1535 1320 1320

Frame widths 600-800mm 2724 2724 2098 1847 1535 1320 1320

Frame widths 300-500mm 3178 3178 2704 2538 2182 1728 1638

Frame widths 600-800mm 3344 3344 2704 2538 2182 1728 1638

4 Batten + 2’X’ Braced Frames (#) or Fully Clad Frames Frame Frame Frame Shelf Frame widths widths widths spacing widths 300-500mm 600-800mm 300-500mm 600-800mm 200mm 1556 1533 2720 2720 300mm 1556 1533 2720 2720 400mm 1433 1433 2098 2098 500mm 1208 1208 1847 1847 600mm 1177 1177 1535 1535 700mm 1027 1027 1320 1320 800mm 1027 1027 1320 1320

Frame widths 300-500mm 3344 3344 2704 2538 2182 1728 1638

Frame widths 600-800mm 3344 3344 2704 2538 2182 1728 1638

(#) The 800mm wide battened and braced frame, has 3 heavy battens, not 4 light duty battens. For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.9


Table H7:

Bay Capacity in kg. Rack heights 3000mm. All uprights types, 1290mm bay lengths. Minimum 3 bays per rack. Upright type ‘S’

Upright type ‘K’

Upright type ‘EK’

3 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 1302 300mm 1302 400mm 1302 500mm 1302 600mm 1194 700mm 1002 800mm 1002

Frame widths 600-800mm 1388 1388 1371 1307 1194 1002 1002

Frame widths 300-500mm 2002 2002 2002 1959 1600 1300 1300

Frame widths 600-800mm 2426 2426 2027 1959 1600 1300 1300

Frame widths 300-500mm 2074 2074 2074 2074 2074 1709 1610

Frame widths 600-800mm 3772 3772 2872 2634 2238 1709 1610

4 Batten Frames Shelf Frame spacing widths 300-500mm 200mm 1478 300mm 1478 400mm 1371 500mm 1307 600mm 1194 700mm 1002 800mm 1002

Frame widths 600-800mm 1533 1533 1371 1307 1194 1002 1002

Frame widths 300-500mm 2584 2584 2027 1959 1600 1300 1300

Frame widths 600-800mm 2766 2766 2027 1959 1600 1300 1300

Frame widths 300-500mm 3178 3178 2872 2634 2238 1709 1610

Frame widths 600-800mm 3772 3772 2872 2634 2238 1709 1610

4 Batten + 2’X’ Braced Frames (#) or Fully Clad Frames Frame Frame Frame Shelf Frame widths widths widths spacing widths 300-500mm 600-800mm 300-500mm 600-800mm 200mm 1556 1533 2720 2720 300mm 1556 1533 2720 2720 400mm 1371 1371 2027 2027 500mm 1307 1307 1959 1959 600mm 1194 1194 1600 1600 700mm 1002 1002 1300 1300 800mm 1002 1002 1300 1300

Frame widths 300-500mm 3772 3772 2872 2634 2238 1709 1610

Frame widths 600-800mm 3772 3772 2872 2634 2238 1709 1610

(#) The 800mm wide battened and braced frame, has 3 heavy battens, not 4 light duty battens. For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.10


BASEPLATE and FLOOR FIXING REQUIREMENTS

Baseplate Select the required baseplate by checking the load passing through the plate into the floor. Standard baseplate = 1500kg per upright (i.e. 3000kg/frame). Standard baseplate plus Heavy Duty levelling plate = 2500kg per upright (5000kg/frame). High Rise baseplate = 3000kg per upright (6000kg/frame).

Floor Fixings Floor fixings are necessary to securely locate the frames in position and to resist overturning. The quantity of floor fixings required will depend on the rack application, and its height to width ratio. If a baseplate is fixed down it must also be secured to the upright. Height To Width Ratio Definition - Single Entry Racks The height to the top loaded level divided by the frame width, i.e. a height of 2500mm and a frame width of 450mm, gives a height to width ratio of 5.56. Height To Width Ratio Definition - Double Entry Racks With frames bolted back to back at the top and bottom, with M6x20mm fixings. The height to the top loaded level divided by the combined frame width, i.e. a height of 2500mm and a combined width of 900mm, gives a height to width ratio of 2.78. Height to Width Ratio not greater than 5 to 1 Providing mechanical handling equipment can not approach, no floor fixings are required. Height to Width Ratio greater than 5 to 1, but less than 8 to 1 Standard baseplate: perimeter uprights must be fixed down with a hammer screw. High Rise baseplate: perimeter uprights must be fixed down with expander bolts. Height to Width Ratio greater than 8 to 1, but less than 10 to 1 Standard baseplate: perimeter uprights must be fixed down with expander bolts. High Rise baseplate: perimeter uprights must be fixed down with expander bolts. Height to Width Ratio greater than 10 to 1 No low rise rack should have a ratio greater than 10 to 1. All racks containing either drawers, trays or doors must be perimeter fixed. All racks must be considered for any special requirements that may require additional floor fixings.

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.11


DESIGN EXAMPLE ONE

Using the above example to demonstrate the correct design procedure. The client has a preference for open frames. Each rack contains 5 bays of shelving within the length. Step 1.

Shelf selection. Using design Table H1 check the suitability of the steel shelves. 1000 x 450mm ‘S’ Standard shelf will support 150kg. Therefore OK to use: ‘S’ Standard duty shelves.

Step 2.

Frame selection. Using design Table H2 for a 2100mm high rack with a bay length of 1000mm. The frame width is 450mm, with a maximum shelf spacing of 400mm. The allowable bay load for a 2 Batten Frame using type S uprights is 1057kg, which exceeds the required 1050kg. Therefore OK to use: 2 batten frame with type S uprights.

Step 3.

Baseplate and Floor fixing requirement. Each baseplate takes 525kg (1050kg/2). Therefore OK to use the Standard Baseplate. Single entry racks: height to width ratio equals 2100/450 = 4.66 Double entry racks: height to width ratio equals 2100/900 = 2.33 Therefore floor fixings are not required unless mechanical handing equipment is likely to come into contact with the rack.

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.12


DESIGN EXAMPLE TWO

Using the above example to demonstrate the correct design procedure. The client has a preference for open frames. Each rack ONLY contains 1 bay of shelving within the length. Step 1.

Shelf selection. Using design Table H1 check the suitability of the steel shelves. 1290 x 400mm ‘H’ heavy shelf will only support 110kg without reinforcement bars, but with one reinforcement bar the load increases to 235kg. Therefore OK to use: ‘H’ heavy duty shelves with 1 reinforcement bar per shelf.

Step 2.

Frame selection. Using design Table H5 for a 2500mm high rack with a bay length of 1290mm. The frame width is 400mm, with a maximum shelf spacing of 400mm. The allowable bay load for a: 2 Batten Frame using type K uprights is 974kg (1218kg x 0.8 single bay factor), 2 Batten Frame using type EK uprights is 1010kg (1262kg x 0.8 single bay factor), 3 Batten Frame using type S uprights is 1222kg (1528kg x 0.8 single bay factor), Therefore OK to use: 3 batten frame with type S uprights.

Step 3.

Baseplate and Floor fixing requirement. Each baseplate takes 525kg (1050kg/2). Therefore OK to use: Standard Baseplate. Single entry racks: height to width ratio equals 2500/400 = 6.25 Double entry racks: height to width ratio equals 2500/800 = 3.13 Therefore the single entry rack must be fully fixed down, whilst the double entry does not require fixings unless mechanical handing equipment is likely to come into contact with the rack.

Issue: Sept 2006

Section H – Low Rise Short Span Applications + Design

Page H.13


SECTION J - LOW RISE MEDIUM SPAN APPLICATIONS and DESIGN INTRODUCTION This section of the manual covers the design of ‘Low Rise Medium Span Shelving’ i.e. Low Rise : shelving heights between 1000 and 3000mm. Medium Span : bay lengths between 1500, and 2500mm. Shelving outside of this range will be covered in a separate section of the manual. The components for this type of shelving are described within: Section B : Frame Components. Section D : Medium Span Bay Components. Design Data The design data contained within this manual is in accordance with the recommendations of “The Federation Europeenne de la Manutention” (FEM) Code 10.2.06. Frame/Upright Types Type S uprights are NOT permitted within ‘Low Rise Medium Span Shelving’. Erection Tolerance For the design data to remain accurate it is important that the shelving is installed within a tolerance of 1/350 both across and down the aisle. (i.e. a 3500mm frame must be installed within 10mm of plumb). Minimum Number of Bays The design tables are based on a minimum of 3 consecutive bays per rack. If a rack contains fewer bays, then the allowable bay load from the design tables needs to be reduced by multiplying by the following factors. Single bay racks (or sections of rack): multiply by 0.8 Two bay racks (or sections of rack):: multiply by 0.9 Different Bay Styles within the same Rack – Bay Load When designing racks that contain bays of the same height, but different bay loads. Design the highest loaded bay according to the total number of bays of this type (i.e. applying the 0.8 or 0.9 factors for short racks). Design each type of lower loaded bay according to the total number of bays of this type including bays of the higher load. Therefore a single low loaded bay may be designed as a multi-bay rack if it is with at least two other higher loaded bays. Different Bay Styles within the same Rack – Bay Height When designing racks that contain bays of different height, each section should be designed for the actual number of bays together of that height. Apply the 0.8 and 0.9 factors as appropriate.

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.1


DESIGN PROCESS

Sketch the desired rack. Indicate bay length, width, and height. Show the number of shelf levels, the desired load per shelf and the pitch between these shelves.

Check the shelf design. Select the preference for either steel shelves or chipboard. Check the required load against the permissible for the selected shelf material.

Check the bay design. Select the preference for either an open frame or a clad frame. The most cost effective open frame will have K uprights with the least allowable number of battens. Check the design of that frame first, and if it fails progress through to an increased number of battens or the use of the EK upright.

Check the baseplate and floor fixing requirements. This involves checking the load through the baseplate, and the height to width ratio of the bay.

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.2


DESIGN TABLES The following tables are provided. Table J1:

Steel Shelf Capacity. Steel shelves supported by a pair of medium span beams.

Table J2:

Chipboard Shelf Capacity. Chipboard supported on cross beams between a pair of medium span beams.

Table J3:

Bay Capacity Rack heights up to 2100mm, K and EK uprights, 1500mm bay lengths.

Table J4:

Bay Capacity Rack heights up to 2100mm, K and EK uprights, 1750 and 2000mm bay lengths.

Table J5:

Bay Capacity Rack heights up to 2100mm, K and EK uprights, 2250 and 2500mm bay lengths.

Table J6:

Bay Capacity Rack heights 2300 and 2500mm, K and EK uprights, 1500mm bay lengths.

Table J7:

Bay Capacity Rack heights 2300 and 2500mm, K and EK uprights, 1750 and 2000mm bay lengths.

Table J8:

Bay Capacity Rack heights 2300 and 2500mm, K and EK uprights, 2250 and 2500mm bay lengths.

Table J9:

Bay Capacity Rack heights of 3000mm, K and EK uprights, 1500mm bay lengths.

Table J10:

Bay Capacity Rack heights of 3000mm, K and EK uprights, 1750 and 2000mm bay lengths.

Table J11:

Bay Capacity Rack heights of 3000mm, K and EK uprights, 2250 and 2500mm bay lengths.

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.3


Table J1:

Steel Shelf Capacity. Steel shelves supported by a pair of medium span beams.

Table J2:

Bay length mm

Shelf capacity kg

1500 1750 2000 2250 2500

400 400 400 400 350

Chipboard Shelf Capacity. Chipboard supported on cross beams between a pair of medium span beams. 18mm thick chipboard Grade P3 to European Standard EN312-3.

Bay length mm

500mm

1500 1750 2000 2250 2500

310 360 415 400 330

Frame width 600mm 800mm 370 435 490 400 330

390 520 490 400 330

1000mm

No of cross beams

390 520 490 400 330

4 5 5 6 6

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.4


Table J3:

Bay Capacity Rack heights up to 2100mm, K and EK uprights, 1500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1774 300mm 1774 400mm 1774 500mm 1774 600mm 1774 700mm 1665 800mm 1556 900mm 1446 1000mm 1337 1100mm 1219 1200mm 1101 1300mm 982 1400mm 864 1500mm 746

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2813 300mm 2681 400mm 2549 500mm 2416 600mm 2284 700mm 2047 800mm 1811 900mm 1574 1000mm 1337 1100mm 1219 1200mm 1101 1300mm 982 1400mm 864 1500mm 746

Upright type ‘EK’

Frame Widths 800 + 1000 mm 2034 2034 2034 2034 2034 1860 1686 1511 1337 1219 1101 982 864 746

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1774 300mm 1774 400mm 1774 500mm 1774 600mm 1774 700mm 1708 800mm 1643 900mm 1577 1000mm 1511 1100mm 1386 1200mm 1261 1300mm 1136 1400mm 1011 1500mm 886

Frame Widths 800 + 1000 mm 2484 2484 2484 2484 2484 2241 1998 1754 1511 1386 1261 1136 1011 886

Frame Widths 800 + 1000 mm 3071 2874 2678 2481 2284 2047 1811 1574 1337 1219 1101 982 864 746

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2813 300mm 2785 400mm 2756 500mm 2728 600mm 2699 700mm 2402 800mm 2105 900mm 1808 1000mm 1511 1100mm 1386 1200mm 1261 1300mm 1136 1400mm 1011 1500mm 886

Frame Widths 800 + 1000 mm 4624 4143 3662 3180 2699 2402 2105 1808 1511 1386 1261 1136 1011 886

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9 Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.5


Table J3:

Bay Capacity (continued). Rack heights up to 2100mm, K and EK uprights, 1500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

Upright type ‘EK’

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 3150 3366 300mm 2965 3127 400mm 2781 2889 500mm 2596 2650 600mm 2411 2411 700mm 2143 2143 800mm 1876 1876 900mm 1608 1608 1000mm 1340 1340 1100mm 1227 1227 1200mm 1115 1115 1300mm 1002 1002 1400mm 890 890 1500mm 777 777

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 4558 5138 300mm 4093 4528 400mm 3629 3919 500mm 3164 3309 600mm 2699 2699 700mm 2402 2402 800mm 2105 2105 900mm 1808 1808 1000mm 1511 1511 1100mm 1386 1386 1200mm 1261 1261 1300mm 1136 1136 1400mm 1011 1011 1500mm 886 886

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.6


Table J4:

Bay Capacity Rack heights up to 2100mm, K and EK uprights, 1750 and 2000mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1774 300mm 1755 400mm 1737 500mm 1718 600mm 1699 700mm 1540 800mm 1380 900mm 1221 1000mm 1061 1100mm 966 1200mm 871 1300mm 777 1400mm 682 1500mm 587

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2813 300mm 2535 400mm 2256 500mm 1978 600mm 1699 700mm 1540 800mm 1380 900mm 1221 1000mm 1061 1100mm 966 1200mm 871 1300mm 777 1400mm 682 1500mm 587

Upright type ‘EK’

Frame Widths 800 + 1000 mm 2034 1950 1867 1783 1699 1540 1380 1221 1061 966 871 777 682 587

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1774 300mm 1755 400mm 1737 500mm 1718 600mm 1699 700mm 1558 800mm 1416 900mm 1275 1000mm 1133 1100mm 1044 1200mm 955 1300mm 865 1400mm 776 1500mm 687

Frame Widths 800 + 1000 mm 2484 2361 2237 2114 1990 1776 1562 1347 1133 1044 955 865 776 687

Frame Widths 800 + 1000 mm 3071 2728 2385 2042 1699 1540 1380 1221 1061 966 871 777 682 587

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2813 300mm 2607 400mm 2402 500mm 2196 600mm 1990 700mm 1776 800mm 1562 900mm 1347 1000mm 1133 1100mm 1044 1200mm 955 1300mm 865 1400mm 776 1500mm 687

Frame Widths 800 + 1000 mm 4624 3966 3307 2649 1990 1776 1562 1347 1133 1044 955 865 776 687

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9 Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.7


Table J4:

Bay Capacity (continued). Rack heights up to 2100mm, K and EK uprights, 1750 and 2000mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

Upright type ‘EK’

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 3150 3366 300mm 2828 2990 400mm 2506 2614 500mm 2184 2238 600mm 1862 1862 700mm 1669 1669 800mm 1477 1477 900mm 1284 1284 1000mm 1091 1091 1100mm 1000 1000 1200mm 909 909 1300mm 819 819 1400mm 728 728 1500mm 637 637

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 4558 4885 300mm 3916 4161 400mm 3274 3438 500mm 2632 2714 600mm 1990 1990 700mm 1776 1776 800mm 1562 1562 900mm 1347 1347 1000mm 1133 1133 1100mm 1044 1044 1200mm 955 955 1300mm 865 865 1400mm 776 776 1500mm 687 687

