ENG assembly instructions tyre racking

TYRE RACKING ASSEMBLY INSTRUCTIONS & INSTRUCTIONS FOR USE Edition no. 7 ©BLS – Brännehylte Lagersystem AB. 220708

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Contents 1. About these instructions.........................................................................................4 2. Before beginning assembly.....................................................................................5 3. Inspection & Maintenance................................................................................... 6 4. Assembly instructions, Single rack.........................................................................7 4.1 Assembling frames and tyre beams ....................................................................8-10 4.2 Assembling floor beams.......................................................................................10 4.3 Stabilisation of bay, longitudinal sections................................................................11 4.4 Splicing of bracing straps.......................................................................................12 4.5 Assembling tyre holders.......................................................................................12 4.6 Distance between tyre holders..............................................................................13 4.7 Anchoring the racking..........................................................................................14 5. Assembly instructions, Double rack......................................................................15 5.1 Assembling frames and tyre beams....................................................................16-18 5.2 Assembling floor beams...................................................................................18-19 5.3 Stabilisation, longitudinal sections.........................................................................19 5.4 Splicing of bracing straps..........................................................................................................20 5.5 Assembling tyre holders...................................................................................20-21 5.6 Distance between tyre holders..............................................................................21 5.7 Anchoring the racking..........................................................................................22

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About these instructions This symbol is used as a warning and/or to emphasise the importance of something

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:

This symbol seeks to draw your attention to something, or remind you about it.

CONTACT US

* assembly * regular inspections (together with the periodic inspection template) * taking corrective action as directed

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

Each installation must be provided with a load sign located in a clearly visible place.

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

Perform regular checks to ensure the technical safety of the tyre racking.

Examples of protocols for periodic pallet racking inspections are available on our website www.blsab.se.

High Chaparral Kulltorp

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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

8 mm

Anchoring Tyre racks must be anchored to the floor to prevent the uprights from moving when using mechanical handling equipment in or near warehouse fixtures.

Safety

List of other useful tools:

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

We recommend that several people take part in the erection and completion of the racking In order to facilitate and ensure a safe installation

-Chalk line -Allen key, 6 mm -Adjustable spanner -Vacuum cleaner Scissor lifts may be used during assembly, depending on the height and number of levels in the installation.

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Inspection & Maintenance Assembly inspections

Inspect the assembly before putting the tyre racking into service to make sure the assembly instructions were followed.

Upgrades and disposal

In the event of redeployment, upgrades or relocation of the storage system, contact BLS AB.

Daily inspections

Inspect the tyre racking daily (as per the items below) to make sure no components affecting load-bearing capacity are damaged. Replace damaged load-bearing parts immediately.

Other parts may be repaired.

Periodic inspections

By law, in addition to self-inspection, the shelves must be checked by a technical expert at least once a year to make sure it complies with assembly instructions.

Visual inspections

Perform a visual inspection to gain a first impression of the condition of the racking.

If the load is well ordered and the tyre racking appears entire, it may be assumed to function well even in terms of safety. If there are many deformed arms, uprights or bracing members, it may be deemed to be in need of a more thorough inspection.

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Rectify any damage caused by e.g. collisions immediately! A damaged upright or arm is a safety hazard.

Deformed arms To prevent damage, correct any deformation due to misshapen fasteners.

For safety reasons, the tyre racking is designed to store tyres by means of two or three arms.

Deformed bracing members Horizontal and diagonal braces are often struck when goods are being loaded, especially if the racking is served by forklift. Thus, check the locations where braces are fastened.

If diagonal braces are deformed, they must be straightened and tensioned. Replace horizontal braces if they show any sharp creases after impact. Straighten longitudinally deformed braces.

Assembly instructions, Single rack

4.1 Assembling frames and tyre beams, Single rack

Up

Down

Nut, M10 (2x)

M10x20 (2x)

1. For easy assembly, place two 45x70 wooden studs on a level floor or table. Lay out uprights of the correct type and length with their backs facing away from each other.

2.. Check that the patterns on the two uprights face in the same direction. Then fit two base plates to the frames. Fasten them to the lower part of the frame using two M10x20 bolts with ribbed flange nuts.

Bolt, M10

Sleeve

Bolt, M10

Bolt, M10

Nut, M10

Nut, M10

3. Install the brace in the second hole from the bottom.

Fasten the brace using an M10 nut and bolt. Use a 75 mm M10 bolt for C90 and a 105 mm M10 bolt for C120 . Use the sleeve as a spacer at the singles sides on bracing member 1.

