Assembly instructions pallet racking BLS

Pallet Racking City Assembly instructions and instructions for use Edition no. 7 ©BLS – Brännehylte Lagersystem AB. 260515

Contents About these instructions.......................................................................................................... 4 Before beginning assembly.................................................................................................... 5 Bracing diagram........................................................................................................................... 6 Detailed overview........................................................................................................................ 7 Installing frames........................................................................................................................ 8-9 Installing X-brace....................................................................................................................... 10 Installing bays........................................................................................................................ 11-12 Installing horizontal push-through protection............................................................ 13 Installing vertical push-through protection................................................................. 14 Installing upright protectors................................................................................................ 15 Installing frame barriers........................................................................................................ 16 installing load signs.................................................................................................................. 17 Inspection & Maintenance.............................................................................................. 19-18

About these instructions Read the entire manual before starting assembly. Follow the directions in the manual to make sure the product complies with current standards.

The purpose of these assembly instructions is to facilitate correct installation and to inform of risks and how to avoid them. Bear in mind that the instructions are for your safety and the safety of others.

Use the assembly instructions and instructions for use in conjunction with: * assembly * regular inspections (together with the periodic inspection template) * taking corrective action as directed Each installation must be fitted with a load sign located in a clearly visible place.

Perform regular checks to ensure the technical safety of the pallet racking. Information about pallet racking inspections are available on our website www.blsab.se.

Parts of the installation instructions and instructions for use refer to the Swedish Standard SS-EN 15635:2008 - Steel static storage systems – Application and maintenance of storage equipment. If necessary, the purchaser or user can obtain the above standard from SIS. See www.sis.se for further information.

Links for downloading BLS installation instructions & instructions for use can be found at www.blsab.se

CONTACT US If in doubt, or for further information, please contact Brännehylte Lagersystem: Telephone

+46 370 30 50 00

Email

info@blsab.se

Website

www.blsab.se

Postal address

P.O. Box 12, SE 335 04 Hillerstorp, Sweden

Street address

Brännehylte Lagersystem AB High Chaparral SE 335 96 Kulltorp, Sweden

Before you begin Recommended tools Underlying surface

The client/user must make sure the floor is able to bear the relevant loads.

13 mm

16 mm

17 mm

Anchoring

8 mm

Pallet racks must be anchored to the floor to prevent the uprights from moving when mechanical handling equipment is used in or near warehouse fixtures.

Safety

Correct rack assembly is essential for a safe structure. Assembly must be carried out professionally and in accordance with these instructions.

Supplied fasteners

Self-drilling screw 5,5x19 part 111616-4-19

* Applies to C90 ** Applies to C110 *** Applies to C120

M8x20 /30/ M10x20

Fasteners not included

or

M8 / M10

nut with flange part 111308-1-20-7 part 111308-7-0-7 part 111310-1-20-7 part 111310-8-0-7

Multi-Monti Expander bolt 10x80 M10x90 part 111009-14

Distance tube 30/43

part 111009

M10

nut lock 30 mm - part 111056*/** 43 mm - part 111056-43*** part 111310-6-0-7

Distance Spacer

150 mm - part 111005 200 mm - part 111210-200 250 mm - part 111210-250 300 mm - part 111210-300

Beam safety pin part 111021

M10x75/105/110

75 mm - part 111310-1-75-7*/** 105 mm - part 111310-1-105-7***

* Leveling Plate

1 mm - part 111076-90-1 2 mm - part 111076-90-2 3 mm - part 111076-90-3

Base plate XL

C90 - part 90-002* C110 - part 110-002** C120 - part 120-002*** 4

Base plate

C90 - part 90-001* C110/120 - part 120-001**/***

**/*** Leveling Plate 1 mm - part 111076-120-1 2 mm - part 111076-120-2 3 mm - part 111076-120-3

*Leveling Plate base plate XL 1 mm - part 90-002-1 2 mm - part 90-002-2 3 mm - part 90-002-3