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.8


Table J5:

Bay Capacity Rack heights up to 2100mm, K and EK uprights, 2250 and 2500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1774 300mm 1609 400mm 1444 500mm 1279 600mm 1114 700mm 1032 800mm 950 900mm 868 1000mm 786 1100mm 714 1200mm 643 1300mm 571 1400mm 500 1500mm 428

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2813 300mm 2388 400mm 1964 500mm 1539 600mm 1114 700mm 1032 800mm 950 900mm 868 1000mm 786 1100mm 714 1200mm 643 1300mm 571 1400mm 500 1500mm 428

Upright type ‘EK’

Frame Widths 800 + 1000 mm 2034 1804 1574 1344 1114 1032 950 868 786 714 643 571 500 428

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1774 300mm 1646 400mm 1518 500mm 1390 600mm 1262 700mm 1143 800mm 1024 900mm 905 1000mm 786 1100mm 726 1200mm 667 1300mm 607 1400mm 548 1500mm 488

Frame Widths 800 + 1000 mm 2484 2183 1883 1582 1281 1157 1034 910 786 726 667 607 548 488

Frame Widths 800 + 1000 mm 3071 2582 2093 1603 1114 1032 950 868 786 714 643 571 500 428

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2813 300mm 2430 400mm 2047 500mm 1664 600mm 1281 700mm 1157 800mm 1034 900mm 910 1000mm 786 1100mm 726 1200mm 667 1300mm 607 1400mm 548 1500mm 488

Frame Widths 800 + 1000 mm 3871 3224 2576 1929 1281 1157 1034 910 786 726 667 607 548 488

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9 Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.9


Table J5:

Bay Capacity (continued). Rack heights up to 2100mm, K and EK uprights, 2250 and 2500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

Upright type ‘EK’

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 3150 3366 300mm 2691 2853 400mm 2231 2339 500mm 1772 1826 600mm 1312 1312 700mm 1195 1195 800mm 1078 1078 900mm 960 960 1000mm 843 843 1100mm 774 774 1200mm 705 705 1300mm 635 635 1400mm 566 566 1500mm 497 497

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 3871 3871 300mm 3231 3231 400mm 2592 2592 500mm 1952 1952 600mm 1312 1312 700mm 1195 1195 800mm 1078 1078 900mm 960 960 1000mm 843 843 1100mm 774 774 1200mm 705 705 1300mm 635 635 1400mm 566 566 1500mm 497 497

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.10


Table J6:

Bay Capacity Rack heights of 2300 and 2500mm, K and EK uprights, 1500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1218 300mm 1218 400mm 1218 500mm 1218 600mm 1218 700mm 1218 800mm 1218 900mm 1218 1000mm 1218 1100mm 1130 1200mm 1042 1300mm 953 1400mm 865 1500mm 777

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2696 300mm 2625 400mm 2554 500mm 2482 600mm 2411 700mm 2143 800mm 1876 900mm 1608 1000mm 1340 1100mm 1227 1200mm 1115 1300mm 1002 1400mm 890 1500mm 777

Upright type ‘EK’

Frame Widths 800 + 1000 mm 1416 1416 1416 1416 1416 1397 1378 1359 1340 1227 1115 1002 890 777

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1262 300mm 1262 400mm 1262 500mm 1262 600mm 1262 700mm 1262 800mm 1262 900mm 1262 1000mm 1262 1100mm 1187 1200mm 1112 1300mm 1036 1400mm 961 1500mm 886

Frame Widths 800 + 1000 mm 2484 2484 2484 2484 2484 2241 1998 1754 1511 1386 1261 1136 1011 886

Frame Widths 800 + 1000 mm 3012 2862 2712 2561 2411 2143 1876 1608 1340 1227 1115 1002 890 777

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2802 300mm 2776 400mm 2751 500mm 2725 600mm 2699 700mm 2402 800mm 2105 900mm 1808 1000mm 1511 1100mm 1386 1200mm 1261 1300mm 1136 1400mm 1011 1500mm 886

Frame Widths 800 + 1000 mm 4624 4143 3662 3180 2699 2402 2105 1808 1511 1386 1261 1136 1011 886

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9 Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.11


Table J6:

Bay Capacity (continued). Rack heights of 2300 and 2500mm, K and EK uprights, 1500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

Upright type ‘EK’

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 3150 3366 300mm 2965 3127 400mm 2781 2889 500mm 2596 2650 600mm 2411 2411 700mm 2143 2143 800mm 1876 1876 900mm 1608 1608 1000mm 1340 1340 1100mm 1227 1227 1200mm 1115 1115 1300mm 1002 1002 1400mm 890 890 1500mm 777 777

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 4558 5138 300mm 4093 4528 400mm 3629 3919 500mm 3164 3309 600mm 2699 2699 700mm 2402 2402 800mm 2105 2105 900mm 1808 1808 1000mm 1511 1511 1100mm 1386 1386 1200mm 1261 1261 1300mm 1136 1136 1400mm 1011 1011 1500mm 886 886

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.12


Table J7:

Bay Capacity Rack heights of 2300 and 2500mm, K and EK uprights, 1750 and 2000mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1218 300mm 1218 400mm 1218 500mm 1218 600mm 1218 700mm 1186 800mm 1155 900mm 1123 1000mm 1091 1100mm 1000 1200mm 909 1300mm 819 1400mm 728 1500mm 637

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2696 300mm 2488 400mm 2279 500mm 2071 600mm 1862 700mm 1669 800mm 1477 900mm 1284 1000mm 1091 1100mm 1000 1200mm 909 1300mm 819 1400mm 728 1500mm 637

Upright type ‘EK’

Frame Widths 800 + 1000 mm 1416 1416 1416 1416 1416 1335 1254 1172 1091 1000 909 819 728 637

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1262 300mm 1262 400mm 1262 500mm 1262 600mm 1262 700mm 1230 800mm 1198 900mm 1165 1000mm 1133 1100mm 1044 1200mm 955 1300mm 865 1400mm 776 1500mm 687

Frame Widths 800 + 1000 mm 2484 2361 2237 2114 1990 1776 1562 1347 1133 1044 955 865 776 687

Frame Widths 800 + 1000 mm 3012 2725 2437 2150 1862 1669 1477 1284 1091 1000 909 819 728 637

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2802 300mm 2599 400mm 2396 500mm 2193 600mm 1990 700mm 1776 800mm 1562 900mm 1347 1000mm 1133 1100mm 1044 1200mm 955 1300mm 865 1400mm 776 1500mm 687

Frame Widths 800 + 1000 mm 4624 3966 3307 2649 1990 1776 1562 1347 1133 1044 955 865 776 687

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9 Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.13


Table J7:

Bay Capacity (continued). Rack heights of 2300 and 2500mm, K and EK uprights, 1750 and 2000mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

Upright type ‘EK’

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 3150 3366 300mm 2828 2990 400mm 2506 2614 500mm 2184 2238 600mm 1862 1862 700mm 1669 1669 800mm 1477 1477 900mm 1284 1284 1000mm 1091 1091 1100mm 1000 1000 1200mm 909 909 1300mm 819 819 1400mm 728 728 1500mm 637 637

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 4558 4885 300mm 3916 4161 400mm 3274 3438 500mm 2632 2714 600mm 1990 1990 700mm 1776 1776 800mm 1562 1562 900mm 1347 1347 1000mm 1133 1133 1100mm 1044 1044 1200mm 955 955 1300mm 865 865 1400mm 776 776 1500mm 687 687

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.14


Table J8:

Bay Capacity Rack heights of 2300 and 2500mm, K and EK uprights, 2250 and 2500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1218 300mm 1218 400mm 1218 500mm 1218 600mm 1218 700mm 1124 800mm 1031 900mm 937 1000mm 843 1100mm 774 1200mm 705 1300mm 635 1400mm 566 1500mm 497

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2696 300mm 2350 400mm 2004 500mm 1658 600mm 1312 700mm 1195 800mm 1078 900mm 960 1000mm 843 1100mm 774 1200mm 705 1300mm 635 1400mm 566 1500mm 497

Upright type ‘EK’

Frame Widths 800 + 1000 mm 1416 1390 1364 1338 1312 1195 1078 960 843 774 705 635 566 497

2 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 1262 300mm 1262 400mm 1262 500mm 1262 600mm 1262 700mm 1157 800mm 1053 900mm 948 1000mm 843 1100mm 774 1200mm 705 1300mm 635 1400mm 566 1500mm 497

Frame Widths 800 + 1000 mm 2484 2191 1898 1605 1312 1195 1078 960 843 774 705 635 566 497

Frame Widths 800 + 1000 mm 3012 2587 2162 1737 1312 1195 1078 960 843 774 705 635 566 497

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2802 300mm 2430 400mm 2057 500mm 1685 600mm 1312 700mm 1195 800mm 1078 900mm 960 1000mm 843 1100mm 774 1200mm 705 1300mm 635 1400mm 566 1500mm 497

Frame Widths 800 + 1000 mm 3871 3231 2592 1952 1312 1195 1078 960 843 774 705 635 566 497

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9 Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.15


Table J8:

Bay Capacity (continued). Rack heights of 2300 and 2500mm, K and EK uprights, 2250 and 2500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

Upright type ‘EK’

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 3150 3366 300mm 2691 2853 400mm 2231 2339 500mm 1772 1826 600mm 1312 1312 700mm 1195 1195 800mm 1078 1078 900mm 960 960 1000mm 843 843 1100mm 774 774 1200mm 705 705 1300mm 635 635 1400mm 566 566 1500mm 497 497

4 Batten Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 500 + 600 800 + 1000 mm mm 200mm 3871 3871 300mm 3231 3231 400mm 2592 2592 500mm 1952 1952 600mm 1312 1312 700mm 1195 1195 800mm 1078 1078 900mm 960 960 1000mm 843 843 1100mm 774 774 1200mm 705 705 1300mm 635 635 1400mm 566 566 1500mm 497 497

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.16


Table J9:

Bay Capacity Rack heights of 3000mm, K and EK uprights, 1500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2002 300mm 2002 400mm 2002 500mm 2002 600mm 2002 700mm 1838 800mm 1674 900mm 1509 1000mm 1345 1100mm 1239 1200mm 1133 1300mm 1028 1400mm 922 1500mm 816

4 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2584 300mm 2540 400mm 2496 500mm 2452 600mm 2408 700mm 2142 800mm 1877 900mm 1611 1000mm 1345 1100mm 1239 1200mm 1133 1300mm 1028 1400mm 922 1500mm 816

Upright type ‘EK’

Frame Widths 800 + 1000 mm 2426 2422 2417 2413 2408 2142 1877 1611 1345 1239 1133 1028 922 816

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2074 300mm 2074 400mm 2074 500mm 2074 600mm 2074 700mm 1981 800mm 1888 900mm 1794 1000mm 1701 1100mm 1558 1200mm 1415 1300mm 1273 1400mm 1130 1500mm 987

Frame Widths 800 + 1000 mm 3982 3741 3499 3258 3016 2687 2359 2030 1701 1558 1415 1273 1130 987

Frame Widths 800 + 1000 mm 2860 2747 2634 2521 2408 2142 1877 1611 1345 1239 1133 1028 922 816

4 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 3178 300mm 3138 400mm 3097 500mm 3057 600mm 3016 700mm 2687 800mm 2359 900mm 2030 1000mm 1701 1100mm 1558 1200mm 1415 1300mm 1273 1400mm 1130 1500mm 987

Frame Widths 800 + 1000 mm 4512 4138 3764 3390 3016 2687 2359 2030 1701 1558 1415 1273 1130 987

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9 Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.17


Table J9:

Bay Capacity (continued). Rack heights of 3000mm, K and EK uprights, 1500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

Upright type ‘EK’

4 Batten + 2 ‘X’ Braced Frames (#), or Fully Clad Frames Frame Shelf Frame Widths spacing Widths 800 + 1000 500 + 600 mm mm 200mm 2720 2720 300mm 2642 2642 400mm 2564 2564 500mm 2486 2486 600mm 2408 2408 700mm 2142 2142 800mm 1877 1877 900mm 1611 1611 1000mm 1345 1345 1100mm 1239 1239 1200mm 1133 1133 1300mm 1028 1028 1400mm 922 922 1500mm 816 816

4 Batten + 2 ‘X’ Braced Frames (#), or Fully Clad Frames Frame Shelf Frame Widths spacing Widths 800 + 1000 500 + 600 mm mm 200mm 4000 4220 300mm 3754 3919 400mm 3508 3618 500mm 3262 3317 600mm 3016 3016 700mm 2687 2687 800mm 2359 2359 900mm 2030 2030 1000mm 1701 1701 1100mm 1558 1558 1200mm 1415 1415 1300mm 1273 1273 1400mm 1130 1130 1500mm 987 987

(#) The 800 and 1000mm wide battened and braced frames, have 3 heavy duty battens, not 4. For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.18


Table J10:

Bay Capacity Rack heights of 3000mm, K and EK uprights, 1750 and 2000mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2002 300mm 1996 400mm 1991 500mm 1985 600mm 1979 700mm 1767 800mm 1554 900mm 1342 1000mm 1129 1100mm 1043 1200mm 957 1300mm 872 1400mm 786 1500mm 700

4 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2584 300mm 2433 400mm 2282 500mm 2130 600mm 1979 700mm 1767 800mm 1554 900mm 1342 1000mm 1129 1100mm 1043 1200mm 957 1300mm 872 1400mm 786 1500mm 700

Upright type ‘EK’

Frame Widths 800 + 1000 mm 2426 2314 2203 2091 1979 1767 1554 1342 1129 1043 957 872 786 700

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2074 300mm 2074 400mm 2074 500mm 2074 600mm 2074 700mm 1880 800mm 1687 900mm 1493 1000mm 1299 1100mm 1195 1200mm 1092 1300mm 988 1400mm 885 1500mm 781

Frame Widths 800 + 1000 mm 3982 3553 3124 2695 2266 2024 1783 1541 1299 1195 1092 988 885 781

Frame Widths 800 + 1000 mm 2860 2640 2420 2199 1979 1767 1554 1342 1129 1043 957 872 786 700

4 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 3178 300mm 2950 400mm 2722 500mm 2494 600mm 2266 700mm 2024 800mm 1783 900mm 1541 1000mm 1299 1100mm 1195 1200mm 1092 1300mm 988 1400mm 885 1500mm 781

Frame Widths 800 + 1000 mm 4512 3951 3389 2828 2266 2024 1783 1541 1299 1195 1092 988 885 781

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9 Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.19


Table J10:

Bay Capacity (continued). Rack heights of 3000mm, K and EK uprights, 1750 and 2000mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

Upright type ‘EK’

4 Batten + 2 ‘X’ Braced Frames (#), or Fully Clad Frames Frame Shelf Frame Widths spacing Widths 800 + 1000 500 + 600 mm mm 200mm 2720 2680 300mm 2535 2505 400mm 2350 2330 500mm 2164 2154 600mm 1979 1979 700mm 1767 1767 800mm 1554 1554 900mm 1342 1342 1000mm 1129 1129 1100mm 1043 1043 1200mm 957 957 1300mm 872 872 1400mm 786 786 1500mm 700 700

4 Batten + 2 ‘X’ Braced Frames (#), or Fully Clad Frames Frame Shelf Frame Widths spacing Widths 800 + 1000 500 + 600 mm mm 200mm 4000 4220 300mm 3567 3732 400mm 3133 3243 500mm 2700 2755 600mm 2266 2266 700mm 2024 2024 800mm 1783 1783 900mm 1541 1541 1000mm 1299 1299 1100mm 1195 1195 1200mm 1092 1092 1300mm 988 988 1400mm 885 885 1500mm 781 781

(#) The 800 and 1000mm wide battened and braced frames, have 3 heavy duty battens, not 4. For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.20


Table J11:

Bay Capacity Rack heights of 3000mm, K and EK uprights, 2250 and 2500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2002 300mm 1889 400mm 1776 500mm 1662 600mm 1549 700mm 1390 800mm 1232 900mm 1073 1000mm 914 1100mm 848 1200mm 782 1300mm 715 1400mm 649 1500mm 583

4 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2584 300mm 2325 400mm 2067 500mm 1808 600mm 1549 700mm 1390 800mm 1232 900mm 1073 1000mm 914 1100mm 848 1200mm 782 1300mm 715 1400mm 649 1500mm 583

Upright type ‘EK’

Frame Widths 800 + 1000 mm 2426 2207 1988 1768 1549 1390 1232 1073 914 848 782 715 649 583

