Hi280 SHELVING DESIGN MANUAL SEPT 2006

Issue: September 2006

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: Amendments are highlighted. Complete new page: New page appears in the top right hand corner of the page. Revised/new illustration: Revised/new illustration appears beneath the illustration. The following pages are either new, or have been revised: Contents Pages: 3. Section A Pages: A.3. Section C Pages: C.3, and 4. Section H Pages: H.2, 4, 12 and 13. Section K Pages: K.2, 4, 28, 29, 31, 33 and 38.

Issue: September 2006 Section - Contents Page 1

MAIN CONTENTS Section A – Product Introduction. Page

Basic system......................................................................................................................... A.1Parameters of the system..................................................................................................... A.2Rack dimensions .................................................................................................................. A.3Shelving components, applications, illustrations .................................................................. A.4

Section B – Frame Components Page

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

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


Section D – Medium Span Bay Components Page

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

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

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

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


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

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

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

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

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 +3°c to +35°c. Although the system principally has a pre-galvanised finish Range 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.


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 is on a 25mm increment, within the following limits. Adjustment 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.



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.

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). Up to 5500mm. B. Battened and braced frame. Up to 5500mm. C. Fully braced frame. 3100 – 12000mm. D. Solid clad frame. 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

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

Swaged connections.

Pre-galvaniseduprights

Painted R7016 uprights

Pre-galvanised uprights


1000mm high frames x ???mm wide.

300mm 450751425 --- 450751455 --- 400mm 450751426 --- 450751456 --- 450mm 450751650 --- 450751660 --- 500mm 450751427 --- 450751457 --- 600mm 450751428 --- 450751458 --- 800mm 450751429 --- 450751459 ---

1000mm 450751430 --- --- ---

1600mm high frames x ???mm wide. 300mm 450751431 --- 450751460 --- 400mm 450751432 --- 450751461 --- 450mm 450751651 --- 450751661 --- 500mm 450751433 --- 450751462 --- 600mm 450751434 --- 450751463 --- 800mm 450751435 --- 450751464 ---

1000mm 450751436 --- --- ---


1000mm 450751442 --- --- --- Continued on the next page.


FRAME CODES (continued)




Swaged connections.


Painted R7016 uprights Pre-galvanised

uprights Painted R7016

uprights


1000mm 450751448 --- --- ---


1000mm 450751454 --- --- ---




Swaged connections.


Painted R7016 uprights Pre-galvanised

uprights Painted R7016

uprights


1000mm 450751487 --- --- ---


FRAME CODES (continued)

2 batten frame (knock down) Type ‘K’ Heavy uprights.


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

Swaged connections.



Pre-galvanised uprights


2100mm high frames x ???mm wide.

300mm 450752437 450791447 450752465 450791453 400mm 450752438 450791448 450752466 450791454 450mm 450752652 450791572 450752662 450791562 500mm 450752439 450791449 450752467 450791455 600mm 450752440 450791450 450752468 450791456 800mm 450752441 450791451 450752469 450791457

1000mm 450752442 450791452 --- ---

2300mm high frames x ???mm wide. 300mm 450752443 450791498 450752470 450791504 400mm 450752444 450791499 450752471 450791505 450mm 450752653 450791573 450752663 450791563 500mm 450752445 450791500 450752472 450791506 600mm 450752446 450791501 450752473 450791507 800mm 450752447 450791502 450752474 450791508

1000mm 450752448 450791503 --- ---

2500mm high frames x ???mm wide. 300mm 450752449 450791509 450752475 450791515 400mm 450752450 450791510 450752476 450791516 450mm 450752654 450791574 450752664 450791564 500mm 450752451 450791511 450752477 450791517 600mm 450752452 450791512 450752478 450791518 800mm 450752453 450791513 450752479 450791519

1000mm 450752454 450791514 --- ---

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. Issue: September 2006 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

Type S Pre-galv

ZN

Type K Pre-galv

ZN

Type K Painted

RAL 7016

Type EK Pre-galv

ZN 1000mm 444046011 --- --- --- 1600mm 444046012 --- --- --- 2100mm 444046013 444046003 444027653 444058301 2300mm 444046014 444046004 444027654 444058302 2500mm 444046015 444046005 444027655 444058303 3000mm 444046016 444046006 444027656 444058304 4600mm --- 444046007 444027657 444058305

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.