**/*** Leveling Plate base plate XL 1 mm - part 110-002-1 2 mm - part 110-002-2 3 mm - part 110-002-3

Floor attachment specification Securing in concrete - Concrete screw

Securing in asphalt - Concrete screw

Multi-Monti M10×60 Drilled hole Ø8 Drill depth 65 mm, cleaned hole Max. Mounting thickness 10 mm

Multi-Monti M10×100 Drilled hole Ø8 Drill depth 115 mm Max. Mounting thickness 50 mm

Multi-Monti M10×80 Drilled hole Ø8 Drill depth 85 mm, cleaned hole Max. Mounting thickness 30 mm

Multi-Monti M10×140 Drilled hole Ø8 Drill depth 155 mm Max. Mounting thickness 90 mm

Multi-Monti M10×100 Drilled hole Ø8 Drill depth 105 mm, cleaned hole Max. Mounting thickness 50 mm

Always use concrete screws and anchoring compound when installing on asphalt.

Max torque impact wrench Multi-Monti M10, 600 Nm

H = Mounting thickness L = Drill depth

Ø = Drilled hole diameter T = Thickness of concrete slab

5

Bracing diagram Table of dimensions Frame depth 500 mm Type of

Construction Upright C90-12

brace

height

Upright C90-10/20

Upright C110-10/20

Upright C120-18/21

1

0 mm

2

500 mm

454 mm

447 mm

426 mm

454 mm

688 mm

683 mm

670 mm

688 mm

Upright C90-10/20

Upright C110-10/20

Upright C120-18/21

Table of dimensions Frame depth 800 mm Type of

Construction Upright C90-12

brace

height

1

0 mm

754 mm

747 mm

726 mm

754 mm

2

500 mm

911 mm

905 mm

888 mm

911 mm

Upright C90-10/20

Upright C110-10/20

Upright C120-18/21

Table of dimensions Frame depth 1100 mm Construction Upright C90-12

brace

height

1

0 mm

1054 mm

1047 mm

1026 mm

1054 mm

2

500 mm

1170 mm

1164 mm

1145 mm

1170 mm

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

1

2 1

2 1

5700-6100

6200-6600

2

2

2

2

2

2 1

2 1

2 11

1

1 2

2

2

2 1

2 2

22

2

2

2

2

2 1

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

212

12 2

2

2

2

2

2

2

2

2

2

2

2

2 2

22

22

2

2

2

2

2

2

2

2

2

2

2

2 2

22

22

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

212

12 2

2 1

2 1

2 1

2 1

2 1

2 1

2 1

8200-8600

2

2

2

2

2

2

2

2

2

2

2

2

2

2 1

2 1

2 2 1

2 2 2 2 2 2 2 2 1

2 2

2 2

22

2

2

2

2

2 2 2

2

2

2

2

2

2

2

2

2 2

22

2

2 2

22

2

2

2 2

22

2

2

2

2 2 2

2

2 2 2

2

2

2

2

2

2

2

2

2

2

2 2

22

2

2 1

2

2 2 1 2

22 12

2

2 2

2

2

2

2

2

2

2

2

2

2

2

2

2

2 1

2 1

12200-12600

2 1

2

1 2

22

2 2 2 2 2 2 1

2 2 2 2 2 2 1

12200-12600

2 1

7700-8100

2

2

21

212

22

2

22

2

2

2 2

2 1

22 12

2

2

1 2

2

2

2

2

2

2

2

22

2

2 2

2

2

2

2

2

2

2

2

2

2

2

2

11700-12100

2

7200-7600

2

2

2

2

1 2

2

11700-12100

2

2

2

2

2

2

11200-11600

2

2

2

2

2

10700-11100

2

2

2

22

2

2

2

11200-11600

2

2

2

6700-7100

2

2

2

2

2

1 2

10200-10600

2

2

2

2

2

10700-11100

2

2

2

2