3 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 2074 300mm 1934 400mm 1795 500mm 1655 600mm 1515 700mm 1365 800mm 1215 900mm 1064 1000mm 914 1100mm 848 1200mm 782 1300mm 715 1400mm 649 1500mm 583

Frame Widths 800 + 1000 mm 3982 3365 2749 2132 1515 1365 1215 1064 914 848 782 715 649 583

Frame Widths 800 + 1000 mm 2860 2532 2205 1877 1549 1390 1232 1073 914 848 782 715 649 583

4 Batten Frames Shelf Frame spacing Widths 500 + 600 mm 200mm 3178 300mm 2771 400mm 2364 500mm 1956 600mm 1549 700mm 1390 800mm 1232 900mm 1073 1000mm 914 1100mm 848 1200mm 782 1300mm 715 1400mm 649 1500mm 583

Frame Widths 800 + 1000 mm 4512 3771 3031 2290 1549 1390 1232 1073 914 848 782 715 649 583

For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9 Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.21


Table J11:

Bay Capacity (continued). Rack heights of 3000mm, K and EK uprights, 2250 and 2500mm bay lengths. Minimum 3 bays per rack. Upright type ‘K’

Upright type ‘EK’

4 Batten + 2 ‘X’ Braced Frames (#), or Fully Clad Frames Frame Shelf Frame Widths spacing Widths 800 + 1000 500 + 600 mm mm 200mm 2720 2860 300mm 2427 2532 400mm 2135 2205 500mm 1842 1877 600mm 1549 1549 700mm 1390 1390 800mm 1232 1232 900mm 1073 1073 1000mm 914 914 1100mm 848 848 1200mm 782 782 1300mm 715 715 1400mm 649 649 1500mm 583 583

4 Batten + 2 ‘X’ Braced Frames (#), or Fully Clad Frames Frame Shelf Frame Widths spacing Widths 800 + 1000 500 + 600 mm mm 200mm 4000 4512 300mm 3387 3771 400mm 2775 3031 500mm 2162 2290 600mm 1549 1549 700mm 1390 1390 800mm 1232 1232 900mm 1073 1073 1000mm 914 914 1100mm 848 848 1200mm 782 782 1300mm 715 715 1400mm 649 649 1500mm 583 583

(#) The 800 and 1000mm wide battened and braced frames, have 3 heavy duty battens, not 4. For single bay racks multiply the values in the tables by a factor of 0.8 For two bay racks multiply the values in the tables by a factor of 0.9

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.22


BASEPLATE and FLOOR FIXING REQUIREMENTS

Baseplate Select the required baseplate by checking the load passing through the plate into the floor. Standard baseplate = 1500kg per upright (i.e. 3000kg/frame). Standard baseplate plus Heavy Duty levelling plate = 2500kg per upright (5000kg/frame). High Rise baseplate = 3000kg per upright (6000kg/frame).

Floor Fixings Floor fixings are necessary to securely locate the frames in position and to resist overturning. The quantity of floor fixings required will depend on the rack application, and its height to width ratio. If a baseplate is fixed down it must also be secured to the upright. Height To Width Ratio Definition - Single Entry Racks The height to the top loaded level divided by the frame width, i.e. a height of 2500mm and a frame width of 450mm, gives a height to width ratio of 5.56. Height To Width Ratio Definition - Double Entry Racks With frames bolted back to back at the top and bottom, with M6x20mm fixings. The height to the top loaded level divided by the combined frame width, i.e. a height of 2500mm and a combined width of 900mm, gives a height to width ratio of 2.78. Height to Width Ratio not greater than 5 to 1 Providing mechanical handling equipment can not approach, no floor fixings are required. Height to Width Ratio greater than 5 to 1, but less than 8 to 1 Standard baseplate: perimeter uprights must be fixed down with a hammer screw. High Rise baseplate: perimeter uprights must be fixed down with expander bolts. Height to Width Ratio greater than 8 to 1, but less than 10 to 1 Standard baseplate: perimeter uprights must be fixed down with expander bolts. High Rise baseplate: perimeter uprights must be fixed down with expander bolts. Height to Width Ratio greater than 10 to 1 No low rise rack should have a ratio greater than 10 to 1. All racks containing either drawers, trays or doors must be perimeter fixed. All racks must be considered for any special requirements that may require additional floor fixings.

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.23


DESIGN EXAMPLE ONE

Using the above example to demonstrate the correct design procedure. The client has a preference for open frames. Each rack contains 5 bays of shelving within the length. Step 1.

Shelf selection. Using design Table J1 check the suitability of the steel shelves. 2000mm long steel shelves will support 400kg. Using design Table J2 check the suitability of the chipboard shelves. 2000mm long chipboard shelves will only support 335kg supported on 5 cross beams. Therefore OK to use: Steel shelves (alternatively quote chipboard with a reduced capacity of 335kg).

Step 2.

Frame selection. Using design Table J4 for a 2100mm high rack with a bay length of 2000mm. The frame width is 600mm, with a maximum shelf spacing of 650mm. The allowable bay load for a 2 Batten Frame using type K uprights is 1540kg, which exceeds the required 1400kg. Therefore OK to use: 2 batten frame with type K uprights.

Step 3.

Baseplate and floor fixing requirement. Each baseplate takes 700kg (1400kg/2). Therefore OK to use the Standard Baseplate. Single entry racks: height to width ratio equals 2100/600 = 3.5 Double entry racks: height to width ratio equals 2100/1200 = 1.75 Therefore floor fixings are not required unless mechanical handing equipment is likely to come into contact with the rack.

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.24


DESIGN EXAMPLE TWO

Using the above example to demonstrate the correct design procedure. The client has a preference for open frames. Each rack only contains 2 bays of shelving within the length. Step 1.

Shelf selection. Using design Table J1 check the suitability of the steel shelves. 2500mm long steel shelves will support 350kg. Using design Table J2 check the suitability of the chipboard shelves. 2500mm long chipboard shelves will support 330kg supported on 6 cross beams. Therefore OK to use: Either steel or chipboard shelves.

Step 2.

Frame selection. Using design Table J8 for a 2500mm high rack with a bay length of 2500mm. The frame width is 800mm, with a maximum shelf spacing of 400mm. The allowable bay load for a: 3 Batten Frame using type K uprights is 1946kg (2162kg x 0.9 two bay factor), 3 Batten Frame using type EK uprights is 2333kg (2592kg x 0.9 two bay factor), 4 Batten Frame using type K uprights is 2105kg (2339kg x 0.9 two bay factor), Therefore OK to use, either: 3 batten frame with type EK uprights, or 4 batten frame with type K uprights.

Step 3.

Baseplate and floor fixing requirement. Each baseplate take 1050kg (2100kg/2). Therefore OK to use Standard Baseplate. Single entry racks: height to width ratio equals 2500/800 = 3.12 Double entry racks: height to width ratio equals 2500/1600 = 1.56 Therefore floor fixings are not required unless mechanical handing equipment is likely to come into contact with the rack.

Issue: Sept 2006 Section J – Low Rise Medium Span Applications + Design

Page J.25


SECTION K – HIGH RISE SHORT SPAN APPLICATIONS and DESIGN INTRODUCTION This section of the manual covers the design of ‘High Rise Short Span Shelving’ i.e. High Rise : shelving heights between 3100 and 12,000mm. Short Span : bay lengths of 900, 1000, and 1290mm. Shelving outside of this range will be covered in a separate section of the manual. The components for this type of shelving are described within: Section B : Frame Components. Section C : Short Span Bay Components. Mechanical Handling / Access Equipment The term ‘High Rise’ when used in conjunction with HI280, means the shelving is tall, it does not indicate that the shelving supports any form of handling or access equipment. HI280 is a hand loaded shelving system, that is free standing and totally independent from the mechanical handling equipment. If the system is required to support such equipment then the application must be referred to the ‘Product Support Department’ for design. These ‘crane type’ applications are not covered within the scope of this manual. Design Data The design data contained within this manual is in accordance with the recommendations of “The Federation Europeenne de la Manutention” (FEM) Code 10.2.06. Frame/Upright Types Type S uprights are NOT permitted within ‘High Rise Short Span Shelving’. Erection Tolerance For the design data to remain accurate it is important that the shelving is installed within a tolerance of 1/350 both across and down the aisle. (i.e. a 3500mm frame must be installed within 10mm of plumb). Minimum Number of Bays The design tables are based on a minimum of 3 consecutive bays per rack. If a rack contains fewer bays, then the design should be referred to the ‘Product Support Department’ for design.

DESIGN To aid the design this section of the manual has been split into two: Section K1

3100 to 5500mm high racks. Using battened, battened and braced, or clad frames, with or without back bracing.

Section K2

3100 to 12,000mm high racks. Using only fully braced or clad frames, and back bracing.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.1


SECTION K1 - DESIGN PROCESS (racks 3100 to 5500mm)

Sketch the desired rack. Indicate bay length, width, and height. Show the number of shelf levels, the desired load per shelf and the pitch between these shelves. Indicate the preference for open or clad frames and backs. Check the shelf design. The most cost effective design will be to use a N normal duty shelf if available in the size you require, followed by a S standard and then a non-reinforced H heavy duty shelf. After that a reinforced H heavy duty shelf with either one or two reinforcement bars. Check the bay design, and position any back bracing accordingly. Three sets of bay design tables are provided: ‘Without Back Bracing’. ‘Back Bracing Every Third Bay’. ‘Back Bracing Every Other Bay’, or ‘Fully Back Clad’ racks Select the preference for either an open frame or a clad frame. The most cost effective frame will have K uprights with the least allowable number of battens. Using the ‘Without Back Bracing’ table, check the design of the chosen frame, and if it fails progress through to an increased number of battens or the use of the EK upright. If the design still fails move onto the next set of tables i.e. ‘Back Bracing every third bay’, and if that fails move on again to the final set ‘Back Bracing every other bay’. This process will give the most cost effective frame with the least amount of back bracing. Note: when back bracing K uprights it is necessary to drill the uprights to accept the fixings, therefore it may be more cost effective to provide the pre-punched EK upright. Check the baseplate, floor fixing, and any top tie requirements. This involves checking the load through the baseplate, and the height to width ratio of the bay. If a bay contains drawer or tray sets it MUST be fixed down regardless of its ratio. Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.2


SECTION K1 - DESIGN TABLES (racks 3100 to 5500mm) The following tables are provided. Table K1:

Shelf Capacity Capacity of the shelf and beam using either none, one, or two reinforcing bars.

Bay Capacity – ‘Without Back Bracing’ Table K2: Table K3: Table K4: Table K5: Table K6: Table K7:

Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length. Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length. Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 900 and 1000mm bay length. Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 1290mm bay length. Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 900 and 1000mm bay length. Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 1290mm bay length.

Bay Capacity – ‘Back Bracing Every Third Bay’ Table K8: Table K9: Table K10: Table K11: Table K12: Table K13:

Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length. Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length. Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 900 and 1000mm bay length. Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 1290mm bay length. Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 900 and 1000mm bay length. Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 1290mm bay length.

Bay Capacity – ‘Back Bracing Every Other Bay’ or ‘Fully Back Clad’ Table K14: Table K15: Table K16: Table K17: Table K18: Table K19:

Issue: Sept 2006

Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length. Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length. Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 900 and 1000mm bay length. Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 1290mm bay length. Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 900 and 1000mm bay length. Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 1290mm bay length.

Section K – High Rise Short Span Applications + Design

Page K.3


New table Table K1:

Shelf Capacity in kg. Capacity of the shelf and beam using either none, one, or two reinforcing bars.

Shelf size

300x900 300x1000 300x1290

400x900

400x1000

400x1290

450x900 450x1000 450X1290 500x900 500x1000 500x1290 600x900 600x1000 600x1290 800x900 800x1000 800x1290

Issue: Sept 2006

Shelf t mm

Shelf Duty

Without bars. kg

0.5 0.7 0.5 0.7 0.5 0.7

N H N H N H

0.5 0.6 0.7 0.5 0.6 0.7 0.5 0.6 0.7

With 1 bar.

With 2 bars.

kg

kg

140 235 135 235 70 110

260 260 235

300 300 350

N S H N S H N S H

140 160 235 140 150 235 75 85 110

260 260 235

300 300 350

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

160 235 150 235 85 110

260 260 235

300 300 350

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

170 235 150 235 85 110

260 260 235

300 300 350

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

150 215 140 215 100 120

290 290 215

380 380 310

0.7 0.7 0.7

H H H

110 110 120

290 290 215

380 380 310

Section K – High Rise Short Span Applications + Design

Page K.4


Table K2:

Bay Capacity in kg – ‘Without Back Bracing’. Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2022 300mm 2022 400mm 1896 500mm 1483 600mm 1241 700mm 1119 800mm 1035

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2320 300mm 2320 400mm 1896 500mm 1483 600mm 1241 700mm 1119 800mm 1035

Upright type ‘EK’

Frame Widths 600-800mm 2320 2320 1896 1483 1241 1119 1035

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2106 300mm 2106 400mm 2106 500mm 1950 600mm 1654 700mm 1385 800mm 1267

Frame Widths 600-800mm 2961 2961 2411 1950 1654 1385 1267

Frame Widths 600-800mm 2320 2320 1896 1483 1241 1119 1035

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2961 300mm 2961 400mm 2411 500mm 1950 600mm 1654 700mm 1385 800mm 1267

Frame Widths 600-800mm 2961 2961 2411 1950 1654 1385 1267

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2320 2320 300mm 2320 2320 400mm 1896 1896 500mm 1483 1483 600mm 1241 1241 700mm 1119 1119 800mm 1035 1035

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2961 2961 300mm 2961 2961 400mm 2411 2411 500mm 1950 1950 600mm 1654 1654 700mm 1385 1385 800mm 1267 1267

Section K – High Rise Short Span Applications + Design

Page K.5


Table K3:

Bay Capacity in kg – ‘Without Back Bracing’. Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2022 300mm 2022 400mm 1753 500mm 1397 600mm 1209 700mm 1093 800mm 1008

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2279 300mm 2279 400mm 1753 500mm 1397 600mm 1209 700mm 1093 800mm 1008

Upright type ‘EK’

Frame Widths 600-800mm 2279 2279 1753 1397 1209 1093 1008

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2106 300mm 2106 400mm 2106 500mm 2043 600mm 1710 700mm 1412 800mm 1263

Frame Widths 600-800mm 3203 3203 2567 2043 1710 1412 1263

Frame Widths 600-800mm 2279 2279 1753 1397 1209 1093 1008

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 3203 300mm 3203 400mm 2567 500mm 2043 600mm 1710 700mm 1412 800mm 1263

Frame Widths 600-800mm 3203 3203 2567 2043 1710 1412 1263

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2279 2279 300mm 2279 2279 400mm 1753 1753 500mm 1397 1397 600mm 1209 1209 700mm 1093 1093 800mm 1008 1008

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3203 3203 300mm 3203 3203 400mm 2567 2567 500mm 2043 2043 600mm 1710 1710 700mm 1412 1412 800mm 1263 1263

Section K – High Rise Short Span Applications + Design

Page K.6


Table K4:

Bay Capacity in kg – ‘Without Back Bracing’. Rack heights 4100 to 5000mm. K and EK uprights, 900 and 1000mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1270 300mm 1270 400mm 1270 500mm 1270 600mm 1104 700mm 984 800mm 896

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2102 300mm 2102 400mm 1648 500mm 1279 600mm 1014 700mm 984 800mm 896

Upright type ‘EK’

Frame Widths 600-800mm 1840 1840 1648 1279 1104 984 896

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1331 300mm 1331 400mm 1331 500mm 1331 600mm 1331 700mm 1220 800mm 1106

Frame Widths 600-800mm 2685 2685 2109 1706 1416 1220 1106

Frame Widths 600-800mm 2112 2112 1648 1279 1014 984 896

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2260 300mm 2260 400mm 2109 500mm 1706 600mm 1416 700mm 1220 800mm 1106

Frame Widths 600-800mm 2685 2685 2109 1706 1416 1220 1106

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2112 2112 300mm 2112 2112 400mm 1648 1648 500mm 1279 1279 600mm 1014 1014 700mm 984 984 800mm 896 896

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2685 2685 300mm 2685 2685 400mm 2109 2109 500mm 1706 1706 600mm 1416 1416 700mm 1220 1220 800mm 1106 1106

Section K – High Rise Short Span Applications + Design

Page K.7


Table K5:

Bay Capacity in kg – ‘Without Back Bracing’. Rack heights 4100 to 5000mm. K and EK uprights, 1290mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1270 300mm 1270 400mm 1270 500mm 1226 600mm 1065 700mm 943 800mm 855

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2014 300mm 2014 400mm 1527 500mm 1226 600mm 1065 700mm 943 800mm 855