Tightening torque for M10 = 9.5 Nm. Use a torque wrench.

Use a 30 mm sleeve for C90 and a 43 mm sleeve for C120.

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4. Install the remaining bracing members according to the brace diagram, back-to-back with the openings facing outwards. Fasten the bracing members using M10 nuts and bolts. Use a 75 mm M10 bolt for C90 and a 105 mm M10 bolt for C120 . Also use a sleeve for the last brace (brace 1). Use a 30 mm sleeve for C90 and a 43 mm sleeve for C120.

4.1 Assembling frames and tyre beams, Single rack

5. Fully assembled frame with upright and braces

6. Position end plates for the desired height separation.

Nut, M10 (2x)

M10x20 (2x)

7. Fasten the end plates using M10x20 bolts and M10 nuts with ribbed flanges. Two bolts per upright.

8. Raise the frames one at a time and then fasten them to each other using the tyre beam. Because the frames may lean initially, they must be plumbed to max H/350 or max 20 mm in the cross- and down aisle.

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4.1 Assembling frames and tyre beams, Single rack M10x130 (2x)

Nut, M10 (2x)

9. Fasten the tyre beam to each end plate using two M10x130 bolts and M10 ribbed flange nuts. The end plates have a 50 mm hole separation, allowing tiers with multiples of this value.

10. Install other beam levels according to the desired height separation.

4.2 Assembling floor beams, Single rack End plate beam levels one, two, three and up; five holes for attachment

Beam, level 4

Beam, level 3

End plate floor beam; three holes for attachment Beam, level 2

Floor beam, level 1

1. Install the floor beam in the same way as the other beam levels. Note the difference between the floor beam end plates compared to the other beam levels.

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4.3 Stabilisation, longitudinal sections, Single rack

Bracket Bracing strap

Bottle screw

1. Stabilise the tyre racking against longitudinal sway by means of the bracing straps and bottle screws supplied by BLS. Carry out cross bracing between tyre beam levels one and two in each section of the racking. Other beam levels need no cross bracing. Fasten a bottle screw and bracing straps to each upright. Locate the bracket next to the nearby tyre beam with end plate.

Note the difference in the location of the bracing straps for the single tyre rack. In the case of single racking, it is attached to the frame.

Nut, M10 (2x) Nut, M10 (2x)

M10x20 (2x)

Allen head bolt, M10x25 (2x)

2. Fasten the bracket to the upright using M10x20 bolts and M10 nuts with ribbed flanges. Fasten the bracing straps and bottle screw using countersunk M10x25 Allen head bolts and M10 nuts with ribbed flanges.

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4.3 Splicing of bracing straps, Single rack Illustration of splicing with a 1 + 1 m strap for 1450 or 1600 mm sections:

Nut, M10 (2x)

Nut, M10

M10x20 (2x)

Allen head bolt, M10x25

1. Use different combinations of bracing straps for cross bracing between tyre beam levels one and two, depending on the rack model for installation. The relevant combination will depend on the length of the tyre beam (1450, 1600, 2225, 2400, 2900 or 3200 mm), as well as the distance between the tyre beams, also known as vertical openings.

The table below shows usage depending on the tyre beam model.

Tyre beam / section length

Max level C/C Tyre beam at height

Bracing strap use per cross brace

1450 mm

1600 mm

4x1m (Splice 1 m straps together.)

1600 mm

1600 mm

4x1m (Splice 1 m straps together.)

2225 mm

1900 mm

2x3m

2400 mm

1900 mm

2x3m

2900 mm

2000 mm

2x3m+2x1m (Splice 1 m and 3 m straps together.)

3200 mm

2000 mm

2x3m+2x1m (Splice 1 m and 3 m straps together.)

BLS provides hole straps in 1 and 3 metre lengths. Use them in different combinations to obtain the appropriate length.

Splice the bracing straps as necessary using M10x20 bolts and M10 nuts with ribbed flanges.

4.4 Assembling tyre holder, Single rack

1. Install the tyre holders on the tyre beans using M8 U-bolts and ribbed M8 nuts. The same procedure applies to single and double-rack arms.