2

1 2

9700-10100

2

2

2

2

10200-10600

2

2

2

2

22

2

9200-9600

2

2

2

2

2

9700-10100

2

2

2

2

9200-9600

2

2

2

6200-6600

2

2

8700-9100

2

2

2

2

2

2

2

2

2

2 2 1 2

2 1

2

2

2

2

2

2

2

22

2 1

2

2

1

2

22

2

2

2

2

2 2 2 2

2

2

2

2

2

2

2

21

2

2

2

2

22

2

2

2

22 12

2

2

2

22

2 2 1 2 2

2

2

22

7700-8100

2

2

7200-7600

2

2

2 2

2

2

1 2

1 2

2

2

8700-9100

6

2

22

2

1 2

2

1 2

5700-6100

3700-4100

2 1

2

2 1

2

6700-7100

1 2

1 2

1 2

1 2

8200-8600

1 2

1 2

2 1

1 2

1 2

67

2700-3100

2

2

2200-2600

2

2 1

2

5200-5600

2

2

1 2

2

4700-5100

1 2 2

1 2 2

2

4200-4600

2

12 2

3700-4100

2

2

5200-5600

2

2

2

2

6200-6600

2

2

2

2

2

4700-5100

2

2

2

2

4200-4600

2

2

2

5700-6100

2

2

2

2

1 2

1 2

2

2

2

2

2

2

2

2

1 2

1200-1600

2 1

1 2

2

3200-3600

1 2

1 2

1 2

2

1 2

1 2

1 2 2

1 2

1 2

1 2

2

1 2

1700-2100

67

Type of

2

2

Detailed overview 1. Frame 2. Beam 3. Push-through protection 4. Upright protector 5. Frame barrier 6. Load sign

7

Installing frames

8

1.

Installing upright base plates (A)

2.

Locate the braces according to the bracing diagram on pages 6. (B) The braces shall be mounted back-to-back, with the openings facing outwards.

3.

Place distance tubes at single braces at the ends of the frame. (C)

4.

Tighten the braces.

M10×75/105 2 pcs M8×20

Distance tube

2 pcs M8 with flange

M10×75/105 Distance tube M10

with lock

(A) When assembling 90 frames: If depth < 600 mm – use XL Base Plate.

M10

with lock

When assembling 110 and 120 frames: If depth < 500 mm – use XL Base Plate

9

X-staga

Installing X-brace Frame to be X‑braced over a minimum of 1/3 of its length.

2.

Frame to be X‑braced above the second beam level as a minimum.

M10x75/105

X-brace

gade gavlar

Second beam level

Frame length

1.

M10

with lock

Washer 10,5x20

M10x75/105 Washer 10,5x20

M10

2st M8x20

with lock

2st M8

with flange

10

Brace X

Brace 2

ade gavlar

Installing bays 1.

Level the floor.

Starting from the highest point, adjust any unevenness using levelling plates. (D)

2.

Erect a starter bay and install beam safety pins in the beam safety holes. (E)

2 pcs Multi-Monti 10×80

/Expander bolts M10×90

Leveling plate 2 pcs beam safety pins per beam

E

3.

Check that the frames do not exceed the specified tolerances with regard to incline.

The incline in relation to plumb may not exceed 3 mm per metre in depth and laterally.

3 5

X

X

11

4.

Install 2 distance spacers between each frame pair. Install distance spacers where braces meet.

Use 2 distance spacers per bay for bays up to 7 metres. If the bay is bigger than 7 metres, use a 3rd distance spacer.

Distance spacers are only fitted for double racks. (F)

2 pcs M10×20

2 pcs M10 with flange

5.