Upright type ‘EK’

Frame Widths 600-800mm 1840 1840 1527 1226 1065 943 855

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1331 300mm 1331 400mm 1331 500mm 1331 600mm 1331 700mm 1239 800mm 1105

Frame Widths 600-800mm 2928 2928 2254 1800 1472 1239 1105

Frame Widths 600-800mm 2014 2014 1527 1226 1065 943 855

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2260 300mm 2260 400mm 2254 500mm 1800 600mm 1472 700mm 1239 800mm 1105

Frame Widths 600-800mm 2928 2928 2254 1800 1472 1239 1105

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2014 2014 300mm 2014 2014 400mm 1527 1527 500mm 1226 1226 600mm 1065 1065 700mm 943 943 800mm 855 855

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2928 2928 300mm 2928 2928 400mm 2254 2254 500mm 1800 1800 600mm 1472 1472 700mm 1239 1239 800mm 1105 1105

Section K – High Rise Short Span Applications + Design

Page K.8


Table K6:

Bay Capacity in kg – ‘Without Back Bracing’. Rack heights 5100 to 5500mm. K and EK uprights, 900 and 1000mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 934 800mm 845

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1804 300mm 1804 400mm 1560 500mm 1209 600mm 1049 700mm 934 800mm 845

Upright type ‘EK’

Frame Widths 600-800mm 1460 1460 1460 1209 1049 934 845

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

Frame Widths 600-800mm 2579 2579 2001 1607 1325 1158 1044

Frame Widths 600-800mm 2031 2031 1560 1209 1049 934 845

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1915 300mm 1915 400mm 1915 500mm 1607 600mm 1325 700mm 1158 800mm 1044

Frame Widths 600-800mm 2579 2579 2001 1607 1325 1158 1044

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2031 2031 300mm 2031 2031 400mm 1560 1560 500mm 1209 1209 600mm 1049 1049 700mm 934 934 800mm 845 845

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2579 2579 300mm 2579 2579 400mm 2001 2001 500mm 1607 1607 600mm 1325 1325 700mm 1158 1158 800mm 1044 1044

Section K – High Rise Short Span Applications + Design

Page K.9


Table K7:

Bay Capacity in kg – ‘Without Back Bracing’. Rack heights 5100 to 5500mm. K and EK uprights, 1290mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1003 700mm 888 800mm 798

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1804 300mm 1804 400mm 1446 500mm 1167 600mm 1003 700mm 888 800mm 798

Upright type ‘EK’

Frame Widths 600-800mm 1460 1460 1446 1167 1003 888 798

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

Frame Widths 600-800mm 2590 2590 2144 1701 1382 1181 1047

Frame Widths 600-800mm 1918 1918 1446 1167 1003 888 798

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1915 300mm 1915 400mm 1915 500mm 1701 600mm 1382 700mm 1181 800mm 1047

Frame Widths 600-800mm 2818 2818 2144 1701 1382 1181 1047

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 1918 1918 300mm 1918 1918 400mm 1446 1446 500mm 1167 1167 600mm 1003 1003 700mm 888 888 800mm 798 798

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2818 2818 300mm 2818 2818 400mm 2144 2144 500mm 1701 1701 600mm 1382 1382 700mm 1181 1181 800mm 1047 1047

Section K – High Rise Short Span Applications + Design

Page K.10


Table K8:

Bay Capacity in kg – ‘Back Bracing Every Third Bay’. Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2022 300mm 2022 400mm 2022 500mm 2022 600mm 2022 700mm 2022 800mm 2022

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2640 300mm 2640 400mm 2640 500mm 2640 600mm 2640 700mm 2640 800mm 2640

Upright type ‘EK’

Frame Widths 600-800mm 2438 2438 2438 2438 2438 2438 2438

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2106 300mm 2106 400mm 2106 500mm 2106 600mm 2106 700mm 2106 800mm 2106

Frame Widths 600-800mm 3890 3890 3890 3890 3890 3890 3890

Frame Widths 600-800mm 2980 2980 2980 2980 2980 2980 2980

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 3228 300mm 3228 400mm 3228 500mm 3228 600mm 3228 700mm 3228 800mm 3228

Frame Widths 600-800mm 4260 4260 4260 4260 4260 4260 4260

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2890 2980 300mm 2890 2980 400mm 2890 2980 500mm 2890 2980 600mm 2890 2980 700mm 2890 2980 800mm 2890 2980

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4260 300mm 3944 4260 400mm 3944 4260 500mm 3944 4260 600mm 3944 4260 700mm 3944 4260 800mm 3944 4260

Section K – High Rise Short Span Applications + Design

Page K.11


Table K9:

Bay Capacity in kg – ‘Back Bracing Every Third Bay’. Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2022 300mm 2022 400mm 2022 500mm 2022 600mm 2022 700mm 2022 800mm 2022

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2640 300mm 2640 400mm 2640 500mm 2640 600mm 2640 700mm 2640 800mm 2640

Upright type ‘EK’

Frame Widths 600-800mm 2438 2438 2438 2438 2438 2438 2438

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2106 300mm 2106 400mm 2106 500mm 2106 600mm 2106 700mm 2106 800mm 2106

Frame Widths 600-800mm 3890 3890 3890 3890 3890 3890 3890

Frame Widths 600-800mm 2980 2980 2980 2980 2980 2980 2980

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 3228 300mm 3228 400mm 3228 500mm 3228 600mm 3228 700mm 3228 800mm 3228

Frame Widths 600-800mm 4260 4260 4260 4260 4260 4260 4260

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2890 2980 300mm 2890 2980 400mm 2890 2980 500mm 2890 2980 600mm 2890 2980 700mm 2890 2980 800mm 2890 2980

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4260 300mm 3944 4260 400mm 3944 4260 500mm 3944 4260 600mm 3944 4260 700mm 3944 4260 800mm 3944 4260

Section K – High Rise Short Span Applications + Design

Page K.12


Table K10:

Bay Capacity in kg – ‘Back Bracing Every Third Bay’. Rack heights 4100 to 5000mm. K and EK uprights, 900 and 1000mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1270 300mm 1270 400mm 1270 500mm 1270 600mm 1270 700mm 1270 800mm 1270

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2102 300mm 2102 400mm 2102 500mm 2102 600mm 2102 700mm 2102 800mm 2102

Upright type ‘EK’

Frame Widths 600-800mm 1840 1840 1840 1840 1840 1840 1840

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1331 300mm 1331 400mm 1331 500mm 1331 600mm 1331 700mm 1331 800mm 1331

Frame Widths 600-800mm 3072 3072 3072 3072 3072 3072 3072

Frame Widths 600-800mm 2452 2452 2452 2452 2452 2452 2452

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2260 300mm 2260 400mm 2260 500mm 2260 600mm 2260 700mm 2260 800mm 2260

Frame Widths 600-800mm 3940 3940 3940 3940 3940 3940 3940

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2720 2720 300mm 2720 2720 400mm 2720 2720 500mm 2720 2720 600mm 2720 2720 700mm 2720 2720 800mm 2720 2720

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4216 300mm 3944 4216 400mm 3944 4216 500mm 3944 4216 600mm 3944 4216 700mm 3944 4216 800mm 3944 4216

Section K – High Rise Short Span Applications + Design

Page K.13


Table K11:

Bay Capacity in kg – ‘Back Bracing Every Third Bay’. Rack heights 4100 to 5000mm. K and EK uprights, 1290mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1270 300mm 1270 400mm 1270 500mm 1270 600mm 1270 700mm 1270 800mm 1270

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2102 300mm 2102 400mm 2102 500mm 2102 600mm 2102 700mm 2102 800mm 2102

Upright type ‘EK’

Frame Widths 600-800mm 1840 1840 1840 1840 1840 1840 1840

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1331 300mm 1331 400mm 1331 500mm 1331 600mm 1331 700mm 1331 800mm 1331

Frame Widths 600-800mm 3072 3072 3072 3072 3072 3072 3072

Frame Widths 600-800mm 2459 2459 2459 2459 2459 2459 2459

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2260 300mm 2260 400mm 2260 500mm 2260 600mm 2260 700mm 2260 800mm 2260

Frame Widths 600-800mm 3940 3940 3940 3940 3940 3940 3940

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2720 2720 300mm 2720 2720 400mm 2720 2720 500mm 2720 2720 600mm 2720 2720 700mm 2720 2720 800mm 2720 2720

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4216 300mm 3944 4216 400mm 3944 4216 500mm 3944 4216 600mm 3944 4216 700mm 3944 4216 800mm 3944 4216

Section K – High Rise Short Span Applications + Design

Page K.14


Table K12:

Bay Capacity in kg – ‘Back Bracing Every Third Bay’. Rack heights 5100 to 5500mm. K and EK uprights, 900 and 1000mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1804 300mm 1804 400mm 1804 500mm 1804 600mm 1804 700mm 1804 800mm 1804

Upright type ‘EK’

Frame Widths 600-800mm 1460 1460 1460 1460 1460 1460 1460

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

Frame Widths 600-800mm 2590 2590 2590 2590 2590 2590 2590

Frame Widths 600-800mm 2222 2222 2222 2222 2222 2222 2222

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1915 300mm 1915 400mm 1915 500mm 1915 600mm 1915 700mm 1915 800mm 1915

Frame Widths 600-800mm 3644 3644 3644 3644 3644 3644 3644

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2720 2720 300mm 2720 2720 400mm 2720 2720 500mm 2720 2720 600mm 2720 2720 700mm 2720 2720 800mm 2720 2720

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4158 300mm 3944 4158 400mm 3944 4158 500mm 3944 4158 600mm 3944 4158 700mm 3944 4158 800mm 3944 4158

Section K – High Rise Short Span Applications + Design

Page K.15


Table K13:

Bay Capacity in kg – ‘Back Bracing Every Third Bay’. Rack heights 5100 to 5500mm. K and EK uprights, 1290mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1804 300mm 1804 400mm 1804 500mm 1804 600mm 1804 700mm 1804 800mm 1804

Upright type ‘EK’

Frame Widths 600-800mm 1460 1460 1460 1460 1460 1460 1460

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

Frame Widths 600-800mm 2590 2590 2590 2590 2590 2590 2590

Frame Widths 600-800mm 2222 2222 2222 2222 2222 2222 2222

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1915 300mm 1915 400mm 1915 500mm 1915 600mm 1915 700mm 1915 800mm 1915

Frame Widths 600-800mm 3644 3644 3644 3644 3644 3644 3644

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2720 2720 300mm 2720 2720 400mm 2720 2720 500mm 2720 2720 600mm 2720 2720 700mm 2720 2720 800mm 2720 2720

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4158 300mm 3944 4158 400mm 3944 4158 500mm 3944 4158 600mm 3944 4158 700mm 3944 4158 800mm 3944 4158

Section K – High Rise Short Span Applications + Design

Page K.16


Table K14:

Bay Capacity in kg – ‘Back Bracing Every Other Bay’ or ‘Fully Back Clad’ Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2022 300mm 2022 400mm 2022 500mm 2022 600mm 2022 700mm 2022 800mm 2022

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2640 300mm 2640 400mm 2640 500mm 2640 600mm 2640 700mm 2640 800mm 2640

Upright type ‘EK’

Frame Widths 600-800mm 2438 2438 2438 2438 2438 2438 2438

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2106 300mm 2106 400mm 2106 500mm 2106 600mm 2106 700mm 2106 800mm 2106

Frame Widths 600-800mm 3890 3890 3890 3890 3890 3890 3890

Frame Widths 600-800mm 2980 2980 2980 2980 2980 2980 2980

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 3228 300mm 3228 400mm 3228 500mm 3228 600mm 3228 700mm 3228 800mm 3228

Frame Widths 600-800mm 4574 4574 4574 4574 4574 4574 4574

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2890 2980 300mm 2890 2980 400mm 2890 2980 500mm 2890 2980 600mm 2890 2980 700mm 2890 2980 800mm 2890 2980

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4574 300mm 3944 4574 400mm 3944 4574 500mm 3944 4574 600mm 3944 4574 700mm 3944 4574 800mm 3944 4574

Section K – High Rise Short Span Applications + Design

Page K.17


Table K15:

Bay Capacity in kg – ‘Back Bracing Every Other Bay’ or ‘Fully Back Clad’ Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2022 300mm 2022 400mm 2022 500mm 2022 600mm 2022 700mm 2022 800mm 2022

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2640 300mm 2640 400mm 2640 500mm 2640 600mm 2640 700mm 2640 800mm 2640

Upright type ‘EK’

Frame Widths 600-800mm 2438 2438 2438 2438 2438 2438 2438

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2106 300mm 2106 400mm 2106 500mm 2106 600mm 2106 700mm 2106 800mm 2106

Frame Widths 600-800mm 3890 3890 3890 3890 3890 3890 3890

Frame Widths 600-800mm 2980 2980 2980 2980 2980 2980 2980

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 3228 300mm 3228 400mm 3228 500mm 3228 600mm 3228 700mm 3228 800mm 3228

Frame Widths 600-800mm 4574 4574 4574 4574 4574 4574 4574

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2890 2980 300mm 2890 2980 400mm 2890 2980 500mm 2890 2980 600mm 2890 2980 700mm 2890 2980 800mm 2890 2980

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4574 300mm 3944 4574 400mm 3944 4574 500mm 3944 4574 600mm 3944 4574 700mm 3944 4574 800mm 3944 4574

Section K – High Rise Short Span Applications + Design

Page K.18


Table K16:

Bay Capacity in kg – ‘Back Bracing Every Other Bay’ or ‘Fully Back Clad’ Rack heights 4100 to 5000mm. K and EK uprights, 900 and 1000mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1270 300mm 1270 400mm 1270 500mm 1270 600mm 1270 700mm 1270 800mm 1270

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2102 300mm 2102 400mm 2102 500mm 2102 600mm 2102 700mm 2102 800mm 2102

Upright type ‘EK’

Frame Widths 600-800mm 1840 1840 1840 1840 1840 1840 1840

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1331 300mm 1331 400mm 1331 500mm 1331 600mm 1331 700mm 1331 800mm 1331

Frame Widths 600-800mm 3072 3072 3072 3072 3072 3072 3072

Frame Widths 600-800mm 2452 2452 2452 2452 2452 2452 2452

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2260 300mm 2260 400mm 2260 500mm 2260 600mm 2260 700mm 2260 800mm 2260

Frame Widths 600-800mm 3940 3940 3940 3940 3940 3940 3940

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2720 2720 300mm 2720 2720 400mm 2720 2720 500mm 2720 2720 600mm 2720 2720 700mm 2720 2720 800mm 2720 2720

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4216 300mm 3944 4216 400mm 3944 4216 500mm 3944 4216 600mm 3944 4216 700mm 3944 4216 800mm 3944 4216

Section K – High Rise Short Span Applications + Design

Page K.19


Table K17:

Bay Capacity in kg – ‘Back Bracing Every Other Bay’ or ‘Fully Back Clad’ Rack heights 4100 to 5000mm. K and EK uprights, 1290mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1270 300mm 1270 400mm 1270 500mm 1270 600mm 1270 700mm 1270 800mm 1270

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2102 300mm 2102 400mm 2102 500mm 2102 600mm 2102 700mm 2102 800mm 2102

Upright type ‘EK’

Frame Widths 600-800mm 1840 1840 1840 1840 1840 1840 1840

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1331 300mm 1331 400mm 1331 500mm 1331 600mm 1331 700mm 1331 800mm 1331

Frame Widths 600-800mm 3072 3072 3072 3072 3072 3072 3072

Frame Widths 600-800mm 2452 2452 2452 2452 2452 2452 2452

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 2260 300mm 2260 400mm 2260 500mm 2260 600mm 2260 700mm 2260 800mm 2260

Frame Widths 600-800mm 3940 3940 3940 3940 3940 3940 3940

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2720 2720 300mm 2720 2720 400mm 2720 2720 500mm 2720 2720 600mm 2720 2720 700mm 2720 2720 800mm 2720 2720

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4216 300mm 3944 4216 400mm 3944 4216 500mm 3944 4216 600mm 3944 4216 700mm 3944 4216 800mm 3944 4216

Section K – High Rise Short Span Applications + Design

Page K.20


Table K18:

Bay Capacity in kg – ‘Back Bracing Every Other Bay’ or ‘Fully Back Clad’ Rack heights 5100 to 5500mm. K and EK uprights, 900 and 1000mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1804 300mm 1804 400mm 1804 500mm 1804 600mm 1804 700mm 1804 800mm 1804

Upright type ‘EK’