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2. Tyre beam length and the number of tyre sets that can be stored will depend on the tyre beam model. Each set of tyres must be supported by at least two tyre holders. We recommend using 3 tyre holders from level 4 upward; BLS provides 2, 3 and 4-set beams as standard. Locate the holders depending on the configuration; see p 13

4.5 Distance between tyre holders, Single rack

2-sets

Section length

a1

b1

c

b2

a2

L=1450*

117.5

490

235

490

117.5

L=1600**

155

490

310

490

155

1. In the case of beam level 4 and levels above, install 3 tyre holders to ensure sets of tyres can be loaded and unloaded easily and safely. Locate the additional holder midway between the two holders already installed (dimensions as per the table above).

*1450 mm – Intended for tyres ≤ 725 mm **1600 mm – Intended for tyres ≤ 800 mm

3-sets

4-sets

Section length

a1

b1

c1

b2

c2

b3

a2

Section length

a1

b1

c1

b2

c2

b3

c3

b4

a2

L=2225*

142.5

490

235

490

235

490

142.5

L=2900*

117.5

490

235

490

235

490

235

490

117.5

L=2400**

155

490

310

490

310

490

155

L=3200**

155

490

310

490

310

490

310

490

155

*2225 mm – Intended for tyres ≤ 725 mm **2400 mm – Intended for tyres ≤ 800 mm

*2900 mm – Intended for tyres ≤ 725 mm **3200 mm – Intended for tyres ≤ 800 mm

*Tables and figures show the recommended positions and distances between tyre holders along the tyre beam.

The same locations and dimensions apply to single and double racks. The illustrations show single tyre beams.

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4.6 Anchoring the racking, Single rack

4.7 Fully assembled single rack

Beam, level 4

Beam, level 3

Beam, level 2 Multi Monti M10 (4x) Multi Monti M10 (4x)

1. Use Multi-Monti M10x60 for anchoring to the floor. Use four bolts for each frame plate. Pre-drill the concrete with a Ø8 mm masonry bit.

Anchoring forms an essential structural component and must be carried out as directed, in order to ensure a safe, stable rack.

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Floor beam, level 1

Assembly instructions, Double rack

5.1 Assembling frames and tyre beams, Double rack

Up

Down

Nut, M10 (2x)

M10x20 (2x)

1. For easy assembly, place two 45x70 wooden studs on a level floor or table. Lay out uprights of the correct type and length with their backs facing away from each other.

2. Check that the patterns on the two uprights face in the same direction. Then fit two base plates to the frames. Fasten them to the lower part of the frame using two M10x20 bolts with ribbed flange nuts.

Bolt, M10

Sleeve

Bolt, M10

Bolt, M10

Nut, M10

Nut, M10

3. Install the brace in the second hole from the bottom.

Fasten the brace using an M10 nut and bolt. Use a 75 mm M10 bolt for C90 and a 105 mm M10 bolt for C120 . Use the sleeve as a spacer at the singles sides on bracing member 1.

Tightening torque for M10 = 9.5 Nm. Use a torque wrench.

Use a 30 mm sleeve for C90 and a 43 mm sleeve for C120.

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4. Install the remaining bracing members according to the brace diagram, back-to-back with the openings facing outwards. Fasten the bracing members using M10 nuts and bolts. Use a 75 mm M10 bolt for C90 and a 105 mm M10 bolt for C120 . Also use a sleeve for the last brace (brace 1). Use a 30 mm sleeve for C90 and a 43 mm sleeve for C120.

5.1 Assembling frames and tyre beams, Double rack

5. Fully assembled frame with upright and braces

6. Position end plates for the desired height separation.

Nut, M10 (2x)

M10x20 (2x)

7. Fasten the end plates using M10x20 bolts and M10 nuts with ribbed flanges. Two bolts per upright.

8. Raise the frames one at a time and then fasten them to each other using the tyre beam. Because the frames may lean initially, they must be plumbed to max H/350 or max 20 m in the transverse and longitudinal rack directions.

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5.1 Assembling frames and tyre beams, Double rack

M10x130 (2x) Frame

End plate Bracket for bracing strap

Tyre beam

Nut, M10 (2x)

9 Fasten the tyre beam to each end plate using two M10x130 bolts and M10 ribbed flange nuts. The end plates have a 50 mm hole separation, allowing tiers with multiples of this value. Install the bracing strap bracket at the same time. On the first beam level, Install the bracket facing up on top of the end plate, and facing down on the underside on beam level two; see next page.

10. Install the bracket facing up at the first beam level. Install the bracket facing down at the second beam level. Install other beam levels without bracing strap brackets.

5.2 Installing floor beams, Double rack

Beam, level 4

Beam, level 3

Beam, level 2

Floor beam, level 1

11. Install other beam levels according to the desired height separation.

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1. Install the floor beam in the same way as the other beam levels.