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.


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.



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 725237051.

MC6S 6x20mm screw 725537151. M6 Nut 731231601.

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.


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.



FRAME BATTEN (continued) Part Codes One piece.

Frame width

Light Duty Swaged

Light Duty Riveted

Heavy Duty Riveted

300mm 444028201 444028250 - 400mm 444028202 444028251 - 450mm 444028210 444028252 - 500mm 444028203 444028253 - 600mm 444028204 444028254 - 800mm - - 444046901

1000mm - - 444046902 4.8 dia. x 7mm long rivet = 722786309.

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.


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.



SOLID FRAME CLADDING (continued) Part Codes One piece. Solid Frame Cladding Sheet – Pre-galvanised.

Frame width ‘W’ 300mm 400mm 450mm 500mm 600mm 800mm

Frame

Height ‘H’ 900mm 444046326 444046327 444046340 444046328 444046339 444046330

1000mm 444046301 444046306 444046341 444046311 444046316 4440463211600mm 444046302 444046307 444046342 444046312 444046317 4440463222100mm 444046303 444046308 444046343 444046313 444046318 4440463232300mm 444046304 444046309 444046344 444046314 444046319 4440463242500mm 444046305 444046310 444046345 444046315 444046320 444046325

Solid Frame Cladding Sheet – Painted Grey White RAL9002.

Frame width ‘W’ 300mm 400mm 450mm 500mm 600mm 800mm

Frame

Height ‘H’ 900mm 444029576 444029577 444029585 444029578 444029579 444029580

1000mm 444029551 444029556 444029586 444029561 444029566 4440295711600mm 444029552 444029557 444029587 444029562 444029567 4440295722100mm 444029553 444029558 444029588 444029563 444029568 4440295732300mm 444029554 444029559 444029589 444029564 444029569 4440295742500mm 444029555 444029560 444029590 444029565 444029570 444029575

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 500mm frame width = 444201173

400mm frame width = 444201171 600mm frame width = 444201174 450mm frame width = 444201172 800mm frame width = 444201175


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.



MESH FRAME CLADDING (continued) Part Codes Individual panels (one piece)

Frame heights ‘H’ 2100mm 2300mm 2500mm

Frame width ‘W’

400mm 444031658 444031659 444031660 450mm 444031671 444031672 444031673 500mm 444031663 444031664 444031665 600mm 444031668 444031669 444031670

Complete kits (panel and brackets)

Frame heights ‘H’ 2100mm 2300mm 2500mm

Frame width ‘W’

400mm 450791343 450791344 450791345 450mm 450791365 450791366 450791367 500mm 450791346 450791347 450791348 600mm 450791349 450791350 450791351

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.


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.


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: Silver appearance.

Tool type EK: Yellow chromate appearance. Part Codes Tool type K: 444033200.

Tool type EK: 444060300.


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: Silver appearance.

Ellipse bit type EK: Yellow chromate appearance. Part Codes Ellipse handle 444044400.

Ellipse bit type K: 444034800. Ellipse bit type EK: 444060400.


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.


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.


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.


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.



New page SHELF (continued) Material + Finish Normal duty shelves: 0.5mm thick pre-galvanised steel.

Standard duty shelves: 0.6mm thick pre-galvanised steel. Heavy duty shelves: 0.7mm thick pre-galvanised steel.

Part Codes One piece ‘Shelf Only’. Stock items shown . Project items shown P.

Shelf size Part code t mm Duty kg Stock/ Project

Min Qty

444046255 0.5 N 140 300x900 444046225 0.7 H 235 P 1000 444046256 0.5 N 135 300x1000 444046206 0.7 H 235 444046254 0.5 N 70 300x1290 444046216 0.7 H 110 P 1000

444046250 0.5 N 140 444046259 0.6 S 160 P 2500 400x900 444046226 0.7 H 235 P 1000 444046251 0.5 N 140 444046257 0.6 S 150 P 2500 400x1000 444046207 0.7 H 235 444046252 0.5 N 75 P 1000 444046260 0.6 S 85 P 2500 400x1290 444046217 0.7 H 110