Frame Widths 600-800mm 1460 1460 1460 1460 1460 1460 1460

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

Frame Widths 600-800mm 2590 2590 2590 2590 2590 2590 2590

Frame Widths 600-800mm 2222 2222 2222 2222 2222 2222 2222

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1915 300mm 1915 400mm 1915 500mm 1915 600mm 1915 700mm 1915 800mm 1915

Frame Widths 600-800mm 3644 3644 3644 3644 3644 3644 3644

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2720 2720 300mm 2720 2720 400mm 2720 2720 500mm 2720 2720 600mm 2720 2720 700mm 2720 2720 800mm 2720 2720

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4216 300mm 3944 4216 400mm 3944 4216 500mm 3944 4216 600mm 3944 4216 700mm 3944 4216 800mm 3944 4216

Section K – High Rise Short Span Applications + Design

Page K.21


Table K19:

Bay Capacity in kg – ‘Back Bracing Every Other Bay’ or ‘Fully Back Clad’ Rack heights 5100 to 5500mm. K and EK uprights, 1290mm bay length. Minimum 3 bays per rack. Upright type ‘K’

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1804 300mm 1804 400mm 1804 500mm 1804 600mm 1804 700mm 1804 800mm 1804

Upright type ‘EK’

Frame Widths 600-800mm 1460 1460 1460 1460 1460 1460 1460

4 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1023 300mm 1023 400mm 1023 500mm 1023 600mm 1023 700mm 1023 800mm 1023

Frame Widths 600-800mm 2590 2590 2590 2590 2590 2590 2590

Frame Widths 600-800mm 2222 2222 2222 2222 2222 2222 2222

5 Batten Frames Shelf Frame spacing Widths 300-500mm 200mm 1915 300mm 1915 400mm 1915 500mm 1915 600mm 1915 700mm 1915 800mm 1915

Frame Widths 600-800mm 3644 3644 3644 3644 3644 3644 3644

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2720 2720 300mm 2720 2720 400mm 2720 2720 500mm 2720 2720 600mm 2720 2720 700mm 2720 2720 800mm 2720 2720

Issue: Sept 2006

5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3944 4216 300mm 3944 4216 400mm 3944 4216 500mm 3944 4216 600mm 3944 4216 700mm 3944 4216 800mm 3944 4216

Section K – High Rise Short Span Applications + Design

Page K.22


SECTION K1 – BACK BRACING / CLADDING (racks 3100 to 5500mm) The back bracing requirement will have been determined through the design process and the use of the ‘Bay Capacity’ tables K2 to K19. These table will have highlighted the need for one of the following bracing solutions: Tables K2 – K7 Racks ‘Without Back Bracing’ Tables K8 – K13 Racks with ‘Back Bracing Every Third Bay’ Tables K14 – K19 Racks with ‘Back Bracing Every Other Bay’ or ‘Fully Back Clad’

Bracing Type The bracing used in these racks will be the 3mm thick ‘Back Brace EK’ which is described within section C of this manual. These braces are bolted to the upright through the holes in the front face of the EK upright. When used in conjunction with K uprights, the uprights will need to be drilled on site to accept the fixing. Alternatively to save site drilling a decision may be taken to upgrade the uprights from K to EK so that the holes are automatically included. Bracing panel height Bay length Hole centres ‘L’ Fixings

1000mm 900mm 1328.0mm

1000mm 1000mm 1395.5mm

1000mm 1290mm 1611.5mm

M6x20mm long screws and nuts.

Back Cladding Type The choice of back cladding type will depend on whether the design requires back braces or not. If back braces ARE required then the cladding must be the structural ‘EK Solid Back Cladding’. If back braces are NOT required then the cladding can be the non-structural type with clips. Both types of cladding are described within section C of this manual. The ‘EK Solid Back Cladding’ is structural and is bolted to the upright through the holes in the front face of the EK upright. When used in conjunction with K uprights, the uprights will need to be drilled on site to accept the fixing. Alternatively to save site drilling a decision may be taken to upgrade the uprights from K to EK so that the holes are automatically included. Panel heights

1000 and 1500mm, Panels may be overlapped to achieve required height.

Fixings

M6x20mm long screws and nuts. The 1000mm panel uses 6 nuts and bolts per panel (3 each side). The 1500mm panel uses 8 nuts and bolts per panel (4 each side).

The ‘Full Width Solid Back Cladding’ which uses clips is NOT structural and can only be used in positions where back bracing is not required. Panel heights

800, 1000, 1200 and 1300mm. A schedule of the recommended panel combinations is given within Appendix B of this manual.

Fixings

6 clips per panel, a piece of cladding trim is used to cover the gap between panels.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.23


Bracing Layout within the Height Bracing commences at the bottom and progresses up the rack in 1000mm panels, with the second panel within the height alternating into the adjacent bay, and then returning for the third panel etc. These panels should be laid out so that the unbraced section ‘A’ at the top of the rack never exceeds 531mm. In racks where this would occur an additional panel must be placed at the top of the rack so that it overlaps ‘B’ the panel below. This overlap should never exceed 500mm.

‘L’ = Bay length (either 900, 1000 or 1290mm centres). Frame Height ‘H’

No. of Panels ‘N’

3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm

3 3 3 3 3 3 4 4 4 4 4 4 4

Issue: Sept 2006

Dimension ‘A’ ‘B’ mm mm 100 131 231 331 431 531 500 400 300 200 100 131 231

Frame Height ‘H’

No. of Panels ‘N’

4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm

4 4 4 5 5 5 5 5 5 5 5 5

Dimension ‘A’ ‘B’ mm mm 331 431 531 500 400 300 200 100 131 231 331 431

Section K – High Rise Short Span Applications + Design

Page K.24


Bracing Layout along the Length of the Rack The use of the design tables will have highlighted the frequency of the back bracing. This will be either ‘Every third bay’ or ‘Every other bay’. The following illustrations show the position that the bracing starts within both a typical single and double entry rack. The bracing then alternates in the height with the adjacent bay as described on the previous page. The bracing locations should be evenly distributed along the whole length of each rack.

Back Bracing Every Third Bay

The number of bracing sets equals the number of bays divided by 3, rounding up if necessary. i.e. a 9 bay rack requires 3 sets, and a 10 bay rack requires 4 sets.

Back Bracing Every Other Bay

The number of bracing sets equals the number of bays divided by 2, rounding up if necessary. i.e. a 9 bay rack requires 5 sets, and a 10 bay rack also requires 5 sets.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.25


SECTION K1 – BASEPLATE and FLOOR FIXING REQUIREMENT (racks 3100 to 5500mm) Baseplate Select the required baseplate by checking the load passing through the plate into the floor. Standard baseplate = 1500kg per upright (i.e. 3000kg/frame). Standard baseplate plus Heavy Duty levelling plate = 2500kg per upright (5000kg/frame). High Rise baseplate = 3000kg per upright (6000kg/frame).

Floor Fixings Floor fixings are necessary to securely locate the frames in position and to resist overturning. The quantity of floor fixings required will depend on the rack application, and its height to width ratio. If a baseplate is fixed down it must also be secured to the upright. Height to Width Ratio Definition - Single Entry Racks The height to the top loaded level divided by the frame width, i.e. a height of 5000mm and a frame width of 450mm, gives a height to width ratio of 11.11. Height to Width Ratio Definition - Double Entry Racks With frames bolted back to back at the top and bottom, with M6x20mm fixings. The height to the top loaded level divided by the combined frame width, i.e. a height of 5000mm and a combined width of 900mm, gives a height to width ratio of 5.56. Height to Width Ratio not greater than 5 to 1 Providing mechanical handling equipment can not approach, and there is no back cladding or bracing, no floor fixings are required. Height to Width Ratio greater than 5 to 1, but less than 8 to 1 Standard baseplate: perimeter uprights must be fixed down with a hammer screw. High Rise baseplate: perimeter uprights must be fixed down with expander bolts. Height to Width Ratio greater than 8 to 1, but less than 10 to 1 Standard baseplate: perimeter uprights must be fixed down with expander bolts. High Rise baseplate: perimeter uprights must be fixed down with expander bolts. Height to Width Ratio greater than 10 to 1, but less than 15 to 1 (Single Entry Racks Only). Standard baseplate: all uprights must be fixed down with expander bolts, and single entry racks top tied to an adjacent double entry rack. High Rise baseplate: all uprights must be fixed down with expander bolts. Height to Width Ratio greater than 15 to 1 (Single Entry Racks Only). Standard baseplate: this baseplate must not be used with ratios greater than 15 to 1. High Rise baseplate: all uprights must be fixed down with expander bolts, and single entry racks top tied to an adjacent double entry rack. All back uprights connected to bracing or EK back cladding must be fixed to the floor. All racks containing either drawers, trays or doors must be perimeter fixed. All racks must be considered for any special requirements that may require additional floor fixings.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.26


SECTION K1 – TOP TIE REQUIREMENT (racks 3100 to 5500mm) When the rack Height to Width ratio dictates, single entry racks need to be top tied to an adjacent double entry rack. These Top Ties provide stability to the structure, they are not designed as a fixing location for any kind of mechanical handling equipment. Position They are positioned at the top of the shelving allowing sufficient clearance below the tie for any handling equipment that is operating within the aisle, whilst also providing uninterrupted access to the top storage location. Section The tie should be designed on a project by project basis, using a suitably available steel section such as slotted angle, designed to meet the load requirements for the given aisle width. Design The steel section should be designed for a compression and tension load equal to 5% of the single entry bay load. Fixing The top tie can be fixed either directly to the upright or via a standard baseplate used as a top cap.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.27


DESIGN EXAMPLE 1

Using the above example to demonstrate the correct design procedure. The client has a preference for open frames. Each rack contains 5 bays of shelving within the length. The client will be using mobile steps to access the top storage levels. Step 1.

Shelf selection. Using design Table K1 check the suitability of the steel shelves. 1000 x 450mm ‘H’ heavy shelf will support 235kg without reinforcement bars. Therefore OK to use: ‘H’ heavy duty shelves without reinforcement.

Step 2.

Frame selection. Using design Table K2 for a 3100mm high rack with a bay length of 1000mm. The frame width is 450mm, with a maximum shelf spacing of 500mm. The allowable bay load for a 4 Batten Frame using type K uprights is 1483kg, which exceeds the required 1255kg. Therefore OK to use: 4 batten frame with type K uprights.

Step 3.

Baseplate and floor fixing requirement. Each baseplate takes 628kg (1255kg/2). Therefore OK to use the Standard Baseplate. Single entry racks: height to width ratio equals 3100/450 = 6.89 Double entry racks: height to width ratio equals 3100/900 = 3.44 Therefore the single entry rack must be fixed down, whilst the double entry only requires fixing because mechanical access equipment is being used to access the higher storage levels.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.28


DESIGN EXAMPLE 2

Using the above example to demonstrate the correct design procedure. The client has a preference for open frames. Each rack contains 10 bays of shelving within the length. The client will be using a free range order picking truck (that does not require any support form the racking), to access the top storage levels. Step 1.

Shelf selection. Using design Table K1 check the suitability of the steel shelves. 1000 x 600mm ‘H’ heavy shelf will support 215kg without reinforcement bars. Therefore OK to use: ‘H’ heavy duty shelves without reinforcement.

Step 2.

Frame selection. Using design ‘Table K6 – Without Back Bracing’ for a 5200mm high rack with a bay length of 1000mm. Frame width is 600mm, with a maximum shelf spacing of 500mm. Not even the strongest frame on this table will carry the required 2090kg bay load. Therefore progress to the next set of tables, with every third bay back braced. Using design ‘Table K12 – Back Bracing Every Third Bay’ for a 5200mm high rack with a bay length of 1000mm. Frame width is 600mm, and maximum shelf spacing of 500mm. The allowable bay load for a: 4 Batten Frame using type EK uprights is 2590 kg, or 5 Batten Frame using type K uprights is 2222 kg.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.29


Therefore OK to use either frame, but because back bracing is required it may be preferable to use the 4 batten frame with the EK uprights that already have holes. Back Bracing is required in every third bay: A rack with 10 bays, divided by 3 = 4 bays (i.e. bays 1, 4, 7, and 10). Step 3.

Baseplate and floor fixing requirement. Each baseplate takes 1045kg (2090kg/2). Therefore OK to use the Standard Baseplate. Single entry racks: height to width ratio equals 5200/600 = 8.67 Double entry racks: height to width ratio equals 5200/1200 = 4.33 Therefore the single entry rack must be fixed down with expander bolts, whilst the double entry only requires fixing because mechanical access equipment is being used to access the higher storage levels.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.30


SECTION K2 - DESIGN PROCESS (racks 3100 to 12,000mm)

Sketch the desired rack. Indicate bay length, width, and height. Show the number of shelf levels, the desired load per shelf and the pitch between these shelves. Indicate the preference for braced or clad, frames and backs. Check the shelf design. The most cost effective design will be to use a N normal duty shelf if available in the size you require, followed by a S standard and then a non-reinforced H heavy duty shelf. After that a reinforced H heavy duty shelf with either one or two reinforcement bars. Check the bay design. With this type of racking the frames must either be fully braced or clad. The backs of the racks must again be braced or clad. Back bracing is in every other bay in single racks and every bay in double racks. Baseplate Standard baseplates can be used up to 5500mm (subject to loading), but racks over 5500mm high must use the High Rise Baseplate. Upright Splice Frame over 8000mm high will need to have spliced uprights. This splice must be positioned in accordance will the recommendations contained with section B, so that the splice plates do not clash with either a shelf, beam, batten, or bracing diagonal. Check the floor fixing, and any top tie requirements. This involves checking the height to width ratio of the bay. If a bay contains drawer or tray sets it MUST be fixed down regardless of its ratio. Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.31


SECTION K2 - DESIGN TABLES (racks 3100 to 12,000mm) The following tables are provided. Table K20:

Shelf Capacity. Capacity of the shelf and beam using either none, one, or two reinforcing bars.

Table K21:

Bay Capacity Rack heights 3100 to 12,000mm. K and EK uprights, Bay lengths 900, 1000 and 1290mm. Fully braced or Clad frames, Back braced or Clad.

______________________________________________________________________________

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.32


New table Table K20:

Shelf Capacity in kg. Capacity of the shelf and beam using either none, one, or two reinforcing bars.

Shelf size

300x900 300x1000 300x1290

400x900

400x1000

400x1290

450x900 450x1000 450X1290 500x900 500x1000 500x1290 600x900 600x1000 600x1290 800x900 800x1000 800x1290

Issue: Sept 2006

Shelf t mm

Shelf Duty

Without bars. kg

0.5 0.7 0.5 0.7 0.5 0.7

N H N H N H

0.5 0.6 0.7 0.5 0.6 0.7 0.5 0.6 0.7

With 1 bar.

With 2 bars.

kg

kg

140 235 135 235 70 110

260 260 235

300 300 350

N S H N S H N S H

140 160 235 140 150 235 75 85 110

260 260 235

300 300 350

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

160 235 150 235 85 110

260 260 235

300 300 350

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

170 235 150 235 85 110

260 260 235

300 300 350

0.6 0.7 0.6 0.7 0.6 0.7

S H S H S H

150 215 140 215 100 120

290 290 215

380 380 310

0.7 0.7 0.7

H H H

110 110 120

290 290 215

380 380 310

Section K – High Rise Short Span Applications + Design

Page K.33


Table K21:

Bay Capacity in kg – Fully braced or Clad frames, Back braced or Clad. Rack heights 3100 to 12,000mm. K and EK uprights, Bay lengths 900, 1000 and 1290mm.

Upright type ‘K’

Upright type ‘EK’

Rack heights 3100 to 5500mm Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2750 2750 300mm 2750 2750 400mm 2750 2750 500mm 2750 2750 600mm 2750 2750 700mm 2750 2750 800mm 2750 2750

Rack heights 3100 to 5500mm Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 4100 4216 300mm 4100 4216 400mm 4100 4216 500mm 4100 4216 600mm 4100 4216 700mm 4100 4216 800mm 4100 4216

Rack heights 5600 to 8000mm Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2576 2736 300mm 2576 2736 400mm 2576 2736 500mm 2576 2736 600mm 2576 2736 700mm 2576 2736 800mm 2576 2736

Rack heights 5600 to 8000mm Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3936 4128 300mm 3936 4128 400mm 3936 4128 500mm 3936 4128 600mm 3936 4128 700mm 3936 4128 800mm 3936 4128

Rack heights 8100 to 12,000mm Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 2568 2640 300mm 2568 2640 400mm 2568 2640 500mm 2568 2640 600mm 2568 2640 700mm 2568 2640 800mm 2568 2640

Rack heights 8100 to 12,000mm Shelf Frame Frame spacing Widths Widths 300-500mm 600-800mm 200mm 3696 3816 300mm 3696 3816 400mm 3696 3816 500mm 3696 3816 600mm 3696 3816 700mm 3696 3816 800mm 3696 3816

For shelving with handling equipment guiding in the rack, the load should be reduced. For further information contact Support Department.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.34


SECTION K2 – BACK BRACING / CLADDING (racks 3100 to 12,000mm) With this type of racking the backs of the racks must either be fully braced or clad. Back bracing is in every other bay.