12

Anchor base plates using 2 pcs Multi-Monti 10×80 (for concrete) or 2 pcs M10×90 expander bolts (for asphalt). (D)

Installing horizontal push-through protection

Safety pin

2 pcs M10

with lock

2 pcs M10×20

13

Installing vertical push-through protection Self‑drilling screw is always fixed in the outermost hole at each beam level. (J+K)

2 pcs Multi-Monti

2 pcs M8

10x80

with lock

2 pcs M8x55

M8

with lock

M8x55

H

I

H J

3 pcs self-drilling screw 5,5x19

K

J

3 pcs self-drilling screw 5,5x19

K

I

Position of vertical holders Pallet width 800 mm (C) From upright to first pallet = 75 mm (E) ! For beam 3600 mm = 87,5mm (E)

14

Beam length (A)

Number of pallets (B)

Between pallets (D)

From upright to centre of pallet (F)

C/C-distance between pallets (G)

1850 mm

2

100 mm

475 mm

900 mm

1900 mm

2

150 mm

475 mm

950 mm

2750 mm

3

100 mm

475 mm

900 mm

2850 mm

3

150 mm

475 mm

950 mm

3600 mm

4

75 mm

487,5 mm

875 mm

3800 mm

4

150 mm

475 mm

950 mm

Installing upright protectors

4 pcs Multi-Monti 10×80

/Expander bolt M10×90

L L

15

150 Min?

Installing frame barriers Frame barrier, single rack

Floor bracket

Frame barriers, double rack

Profile

End caps 2 pcs M8×110

4 pcs Multi-Monti 10×80

/Expander bolt

2 pcs M8×30

M10×90

2 pcs M8 with flange

2 pcs M8 with flange

Joint

2 pcs M8×110

2 pcs M8 with flange

16

Installing load signs At least one load sign per rack must be clearly visible.

2 pcs M10×30 2 pcs M10 nut

17

Inspection & Maintenance Inspection and service according to SS-EN 15635 SS EN-15635 is the European standard for steel static storage systems and outlines guidelines for the installation, operation, and maintenance of the storage system.

Assembly inspection Inspect the assembly before putting the pallet racking into service to confirm compliance with the assembly instructions.

Regular inspection Storage systems must undergo a visual inspection every week or at other regular intervals to ensure that no load-bearing parts are damaged. A formal written report must be prepared for the regular inspections.

Periodic inspection Storage systems must be inspected annually by an individual with the requisite technical knowledge.

The inspection, along with specified risks and measures, must be documented in a report and submitted to the person responsible.

Damage to the storage systems Damage to load-bearing parts in the racking must be remedied immediately by replacing the part as this poses a safety risk. Other parts may be repaired.

For more information, refer to SS-EN 15635 Steel static storage systems - Installation, operation and maintenance

Checks during regular inspections

18

1.

Check that there are beam safety pins on all sides of the beams.

2.

Check that there is no damage to the beams, uprights, and bracing members. If necessary, replace damaged components immediately as they pose a safety hazard.

3.

Check that there is a load sign and that it refers to the relevant racking configuration. At least one sign must be clearly visible.

4.

Check to ensure the pallets and beams are not overloaded.

5.

Check that there is an upright protector on the frames and uprights, and that the forklift aisles are correctly sized.

6.

Check to ensure the floor is not damaged and that the racking is anchored to the floor.

Damage In the event of damage of a local nature (dents, kinks, tears and cracks), always replace the parts.

Tolerance The maximum residual vertical deformation (after unloading from the maximum load) must not exceed the beam length L/200. Maximum residual horizontal deformation L/400.

Deformed uprights Uprights may deform outwards a maximum of 5 mm/m in relation to plumb along the length of the racking, and a maximum of 3 mm/m along the depth..

3

Brace deformation

5

X

X

Brace deformation must not exceed 10 mm per metre. This applies regardless of the direction of deformation.

Incline The incline in relation to plumb may not exceed 3 mm per metre in depth and laterally.

X

X 19

BLS AB - Box 12 - SE 335 04 Hillerstorp Sweden +46 370-30 50 00 - blsab.se