5.3 Stabilisation, longitudinal sections, Double rack End plate beam levels two, three and up; five holes for attachment

End plate floor beam level 1; three holes for attachment

2. Note the difference between the floor beam end plates compared to the other beam levels.

1. Stabilise the tyre racking against longitudinal sway by means of bracing straps and bottle screws. Attach the bottle screws and bracing straps via the bracing strap brackets in each respective tyre beam between beam levels one and two. Do not cross brace other beam levels.

First beam level

Second beam level

Nut, M10 (2x) Allen head bolt, M10x25 (2x)

Nut, M10 M10x20

1. Fasten the bracing straps and bottle screw using countersunk M10x25 Allen head bolts and M10 nuts with ribbed flanges to the bracing strap bracket

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5.4 Splicing bracing straps, Double rack Illustration of splicing with a 1 + 1 m strap for 1450 or 1600 mm sections:

Nut, M10 (2x)

Nut, M10

M10x20 (2x)

Allen head bolt, M10x25

1. Use different combinations of bracing straps for cross bracing between tyre beam levels one and two, depending on the rack model for installation. The relevant combination will depend on the length of the tyre beam (1450, 1600, 2225, 2400, 2900 or 3200 mm), as well as the distance between the tyre beams, also known as vertical openings.

The table below shows usage depending on the tyre beam model.

Tyre beam / section length

Max level C/C Tyre beam at height

Bracing strap use per cross brace

1450 mm

1600 mm

4x1m (Splice 1 m straps together.)

1600 mm

1600 mm

4x1m (Splice 1 m straps together.)

2225 mm

1900 mm

2x3m

2400 mm

1900 mm

2x3m

2900 mm

2000 mm

2x3m+2x1m (Splice 1 m and 3 m straps together.)

3200 mm

2000 mm

2x3m+2x1m (Splice 1 m and 3 m straps together.)

BLS provides hole straps in 1 and 3 metre lengths. Use them in different combinations to obtain the appropriate length.

Splice the bracing straps as necessary using M10x20 bolts and M10 nuts with ribbed flanges.

5.5 Assembling tyre holder, Double rack

1. Install the tyre holders on the tyre beans using M8 U-bolts and ribbed M8 nuts. The same procedure applies to single and double-rack arms.

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2. Tyre beam length and the number of tyre sets that can be stored will depend on the tyre beam model. Each set of tyres must be supported by at least two tyre holders. We recommend using 3 tyre holders from level 4 upward; BLS provides 2, 3 and 4-set beams as standard. Locate the holders depending on the configuration; see p 21

5.5 Distance between tyre holders, Double rack 2-sets

Section length

a1

b1

c

b2

a2

In the case of beam level 4 and levels above, install 3 tyre L=1450* 117.5 490 235 490 117.5 holders to ensure sets of tyres can be loaded and unloadL=1600** 155 490 310 490 155 ed easily and safely. Locate the additional holder midway between the two holders already installed (dimensions as per *1450 mm – Intended for tyres ≤ 725 mm the table above). **1600 mm – Intended for tyres ≤ 800 mm

3-sets

4-sets

Section length

a1

b1

c1

b2

c2

b3

a2

L=2225*

142.5

490

235

490

235

490

142.5

L=2400**

155

490

310

490

310

*2225 mm – Intended for tyres ≤ 725 mm **2400 mm – Intended for tyres ≤ 800 mm

490

155

Section length

a1

b1

c1

b2

c2

b3

c3

b4

a2

L=2900*

117.5

490

235

490

235

490

235

490

117.5

L=3200**

155

490

310

490

310

490

310

490

155

*2900 mm – Intended for tyres ≤ 725 mm **3200 mm – Intended for tyres ≤ 800 mm

*Tables and figures show the recommended positions and distances between tyre holders along the tyre beam. The same locations and dimensions apply to single and double racks. The illustrations show single tyre beams.

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5.6 Anchoring the racking, Double rack

5.7 Fully assembled double rack

Beam, level 4

Beam, level 3

Multi Monti M10 (4x)

Beam, level 2

Multi Monti M10 (4x) Floor beam, level 1

1. Use Multi-Monti M10x60 for anchoring to the floor. Use four bolts for each frame plate. Pre-drill the concrete with a Ø8 mm masonry bit.

Anchoring forms an essential structural component and must be carried out as directed, in order to ensure a safe, stable rack.

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Brännehylte Lagersystem AB

+46 370 30 50 00

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