Bracing Type The bracing used in these racks will be the ‘Back Brace EK’ as described within section K1. The bracing is set out in 1000mm high panels commencing at the bottom of the racks and progressing to full height using the patterns described, just adding extra 1000mm panels to achieve the required height.

Back Cladding Type In bays where the design dictates the use of back braces, these braces can only be substituted by the structural bolted ‘EK Solid Back Cladding’ which is described within section K1. In theory bays where braces are not required can be fitted with the non-structural cladding using clips. However this complicates the design and the build process on site, which may out weigh any possible material cost savings.

Bracing Layout along the Length of the Rack The following illustration shows the position of this bracing in every other bay.

The number of bracing sets equals the number of bays divided by 2, rounding up if necessary. i.e. a 9 bay single rack requires 5 sets, and a 10 bay single rack also requires 5 sets.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.35


SECTION K2 – BASEPLATE and FLOOR FIXING REQUIREMENT (racks 3100 to 12,000mm) Baseplate Select the required baseplate by checking the load passing through the plate into the floor. Standard baseplate = 1500kg per upright (i.e. 3000kg/frame). Standard baseplate plus Heavy Duty levelling plate = 2500kg per upright (5000kg/frame). High Rise baseplate = 3000kg per upright (6000kg/frame). Racks over 5500mm high must use the High Rise Baseplate. Floor Fixings Floor fixings are necessary to securely locate the frames in position and to resist overturning. The quantity of floor fixings required will depend on the rack application, and its height to width ratio. If a baseplate is fixed down it must also be secured to the upright. Height To Width Ratio Definition - Single Entry Racks The height to the top loaded level divided by the frame width, i.e. a height of 5000mm and a frame width of 450mm, gives a height to width ratio of 11.11. Height To Width Ratio Definition - Double Entry Racks With frames bolted back to back at the top and bottom, with M6x20mm fixings. The height to the top loaded level divided by the combined frame width, i.e. a height of 5000mm and a combined width of 900mm, gives a height to width ratio of 5.56. Height to Width Ratio not greater than 5 to 1 Providing mechanical handling equipment can not approach, and there is no back cladding or bracing, no floor fixings are required. Height to Width Ratio greater than 5 to 1, but less than 8 to 1 Standard baseplate: perimeter uprights must be fixed down with a hammer screw. High Rise baseplate: perimeter uprights must be fixed down with expander bolts. Height to Width Ratio greater than 8 to 1, but less than 10 to 1 Standard baseplate: perimeter uprights must be fixed down with expander bolts. High Rise baseplate: perimeter uprights must be fixed down with expander bolts. Height to Width Ratio greater than 10 to 1, but less than 15 to 1 Standard baseplate: perimeter uprights must be fixed down with expander bolts, and single entry racks top tied to an adjacent double entry rack. High Rise baseplate: perimeter uprights must be fixed down with expander bolts. Height to Width Ratio greater than 15 to 1, but less than 20 to 1 (Single Entry Racks Only). No double entry rack is allowed to exceed a ratio greater than 15 to 1 Standard baseplate: this baseplate must not be used with ratios greater than 15 to 1. High Rise baseplate: all uprights must be fixed down with expander bolts, and single entry racks top tied to an adjacent double entry rack. All back uprights connected to bracing or EK back cladding must be fixed to the floor. All racks containing either drawers, trays or doors must be perimeter fixed. All racks must be considered for any special requirements that may require additional floor fixings.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.36


SECTION K2 – TOP TIE REQUIREMENT (racks 3100 to 12,000mm) When the rack Height to Width ratio dictates, single entry racks need to be top tied to an adjacent double entry rack. These Top Ties provide stability to the structure, they are not designed as a fixing location for any kind of mechanical handling equipment. Position They are positioned at the top of the shelving allowing sufficient clearance below the tie for any handling equipment that is operating within the aisle, whilst also providing uninterrupted access to the top storage location. Section The tie should be designed on a project by project basis, using a suitably available steel section such as slotted angle, designed to meet the load requirements for the given aisle width. Design The steel section should be designed for a compression and tension load equal to 5% of the single entry bay load. Fixing The top tie can be fixed either directly to the upright or via a standard baseplate used as a top cap.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.37


DESIGN EXAMPLE 3

Using the above example to demonstrate the correct design procedure. The client has a preference for clad frames and clad backs. Each rack contains 10 bays of shelving within the length. The client will be using a free range order picking truck (that does not require any support form the racking), to access the top storage levels. Step 1.

Shelf selection. Using design Table K20 check the suitability of the steel shelves. 1000 x 600mm ‘H’ heavy shelf will support 215kg without reinforcement bars. Therefore OK to use: ‘H’ heavy duty shelves without reinforcement.

Step 2.

Frame selection. Using design ‘Table K21 – With Back Bracing’ for a 9200mm high rack with a bay length of 1000mm. Frame width is 600mm, with a maximum shelf spacing of 500mm. The allowable bay load for a: 9200mm Clad frame using type EK uprights is 3816kg. Therefore OK to use clad frame, with EK uprights. The uprights are over 8000mm high and will therefore need to be spliced. The ideal position would be at half height (4600mm), but that clashes with the shelf at 4700mm. Therefore the splice needs to be raised to say 5000mm. If this were a braced frame that position would also need to be checked to ensure it didn’t clash with a frame batten or brace. Details of the splice location are contained within Section B under the splice description.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.38


Step 3.

Baseplate and floor fixing requirement. The rack is over 5500mm high and therefore must use the High Rise Baseplate. Single entry racks: height to width ratio equals 9200/600 = 15.3 Double entry racks: height to width ratio equals 9200/1200 = 7.7 Therefore the single entry rack must be fixed down, with expander bolts and top tied to an adjacent double entry rack. The double entry rack should be perimeter fixed down with expander bolts.

Issue: Sept 2006

Section K – High Rise Short Span Applications + Design

Page K.39


APPENDIX A – FRAME ASSEMBLY SCHEDULE This Appendix provides detailed dimensions of how the frames should be constructed, where to position the horizontal battens, and the location of frame bracing node points. The strength data contained within the manual is a result of extensive tests and calculation and involves the correct positioning of battens, braces, and fixings. It is therefore most important that correct assembly information is relayed to those constructing the frames and that the details are strictly adhered to. The design process will have highlighted which style of frame is needed for each particular application.The following schedules are included: L/D = Light Duty,

H/D = Heavy Duty

Page

Low Rise - Fixed Height Frames up to 3000mm 2 L/D Battens (swaged or riveted) 300 to 600mm widths. 2 H/D Battens (riveted) 800, and 1000mm widths. 3 L/D Battens (swaged or riveted) 300 to 600mm widths. 3 H/D Battens (riveted) 800, and 1000mm widths. 4 L/D Battens (swaged or riveted) 300 to 600mm widths. 4 H/D Battens (riveted) 800, and 1000mm widths. 4 L/D Battens (swaged) + 2 ‘X’ braces 300 to 600mm widths. 4 L/D Battens (riveted) + 2 ‘X’ braces 300 to 600mm widths. 3 H/D Battens (riveted) + 2 ‘X’ braces 800, and 1000mm widths.

App A.2 App A.3 App A.4 App A.5 App A.6 App A.7 App A.8 App A.9 App A.10

High Rise - Variable Height Frames from 3100 to 5500mm 4 L/D Battens (swaged or riveted) 300 to 600mm widths. 4 H/D Battens (riveted) 800, and 1000mm widths. 5 L/D Battens (swaged or riveted) 300 to 600mm widths. 5 H/D Battens (riveted) 800, and 1000mm widths. 4 H/D Battens (riveted) + 2 ‘X’ braces 800, and 1000mm widths. 5 L/D Battens (swaged) + 2 ‘X’ braces 300 to 600mm widths. 5 L/D Battens (riveted) + 2 ‘X’ braces 300 to 600mm widths. 5 H/D Battens (riveted) + 2 ‘X’ braces 800, and 1000mm widths.

App A.11, 12 App A.13, 14 App A.15, 16 App A.17, 18 App A.19 App A.20, 21 App A.22, 23 App A.24, 25

High Rise - Variable Height Frames from 3100 to 12,000mm Fully braced with L/D battens (swaged) 300 to 600mm widths. Fully braced with L/D battens (riveted) 300 to 600mm widths. Fully braced with H/D battens (riveted) 800, and 1000mm widths.

App A.26, 27, 28 App A.29, 30, 31 App A.32, 33, 34

Solid Clad Frames - Variable Height Frames to 12,000mm

App A.35, 36, 37, 38

Upright Splices Frames over 8000mm high need upright splices. These splices need to be carefully positioned to ensure they do not coincide with either, a shelf, a batten, or bracing diagonal. The rules for positioning these splices are contained within Section B – Frame Components.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.1


LOW RISE - 2 LIGHT DUTY BATTENS (swaged or riveted).

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Light duty batten Rivet 4.8 x 7mm (only for riveted frames)

Frame Height ‘H’

First Batten ‘A’

Batten Centres ‘B’

2 2 2 2 8

Top Batten ‘C’

1000mm 211 600 189 1600mm 311 800 489 2100mm 311 1300 489 2300mm 311 1500 489 2500mm 311 1700 489 Note: Riveted battens must be lowered by 50mm

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.2


LOW RISE - 2 HEAVY DUTY BATTENS (riveted).

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Heavy duty batten Rivet 4.8 x 7mm

2 2 2 2 12

Frame Height ‘H’

First Batten ‘A’

Batten Centres ‘B’

Top Batten ‘C’

1000mm 1600mm 2100mm 2300mm 2500mm

211 211 311 311 311

600 900 1300 1500 1700

189 489 489 489 489

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.3


LOW RISE - 3 LIGHT DUTY BATTENS (swaged or riveted).

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Light duty batten Rivet 4.8 x 7mm (only for riveted frames)

2 2 2 3 12

Frame Height ‘H’

First Batten ‘A’

Batten Centres ‘B’

Batten Centres ‘C’

Top Batten ‘D’

2100mm 2300mm 2500mm 3000mm

311 311 311 311

600 600 700 900

700 900 1000 1300

489 489 489 489

Note: Riveted battens must be lowered by 50mm

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.4


LOW RISE - 3 HEAVY DUTY BATTENS (riveted).

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Heavy duty batten Rivet 4.8 x 7mm

2 2 2 3 18

Frame Height ‘H’

First Batten ‘A’

Batten Centres ‘B’

Batten Centres ‘C’

Top Batten ‘D’

2100mm 2300mm 2500mm 3000mm

311 311 311 311

600 600 700 900

700 900 1000 1300

489 489 489 489

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.5


LOW RISE - 4 LIGHT DUTY BATTENS (swaged or riveted).

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Light duty batten Rivet 4.8 x 7mm (only for riveted frames)

2 2 2 4 16

Frame Height ‘H’

First Batten ‘A’

Batten Centres ‘B’

Batten Centres ‘C’

Batten Centres ‘D’

Top Batten ‘E’

2100mm 2300mm 2500mm 3000mm

211 211 211 211

300 400 400 500

500 500 600 800

600 700 800 1000

489 489 489 489

Note: Riveted battens must be lowered by 50mm

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.6


LOW RISE - 4 HEAVY DUTY BATTENS (riveted).

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Heavy duty batten Rivet 4.8 x 7mm

2 2 2 4 24

Frame Height ‘H’

First Batten ‘A’

Batten Centres ‘B’

Batten Centres ‘C’

Batten Centres ‘D’

Top Batten ‘E’

2100mm 2300mm 2500mm 3000mm

211 211 211 211

300 400 400 500

500 500 600 800

600 700 800 1000

489 489 489 489

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.7


LOW RISE - 4 LIGHT DUTY BATTENS (swaged) + 2 ‘X’ BRACES.

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Light duty batten (swage holes) Frame brace Rivet 4.8 x 7mm

Issue: September 2006

Appendix A – Frame Assembly Schedule

2 2 2 4 4 8

Page App A.8


LOW RISE - 4 LIGHT DUTY BATTENS (riveted) + 2 ‘X’ BRACES.

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Light duty batten (rivet holes) Frame brace Rivet 4.8 x 7mm

Issue: September 2006

Appendix A – Frame Assembly Schedule

2 2 2 4 4 24

Page App A.9


LOW RISE - 3 HEAVY DUTY BATTENS (riveted) + 2 ‘X’ BRACES.

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Heavy duty batten Frame brace Rivet 4.8 x 7mm

Issue: September 2006

Appendix A – Frame Assembly Schedule

2 2 2 3 4 26

Page App A.10


HIGH RISE - 4 LIGHT DUTY BATTENS (swaged or riveted).

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Light duty batten Rivet 4.8 x 7mm (only for riveted frames)

2 2 2 4 16

The chart containing the schedule of dimensions is shown on the following page.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.11


HIGH RISE - 4 LIGHT DUTY BATTENS (swaged or riveted) (continued).

Frame Height ‘H’ 3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm

Issue: September 2006

First Batten ‘A’

Batten Centres ‘B’

Batten Centres ‘C’

Batten Centres ‘D’

211 600 900 900 211 600 1000 900 211 600 1000 1000 211 700 1000 1000 211 700 1000 1100 211 700 1100 1100 211 700 1100 1200 211 800 1100 1200 211 800 1100 1300 211 800 1200 1300 211 800 1300 1300 211 900 1200 1400 211 900 1300 1400 211 900 1300 1500 211 900 1400 1500 211 1000 1300 1600 211 1000 1400 1600 211 1000 1400 1700 211 1000 1500 1700 211 1100 1500 1700 211 1100 1500 1800 211 1100 1600 1800 211 1100 1600 1900 211 1200 1600 1900 211 1200 1600 2000 Note: Riveted battens must be lowered by 50mm

Appendix A – Frame Assembly Schedule

Top Batten ‘E’ 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489

Page App A.12


HIGH RISE - 4 HEAVY DUTY BATTENS (riveted).

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Heavy duty batten Rivet 4.8 x 7mm

2 2 2 4 24

The chart containing the schedule of dimensions is shown on the following page.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.13


HIGH RISE - 4 HEAVY DUTY BATTENS (riveted) (continued).

Frame Height ‘H’

First Batten ‘A’

Batten Centres ‘B’

Batten Centres ‘C’

Batten Centres ‘D’

Top Batten ‘E’

3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm

211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211

600 600 600 700 700 700 700 800 800 800 800 900 900 900 900 1000 1000 1000 1000 1100 1100 1100 1100 1200 1200

900 1000 1000 1000 1000 1100 1100 1100 1100 1200 1300 1200 1300 1300 1400 1300 1400 1400 1500 1500 1500 1600 1600 1600 1600

900 900 1000 1000 1100 1100 1200 1200 1300 1300 1300 1400 1400 1500 1500 1600 1600 1700 1700 1700 1800 1800 1900 1900 2000

489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.14


HIGH RISE - 5 LIGHT DUTY BATTENS (swaged or riveted).

Component take-off Upright Baseplate Upright to baseplate fixing (when required) Light duty batten Rivet 4.8 x 7mm (only for riveted frames)

Quantity 2 2 2 5 20

The chart containing the schedule of dimensions is shown on the following page.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.15


HIGH RISE - 5 LIGHT DUTY BATTENS (swaged or riveted) (continued).

Frame Height ‘H’

First Batten ‘A’

Batten Centres ‘B’

Batten Centres ‘C’

Batten Centres ‘D’

Batten Centres ‘E’

Top Batten ‘F’

3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm

211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211

400 400 500 500 500 500 500 600 600 600 600 600 700 700 700 700 700 800 800 800 800 800 900 900 900

600 600 600 600 600 700 700 600 700 700 800 800 700 800 800 800 900 800 900 900 900 1000 900 1000 1000

700 700 700 700 800 800 800 900 800 900 900 900 1000 900 1000 1100 1000 1100 1000 1100 1200 1100 1200 1100 1200

700 800 800 900 900 900 1000 1000 1100 1100 1100 1200 1200 1300 1300 1300 1400 1400 1500 1500 1500 1600 1600 1700 1700

489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489

Note: Riveted battens must be lowered by 50mm

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.16


HIGH RISE - 5 HEAVY DUTY BATTENS (riveted).

Component take-off Upright Baseplate Upright to baseplate fixing (when required) Heavy duty batten Rivet 4.8 x 7mm (only for riveted frames)

Quantity 2 2 2 5 30

The chart containing the schedule of dimensions is shown on the following page.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.17


HIGH RISE - 5 HEAVY DUTY BATTENS (riveted) (continued).

Frame Height ‘H’

First Batten ‘A’

Batten Centres ‘B’

Batten Centres ‘C’

Batten Centres ‘D’

Batten Centres ‘E’

Top Batten ‘F’

3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm

211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211 211

400 400 500 500 500 500 500 600 600 600 600 600 700 700 700 700 700 800 800 800 800 800 900 900 900

600 600 600 600 600 700 700 600 700 700 800 800 700 800 800 800 900 800 900 900 900 1000 900 1000 1000

700 700 700 700 800 800 800 900 800 900 900 900 1000 900 1000 1100 1000 1100 1000 1100 1200 1100 1200 1100 1200

700 800 800 900 900 900 1000 1000 1100 1100 1100 1200 1200 1300 1300 1300 1400 1400 1500 1500 1500 1600 1600 1700 1700

489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489 489

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.18


HIGH RISE - 4 HEAVY DUTY BATTENS (riveted) + 2 ‘X’ BRACES.

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Heavy duty batten Frame brace Rivet 4.8 x 7mm Frame Height Dimension ‘A’ Dimension ‘B’

Issue: September 2006

3100mm 300mm 189mm

2 2 2 4 4 32 3200mm 400mm 189mm

3300mm 400mm 289mm

Appendix A – Frame Assembly Schedule

3400mm 400mm 389mm

Page App A.19


HIGH RISE - 5 LIGHT DUTY BATTENS (swaged) + 2 ‘X’ BRACES.

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Light duty batten (swage holes) Frame brace Rivet 4.8 x 7mm

2 2 2 5 4 8

The chart containing the schedule of dimensions is shown on the following page.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.20


HIGH RISE - 5 LIGHT DUTY BATTENS (swaged) + 2 ‘X’ BRACES (continued).

Issue: September 2006

Frame Height ‘H’

Batten Centres ‘A’

Batten Centres ‘B’

3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm

200 200 200 300 300 400 400 400 500 500 600 600 600 700 700 800 800 800 900 900 1000 1000 1000 1100 1100

200 300 400 400 500 500 600 700 700 800 800 900 1000 1000 1100 1100 1200 1300 1300 1400 1400 1500 1600 1600 1700

Appendix A – Frame Assembly Schedule

Page App A.21


HIGH RISE - 5 LIGHT DUTY BATTENS (riveted) + 2 ‘X’ BRACES.

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Light duty batten (rivet holes) Frame brace Rivet 4.8 x 7mm

2 2 2 5 4 28

The chart containing the schedule of dimensions is shown on the following page.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.22


HIGH RISE - 5 LIGHT DUTY BATTENS (riveted) + 2 ‘X’ BRACES (continued).

Issue: September 2006

Frame Height ‘H’

Batten Centres ‘A’

Batten Centres ‘B’

3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm

200 200 200 300 300 400 400 400 500 500 600 600 600 700 700 800 800 800 900 900 1000 1000 1000 1100 1100

200 300 400 400 500 500 600 700 700 800 800 900 1000 1000 1100 1100 1200 1300 1300 1400 1400 1500 1600 1600 1700

Appendix A – Frame Assembly Schedule

Page App A.23


HIGH RISE - 5 HEAVY DUTY BATTENS (riveted) + 2 ‘X’ BRACES.

Component take-off

Quantity

Upright Baseplate Upright to baseplate fixing (when required) Heavy duty batten Frame brace Rivet 4.8 x 7mm

2 2 2 5 4 38

The chart containing the schedule of dimensions is shown on the following page.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.24


HIGH RISE - 5 HEAVY DUTY BATTENS (riveted) + 2 ‘X’ BRACES (continued).

Frame Height ‘H’

Batten Centres ‘A’

Batten Centres ‘B’

Top Batten ‘C’

3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm

300 400 400 400 500 500 500 600 600 700 700 700 800 800 900 900 1000 1000 1100 1100 1200

400 400 400 500 400 500 600 500 600 600 700 800 800 900 900 1000 1000 1100 1100 1200 1200

189 189 289 289 389 389 389 489 489 489 489 489 489 489 489 489 489 489 489 489 489

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.25


HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (swaged).

‘H’ = Frame height,

‘N’ = required number of bracing panels.

A Fully Braced frame consists of a number of standard height bracing panels, plus the possibility of either one or two additional horizontal battens. See ‘#’ above. When using light duty swaged battens the bracing panel height is 1000mm. The chart containing the schedule of dimensions is shown on the following pages, it details the number of panels, and the number of additional battens if required.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.26


HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (swaged) (continued). Frame height ‘H’ 3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm 5600mm 5700mm 5800mm 5900mm 6000mm 6100mm 6200mm 6300mm 6400mm 6500mm 6600mm 6700mm 6800mm 6900mm 7000mm 7100mm 7200mm 7300mm 7400mm 7500mm

No. of No. of panels extra ‘N’ battens 2 2 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 7 7 7

Issue: September 2006

2 2 1 1 1 1 2 2 1 1 1 1 2 2 1 1 1 1 2 2 1 1 1 1 2 2 -

Batten centres (mm) ‘A’

‘B’

Material take-off battens braces rivets

‘C’

89 189 89 189 289 389 89 189 289 389 89 189 89 189 289 389 89 189 289 389 89 189 89 189 289 389 89 189 289 389 89 189 89 189 289 389 89 189 289 389 89 189 89 189 289

Appendix A – Frame Assembly Schedule

5 5 4 4 4 4 5 5 5 5 6 6 5 5 5 5 6 6 6 6 7 7 6 6 6 6 7 7 7 7 8 8 7 7 7 7 8 8 8 8 9 9 8 8 8

4 4 6 6 6 6 6 6 6 6 6 6 8 8 8 8 8 8 8 8 8 8 10 10 10 10 10 10 10 10 10 10 12 12 12 12 12 12 12 12 12 12 14 14 14

8 8 12 12 12 12 12 12 12 12 12 12 16 16 16 16 16 16 16 16 16 16 20 20 20 20 20 20 20 20 20 20 24 24 24 24 24 24 24 24 24 24 28 28 28

Page App A.27


HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (swaged) (continued). Frame height ‘H’ 7600mm 7700mm 7800mm 7900mm 8000mm 8100mm 8200mm 8300mm 8400mm 8500mm 8600mm 8700mm 8800mm 8900mm 9000mm 9100mm 9200mm 9300mm 9400mm 9500mm 9600mm 9700mm 9800mm 9900mm 10000mm 10100mm 10200mm 10300mm 10400mm 10500mm 10600mm 10700mm 10800mm 10900mm 11000mm 11100mm 11200mm 11300mm 11400mm 11500mm 11600mm 11700mm 11800mm 11900mm 12000mm

No. of No. of panels extra ‘N’ battens 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 10 10 10 10 10 10 10 10 10 10 11 11 11 11 11 11 11 11

Issue: September 2006

1 1 1 1 2 2 1 1 1 1 2 2 1 1 1 1 2 2 1 1 1 1 2 2 1 1 1 1

Batten centres (mm) ‘A’

‘B’

Material take-off battens braces rivets

‘C’

389 89 189 289 389 89 189 89 189 289 389 89 189 289 389 89 189 89 189 289 389 89 189 289 389 89 189 89 189 289 389 89 189 289 389 89 189 89 189 289 389 89 189 289 389

Appendix A – Frame Assembly Schedule

8 9 9 9 9 10 10 9 9 9 9 10 10 10 10 11 11 10 10 10 10 11 11 11 11 12 12 11 11 11 11 12 12 12 12 13 13 12 12 12 12 13 13 13 13

14 14 14 14 14 14 14 16 16 16 16 16 16 16 16 16 16 18 18 18 18 18 18 18 18 18 18 20 20 20 20 20 20 20 20 20 20 22 22 22 22 22 22 22 22

28 28 28 28 28 28 28 32 32 32 32 32 32 32 32 32 32 36 36 36 36 36 36 36 36 36 36 40 40 40 40 40 40 40 40 40 40 44 44 44 44 44 44 44 44

Page App A.28


HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (riveted).

‘H’ = Frame height,

‘N’ = required number of bracing panels.

A Fully Braced frame consists of a number of standard height bracing panels, plus the possibility of either one or two additional horizontal battens. See ‘#’ above. When using light duty riveted battens the bracing panel height is 1100mm. The chart containing the schedule of dimensions is shown on the following pages, it details the number of panels, and the number of additional battens if required.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.29


HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (riveted) (continued). Frame height ‘H’ 3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm 5600mm 5700mm 5800mm 5900mm 6000mm 6100mm 6200mm 6300mm 6400mm 6500mm 6600mm 6700mm 6800mm 6900mm 7000mm 7100mm 7200mm 7300mm 7400mm 7500mm

No. of No. of panels extra ‘N’ battens 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6

Issue: September 2006

2 2 2 2 2 1 1 1 2 2 2 2 2 1 1 1 2 2 2 2 2 1 1 1 2 2 2 2 2 1 1 1 2

Batten centres (mm) ‘A’

‘B’

300 300 300 400 400

139 239 339 239 339

‘C’

Material take-off battens braces rivets ‘D’

139 239 339 139 239 339 300 300 300 400 400

139 239 339 239 339 139 239 339 139 239 339

300 300 300 400 400

139 239 339 239 339 139 239 339 139 239 339

300 300 300 400 400

139 239 339 239 339 139 239 339 139 239 339

300

139

Appendix A – Frame Assembly Schedule

5 5 5 5 5 4 4 4 5 5 5 6 6 6 6 6 5 5 5 6 6 6 7 7 7 7 7 6 6 6 7 7 7 8 8 8 8 8 7 7 7 8 8 8 9

4 4 4 4 4 6 6 6 6 6 6 6 6 6 6 6 8 8 8 8 8 8 8 8 8 8 8 10 10 10 10 10 10 10 10 10 10 10 12 12 12 12 12 12 12

28 28 28 28 28 28 28 28 32 32 32 36 36 36 36 36 36 36 36 40 40 40 44 44 44 44 44 44 44 44 48 48 48 52 52 52 52 52 52 52 52 56 56 56 60

Page App A.30


HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (riveted) (continued). Frame height ‘H’ 7600mm 7700mm 7800mm 7900mm 8000mm 8100mm 8200mm 8300mm 8400mm 8500mm 8600mm 8700mm 8800mm 8900mm 9000mm 9100mm 9200mm 9300mm 9400mm 9500mm 9600mm 9700mm 9800mm 9900mm 10000mm 10100mm 10200mm 10300mm 10400mm 10500mm 10600mm 10700mm 10800mm 10900mm 11000mm 11100mm 11200mm 11300mm 11400mm 11500mm 11600mm 11700mm 11800mm 11900mm 12000mm

No. of No. of panels extra ‘N’ battens 6 6 6 6 7 7 7 7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 9 10 10 10 10 10 10 10 10

Issue: September 2006

2 2 2 2 1 1 1 2 2 2 2 2 1 1 1 2 2 2 2 2 1 1 1 2 2 2 2 2 1 1 1 2 2

Batten centres (mm) ‘A’

‘B’

300 300 400 400

239 339 239 339

‘C’

Material take-off battens braces rivets ‘D’

139 239 339 139 239 339 300 300 300 400 400

139 239 339 239 339 139 239 339 139 239 339

300 300 300 400 400

139 239 339 239 339 139 239 339 139 239 339

300 300 300 400 400

139 239 339 239 339 139 239 339 139 239 339

300 300

139 239

Appendix A – Frame Assembly Schedule

9 9 9 9 8 8 8 9 9 9 10 10 10 10 10 9 9 9 10 10 10 11 11 11 11 11 10 10 10 11 11 11 12 12 12 12 12 11 11 11 12 12 12 13 13

12 12 12 12 14 14 14 14 14 14 14 14 14 14 14 16 16 16 16 16 16 16 16 16 16 16 18 18 18 18 18 18 18 18 18 18 18 20 20 20 20 20 20 20 20

60 60 60 60 60 60 60 64 64 64 68 68 68 68 68 68 68 68 72 72 72 76 76 76 76 76 76 76 76 80 80 80 84 84 84 84 84 84 84 84 88 88 88 92 92

Page App A.31


HIGH RISE – FULLY BRACED with HEAVY DUTY BATTENS (riveted).

‘H’ = Frame height,

‘N’ = required number of bracing panels.

A Fully Braced frame consists of a number of standard height bracing panels, plus the possibility of either one or two additional horizontal battens. See ‘#’ above. When using heavy duty riveted battens the bracing panel height is 1200mm. The chart containing the schedule of dimensions is shown on the following pages, it details the number of panels, and the number of additional battens if required.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.32


HIGH RISE – FULLY BRACED with HEAVY DUTY BATTENS (riveted) (continued). Frame height ‘H’ 3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm 5600mm 5700mm 5800mm 5900mm 6000mm 6100mm 6200mm 6300mm 6400mm 6500mm 6600mm 6700mm 6800mm 6900mm 7000mm 7100mm 7200mm 7300mm 7400mm 7500mm

No. of No. of panels extra ‘N’ battens 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5

Issue: September 2006

1 1 1 1 1 2 2 2 2 1 1 1 1 1 2 2 2 2 1 1 1 1 1 2 2 2 2 1 1 1 1 1 2 2 2 2

Batten centres (mm) ‘A’

‘B’

189 189 289 389 489

300 400 400 400 400

‘C’

Material take-off battens braces rivets ‘D’

189 289 389 489 189 289 389 189 189 289 389 489

300 400 400 400 400 189 289 389 489 189 289 389

189 189 289 389 489

300 400 400 400 400 189 289 389 489 189 289 389

189 189 289 389 489

300 400 400 400 400 189 289 389 489

Appendix A – Frame Assembly Schedule

4 4 4 4 4 5 5 5 5 4 4 4 5 5 5 5 5 6 6 6 6 5 5 5 6 6 6 6 6 7 7 7 7 6 6 6 7 7 7 7 7 8 8 8 8

4 4 4 4 4 4 4 4 4 6 6 6 6 6 6 6 6 6 6 6 6 8 8 8 8 8 8 8 8 8 8 8 8 10 10 10 10 10 10 10 10 10 10 10 10

32 32 32 32 32 38 38 38 38 36 36 36 42 42 42 42 42 48 48 48 48 46 46 46 52 52 52 52 52 58 58 58 58 56 56 56 62 62 62 62 62 68 68 68 68

Page App A.33


HIGH RISE – FULLY BRACED with HEAVY DUTY BATTENS (riveted) (continued). Frame height ‘H’ 7600mm 7700mm 7800mm 7900mm 8000mm 8100mm 8200mm 8300mm 8400mm 8500mm 8600mm 8700mm 8800mm 8900mm 9000mm 9100mm 9200mm 9300mm 9400mm 9500mm 9600mm 9700mm 9800mm 9900mm 10000mm 10100mm 10200mm 10300mm 10400mm 10500mm 10600mm 10700mm 10800mm 10900mm 11000mm 11100mm 11200mm 11300mm 11400mm 11500mm 11600mm 11700mm 11800mm 11900mm 12000mm

No. of No. of panels extra ‘N’ battens 6 6 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9

Issue: September 2006

1 1 1 1 1 2 2 2 2 1 1 1 1 1 2 2 2 2 1 1 1 1 1 2 2 2 2 1 1 1 1 1 2

Batten centres (mm) ‘A’

‘B’

‘C’

Material take-off battens braces rivets ‘D’ 189 289 389

189 189 289 389 489

300 400 400 400 400 189 289 389 489 189 289 389

189 189 289 389 489

300 400 400 400 400 189 289 389 489 189 289 389

189 189 289 389 489

300 400 400 400 400 189 289 389 489 189 289 389

189 189 289 389 489

300 400 400 400 400 189

Appendix A – Frame Assembly Schedule

7 7 7 8 8 8 8 8 9 9 9 9 8 8 8 9 9 9 9 9 10 10 10 10 9 9 9 10 10 10 10 10 11 11 11 11 10 10 10 11 11 11 11 11 12

12 12 12 12 12 12 12 12 12 12 12 12 14 14 14 14 14 14 14 14 14 14 14 14 16 16 16 16 16 16 16 16 16 16 16 16 18 18 18 18 18 18 18 18 18

66 66 66 72 72 72 72 72 78 78 78 78 76 76 76 82 82 82 82 82 88 88 88 88 86 86 86 92 92 92 92 92 98 98 98 98 96 96 96 102 102 102 102 102 108

Page App A.34


FULLY SOLID CLAD FRAMES.

‘H’ = Frame height,

‘N’ = required number of cladding sheets.

Each cladding sheet must be secured with either swage or rivet connections, positioned at the top, the bottom and the rest evenly distributed in between at no more than 400mm centres. For a 900mm sheet use 6 connections, 1000mm = 8, 1600mm = 10, 2100mm = 12, 2300mm = 14, and 2500mm = 14 connections. Half to each upright. A chart detailing the recommended cladding sheet combinations for each frame height is shown on the following pages.

Issue: September 2006

Appendix A – Frame Assembly Schedule

Page App A.35


FULLY SOLID CLAD FRAMES (continued). Frame height ‘H’

No. of No. of No. of clad clad swage sheets trim fixings

1000mm 1600mm 2100mm 2300mm 2500mm 3000mm

1 1 1 1 1 2

1

8 10 12 14 14 18

3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm 5600mm 5700mm 5800mm 5900mm

2 2 2 2 2 3 2 4 2 3 2 2 3 2 3 2 3 2 3 2 3 3 3 3 3 3 3 3 3

1 1 1 1 1 2 1 3 1 2 1 1 2 1 2 1 2 1 2 1 2 2 2 2 2 2 2 2 2

20 20 22 20 22 26 22 28 24 26 24 24 30 26 30 26 30 28 32 28 32 32 32 34 34 36 34 36 34

Issue: September 2006

Quantity of each cladding sheet type 900 1000 1600 2100 2300 2500 mm mm mm mm mm mm

1 1 1 1 1 1

1

1

1 2

1

1

1 1 2 2

2

1

1

1 1 1 1

1

1

1 1

1

1 2

2 1

1 1

2 1

1

1

1

1 1

1 2

1 2 1

1 1

1 1 1 1

2 1 2 1 1

1 1 2

2 1 1

Appendix A – Frame Assembly Schedule

1

1

1 1 2

Page App A.36


FULLY SOLID CLAD FRAMES (continued). Frame height ‘H’

6000mm 6100mm 6200mm 6300mm 6400mm 6500mm 6600mm 6700mm 6800mm 6900mm 7000mm 7100mm 7200mm 7300mm 7400mm 7500mm 7600mm 7700mm 7800mm 7900mm 8000mm 8100mm 8200mm 8300mm 8400mm 8500mm 8600mm 8700mm 8800mm 8900mm 9000mm 9100mm 9200mm 9300mm 9400mm 9500mm 9600mm 9700mm 9800mm 9900mm

No. of No. of No. of clad clad swage sheets trim fixings

3 4 3 3 3 4 3 3 4 3 4 3 4 3 4 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 4 5 4 5 4 5

Issue: September 2006

2 3 2 2 2 3 2 2 3 2 3 2 3 2 3 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 4 3 4 3 4 3 4

36 40 36 36 38 40 38 38 44 42 44 40 46 42 46 42 46 46 48 50 48 50 48 50 48 50 50 52 50 52 54 52 56 54 56 58 54 58 56 60

Quantity of each cladding sheet type 900 1000 1600 2100 2300 2500 mm mm mm mm mm mm

1 2

1 1

1 3

1 1

1

2 1 1 1

1 1 2

2

1 3

2

2 2

1 1

1

1

1

1 1

1

2 1 1

2

1

3 3 1 2

1 2 1 2 1

1 1 2 1 1

1

2 1 3 2 1

1 1 2 2

4 1

3 3 1

1 2

3 1 1

1 3

1

1 1 2 3

4 1

4 3 2 2

1 2

2

1

Appendix A – Frame Assembly Schedule

1 1 2

1 3 3 3

Page App A.37


FULLY SOLID CLAD FRAMES (continued). Frame height ‘H’ 10000mm 10100mm 10200mm 10300mm 10400mm 10500mm 10600mm 10700mm 10800mm 10900mm 11000mm 11100mm 11200mm 11300mm 11400mm 11500mm 11600mm 11700mm 11800mm 11900mm 12000mm

No. of No. of No. of clad clad swage sheets trim fixings 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 6 5 6

Issue: September 2006

3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 4 5

56 62 64 62 62 60 64 62 66 62 64 66 64 68 66 70 66 70 70 70 72

Quantity of each cladding sheet type 900 1000 1600 2100 2300 2500 mm mm mm mm mm mm 4 1 1 1 1 1

2 5 1 4

1

4 4 3 2

1

3 1 4

1

4 4

1 1

2 1 1

1

3 3 4 1 5

1 2 2

Appendix A – Frame Assembly Schedule

3 2

4 1 3 2

3 4 1 2

Page App A.38


APPENDIX B – FULL WIDTH BACK CLADDING SCHEDULE

This Appendix details the combination of ‘Full Width Back Cladding Panels’ required to equip each rack height. Individual panels have a nominal height of either 800, 1000, 1200, or 1300mm. Each panel is secured to the uprights with 6 back cladding clips, three either side of the panel. The hook on the clip passes through the rectangular hooks punched along the edges of the panel. Cladding trim is used to cover the gap between these panels. The length of this trim is 140mm less than the bay length. The schedules are detailed on the following pages.

Issue: Sept 2006

Appendix B – Full Width Back Cladding Schedule

Page App B.1


FULL WIDTH BACK CLADDING SCHEDULE (continued) Rack height ‘H’

No. of cladding sheets

No. of cladding trims

No. of cladding clips

1000mm 1600mm 2100mm 2300mm 2500mm 3000mm

1 2 2 2 2 3

1 1 1 1 2

6 12 12 12 12 18

3100mm 3200mm 3300mm 3400mm 3500mm 3600mm 3700mm 3800mm 3900mm 4000mm 4100mm 4200mm 4300mm 4400mm 4500mm 4600mm 4700mm 4800mm 4900mm 5000mm 5100mm 5200mm 5300mm 5400mm 5500mm 5600mm 5700mm 5800mm 5900mm

3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5

2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4

18 18 18 18 18 18 18 18 18 24 24 24 24 24 24 24 24 24 24 24 24 24 30 30 30 30 30 30 30

Issue: Sept 2006

Quantity of each cladding sheet type 800 1000 1200 1300 mm mm mm mm

1 2 1 1 1

1 1 1

3

1

1

1 2 2 1 1

4 2 3 3 2 2 1 1

4 3 3 2 2 1 1

Appendix B – Full Width Back Cladding Schedule

1 1 1 2 1 3 2 1

1 1 2 3 1

1 1 2 1 3 2 4 3 2 1

2 1 3 2 4 3

1 1 1 2 3 4 1 1 1 1

Page App B.2


FULL WIDTH BACK CLADDING SCHEDULE (continued) Rack height ‘H’

No. of cladding sheets

No. of cladding trims

No. of cladding clips

6000mm 6100mm 6200mm 6300mm 6400mm 6500mm 6600mm 6700mm 6800mm 6900mm 7000mm 7100mm 7200mm 7300mm 7400mm 7500mm 7600mm 7700mm 7800mm 7900mm 8000mm 8100mm 8200mm 8300mm 8400mm 8500mm 8600mm 8700mm 8800mm 8900mm 9000mm 9100mm 9200mm 9300mm 9400mm 9500mm 9600mm 9700mm 9800mm 9900mm

5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8

4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7

30 30 30 30 30 30 36 36 36 36 36 36 36 36 36 36 36 36 36 42 42 42 42 42 42 42 42 42 42 42 42 42 48 48 48 48 48 48 48 48

Issue: Sept 2006

Quantity of each cladding sheet type 800 1000 1200 1300 mm mm mm mm

5 4 3 2 1 3 3 2 2 1 1

3 2 2 1 1

2 2 1 1

Appendix B – Full Width Back Cladding Schedule

3 2 4 3 5 4 6 5 4 3 2 1 3 5 4 6 5 7 6 5 4 3 2 1 6 5 7 6 8 7 6 5

1 2 3 4 5 1 1 1 1 2 3 4 5 6 1 1 1 1 2 3 4 5 6 7 1 1 1 2 3

Page App B.3


FULL WIDTH BACK CLADDING SCHEDULE (continued) Rack height ‘H’

No. of cladding sheets

No. of cladding trims

No. of cladding clips

10000mm 10100mm 10200mm 10300mm 10400mm 10500mm 10600mm 10700mm 10800mm 10900mm 11000mm 11100mm 11200mm 11300mm 11400mm 11500mm 11600mm 11700mm 11800mm 11900mm 12000mm

8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 9 9 9 10 10 10

7 7 7 7 7 8 8 8 8 8 8 8 8 8 8 8 8 8 9 9 9

48 48 48 48 48 54 54 54 54 54 54 54 54 54 54 54 54 54 60 60 60

Issue: Sept 2006

Quantity of each cladding sheet type 800 1000 1200 1300 mm mm mm mm

4 3 2 1 2 1 1

1 1

Appendix B – Full Width Back Cladding Schedule

6 8 7 9 8 7 6 5 4 3 2 1 9 8 10

4 5 6 7 8 1 1 1 2 3 4 5 6 7 8 9 1

Page App B.4


APPENDIX C – PLASTIC TRAYS and BINS

Dexion offers a wide range of plastic trays and bins, from the very small parts bin, all the way up to the large Euro Containers. This appendix to the manual describes the part of that extensive range that is most suited to use with the HI280 shelving system. It gives an overview of the tray and bin ranges and how each interfaces with the shelving, recommending required shelf pitches, and the combination of units along the shelf for each of the bay sizes. Reference should be made to separate product data / literature if more information is required about specific details regarding each products features. The most suitable trays and bins for HI280 include: ARCA Series 45, 91, and 92 of Storage Trays. ARCA ranges of Modular Bins and Storage Bins. ______________________________________________________________________________ The above illustration shows a typical 1000 x 500 x 2100mm bay of HI280 shelving, containing: 40 trays 9221.760, 24 trays 9223.760, 12 bins 9069.000 and 3 bins 9071.000

Issue: September 2006

Appendix C – Plastic Bins

Page App C.1


PLASTIC TRAY and BIN FEATURES.

Full height front

Part height front

Front to back dividers

Left to right dividers

ARCA Series 45 storage trays Series 91 storage trays Series 92 storage trays Modular bins (9068-9070) Storage bins (9071-9072)

Clear front flap

Label facility

Colours

B B,ESD B,ESD B,R,Y B,G,R,Y

Colours: B = Blue, G = Green, R = Red, Y = Yellow. ESD = Specialist trays made of conductive material.

Issue: September 2006

Appendix C – Plastic Bins

Page App C.2


HOW TO FIND THE CORRECT TRAY or BIN. Use the following charts to find the tray or bin with the dimensions you require.

ARCA Trays and Bins. Unit width

62mm

80mm

400mm shelf width (front to back). 94mm 4532.760 115mm 188mm 4530.760 230mm 500mm shelf width (front to back). 94mm 4537.760 115mm 9221.760 188mm 4536.760 230mm 9223.760 310mm 600mm shelf width (front to back). 115mm 9231.760 230mm 9233.760

Unit Height 100mm 150mm

200mm

250mm

9071.000

9072.000

250mm

300mm

9111.760 9113.760

9068.000

9121.760 9123.760

9131.760 9133.760

9069.000

9070.000

Recommended HI280 Shelf Pitch (top of shelf to top of shelf). 100mm 125mm 150mm 200mm

Unit sizes are the external dimensions and should be considered nominal. The recommended shelf pitches assume all contents are contained within the height of the tray/bin.

Issue: September 2006

Appendix C – Plastic Bins

Page App C.3


TRAY or BIN COMBINATIONS (along a shelf). With such a wide range of unit sizes it is possible to achieve numerous different combinations of tray or bins along the length of a shelf. When planning these combinations it is worth considering the following points: 1. Unit sizes are nominal, and are the external dimensions. 2. Select the correct unit, with front to back dimensions to suit your shelf width. 3. Always use the same height bins on the same shelf, otherwise it is wasteful in height. 4. Operating clearances should be left between units, and between units and the uprights. 5. Unit sides may bow slightly if heavily loaded. 6. The available space between the HI280 uprights is 50mm less than the bay length. 7. Choice of colour for unit size identification, or stock control segregation. Some of the unit sizes are more suitable than others to the different shelf lengths. The following charts give some recommended combinations for each of the bay sizes. These combinations are based on using a common unit on a shelf without mixing units. A cross reference is also provided to show which of the combinations are available for individual shelf widths

300mm

Shelf width (front to back) 400mm 450mm 500mm

600mm

900mm bay (850mm clear between uprights). 8 x 94mm wide Arca series 45 trays 4 x 188mm wide Arca series 45 trays

1000mm bay (950mm clear between uprights). 9 x 94mm wide Arca series 45 trays 8 x 115mm wide Arca series 91 trays 8 x 115mm wide Arca series 92 trays 4 x 230mm wide Arca series 91 trays 4 x 230mm wide Arca series 92 trays 3 x 310mm wide Arca bins

1290mm bay (1240mm clear between uprights). 12 x 94mm wide Arca series 45 trays 10 x 115mm wide Arca series 91 trays 10 x 115mm wide Arca series 92 trays 6 x 188mm wide Arca series 45 trays 5 x 230mm wide Arca series 91 trays 5 x 230mm wide Arca series 92 trays Other combinations are possible but don’t necessarily make full use of the available space and hence are less efficient in space utilisation.

Issue: September 2006

Appendix C – Plastic Bins

Page App C.4


APPENDIX D – LOAD NOTICES All HI280 shelving installations should be supplied with load notices stating the capacity of the equipment installed. In addition to this, the notice should include the suppliers name and date of installation. Differing styles or configurations of rack will need their own notices. Notices should be fitted at regular intervals and displayed in prominent positions where they are clearly visible. Each must measure at least 125x250mm. The following is an example of a typical sign currently in use for this purpose.

Issue: September 2006

Appendix D – Load Notices

Page App D.1


APPENDIX E - EU MANUAL HANDLING DIRECTIVE This appendix has been included to highlight the existence of the EU Directive on Manual Handling The directive sets out the Employers responsibility to make suitable and sufficient assessment of the risks to the safety of their Employees whilst lifting and lowering loads. This responsibly is one that our clients need to concern themselves with when planning and operating their warehouses. If during the course of our discussions with them it becomes apparent that they are unaware of their responsibility, then we have a moral duty to advise them that a directive does exist, and that they do have responsibilities under it. The directive is a comprehensive document, which also contains help and advise on assessing risk, together with handling suggestions.

The above illustration is an extract from the document. The loads indicated are for men, the figures should be reduced by a third (34%) for women. The document provides the above loads as a guideline, recognising the wide range of personal capabilities, together with the diversity of handling situations, therefore suggesting where appropriate assessment is undertaken.

Issue: September 2006

Appendix E – EU Manual Handling Directive

Page App E.1


APPENDIX F – HI280 on MOBILE BASES This appendix describes the use of HI280 shelving on mobile bases. The mobile bases themselves are not detailed within this manual and separate reference needs to be made to the appropriate publications. The standard design rules that apply for static racks need to be amended for use within mobile applications. These considerations include: frame types, reduced bay loads, fixings, etc.

The above illustration shows a pair of typical HI280 frames mounted on a Compactus mobile base. Base Type HI280 is only suitable for mounting on ‘powered’ or ‘hand cranked’ base types, it is not suitable for use on ‘push pull’ type bases. Fixings The special baseplates and fixings used to mount the shelving on the base should be sourced with the shelving.

Issue: September 2006

Appendix F – HI280 on Mobile Bases

Page App F.1


HI280 Design

Base for Mobile The base consists of a shelf beam that is installed between the front uprights. The shelf that it supports is therefore installed back to front. It is available in both pre-galvanised and painted Grey White RAL 9002 finish. Frame Limitations Frame heights on mobile bases are limited to 2500mm. Only single entry racks greater than 500mm are permitted. All double entry racks are permitted. Frame type The only frames permitted on mobile bases are either ‘Fully Solid Clad’ or ‘Battened and Braced’ (as used in the bottom tier of a multi-tier installation). The use of the type S upright is permitted on mobile bases. Bay loads Bay loads are limited to 900kg. These should be checked against the mobile base design for each rack configuration to ensure the base capacity is sufficient. Part Codes Shelf beam painted Grey White RAL 9002:

900mm = 444047055, 1000mm = 444047052, 1290mm = 444047054.

Mobile baseplate = 444051400.

Issue: September 2006

Appendix F – HI280 on Mobile Bases

Page App F.2

Hi280 SHELVING DESIGN MANUAL SEPT 2006  

The components have been designed and tested in accordance with the recommendations of “The Federation Europeenne de la Manutention” (FEM)....

Hi280 SHELVING DESIGN MANUAL SEPT 2006  

The components have been designed and tested in accordance with the recommendations of “The Federation Europeenne de la Manutention” (FEM)....

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