444046262 0.6 S 160 450x900 444046227 0.7 H 235 P 1000 444046263 0.6 S 150 450x1000 444046235 0.7 H 235 P 1000 444046264 0.6 S 85 450X1290 444046236 0.7 H 110 P 1000

444046266 0.6 S 170 500x900 444046228 0.7 H 235 P 1000 444046258 0.6 S 150 500x1000 444046208 0.7 H 235 444046267 0.6 S 85 P 1000 500x1290 444046218 0.7 H 110

444046268 0.6 S 150 600x900 444046229 0.7 H 215 P 1000 444046269 0.6 S 140 600x1000 444046209 0.7 H 215 444046270 0.6 S 100 P 1000 600x1290 444046219 0.7 H 120

800x900 444046230 0.7 H 110

800x1000 444046210 0.7 H 110 800x1290 444046220 0.7 H 120

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.


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.

Frame width ‘W’ 300mm 400mm 450mm 500mm 600mm 800mm Normal support 444046801 444046802 444046806 444046803 444046804 444046805Base support 444050701 444050702 444050706 444050703 444050703 444050703


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.

Frame width ‘W’ 300mm 400mm 450mm 500mm 90mm high 661400 661410 661414 661420

140mm high 661402 661412 661416 661422


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.

Frame width ‘W’ Shelf pitch 300mm 400mm 450mm 500mm 600mm 800mm

200mm 444056601 444056604 444056625 444056608 - - 250mm 444056602 444056605 444056626 444056609 - - 300mm 444056603 444056606 444056627 444056610 444056614 - 400mm - 444056607 444056628 444056611 444056615 444056617500mm - - 444056629 444056612 - - 600mm - - - 444056613 444056616 444056618


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.


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.



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.

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.



FULL WIDTH SOLID BACK CLADDING (continued) Individual panels (one piece)

Pre-galvanised Painted Grey White RAL9002 Bay length ‘L’ Bay length ‘L’

Panel height 900mm 1000mm 1290mm 900mm 1000mm 1290mm

800mm 444201021 444201029 444201031 444201080 444201089 4442010911000mm 444201022 444201006 444201016 444201081 444201056 4442010661200mm 444201023 444201030 444201032 444201082 444201090 4442010921300mm 444201024 444201007 444201017 444201083 444201057 444201057

Back cladding clip = 444033100. Complete kits (panels, cladding trim and clips)

Pre-galvanised Painted Grey White RAL9002 Bay length ‘L’ Bay length ‘L’

Bay height 900mm 1000mm 1290mm 900mm 1000mm 1290mm

1000mm 450792000 450792020 450792030 450792040 450792050 4507920601600mm 450792001 450792021 450792031 450792041 450792051 4507920612100mm 450792002 450792022 450792032 450792042 450792052 4507920622300mm 450792003 450792023 450792033 450792043 450792053 4507920632500mm 450792004 450792024 450792034 450792044 450792054 450792064

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 Component code Kit code

1000mm 444046406 450791162 1600mm 444046407 450791163 2100mm 444046408 450791164 Cladding clip 444033100


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 Bay length ‘L’

Panel height 900mm 1000mm 1290mm 1000mm 444059307 444059302 444059303 1500mm 444059308 444059305 MC6S 6x20mm screw = 725537151, M6M nut = 731231601.


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 length ‘L’ Bay height 900mm 1000mm 1290mm

2100mm 444031857 444031851 444031854 2300mm 444031858 444031852 444031855 2500mm 444031859 444031853 444031856

Complete kits (panel and clips)

Bay length ‘L’ Bay height 900mm 1000mm 1290mm

2100mm 450791358 450791352 450791355 2300mm 450791359 450791353 450791356 2500mm 450791360 450791354 450791357


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.


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.


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.


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.


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 Hole centres ‘X’ Overall length ‘L’ 900mm 1328.0mm 1353.0mm 1000mm 1395.5mm 1420.5mm 1290mm 1611.5mm 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.


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.


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.



STEEL IN-FILL SHELVES (continued)

Individual shelves (one piece) Frame width ‘W’ Panel length

‘L’ 500mm 600mm 800mm 1000mm

129mm 444030301 444030302 444030303 444030304 246mm 444030305 444030306 444030307 444030308 258mm 444030309 444030310 444030311 444030312

Complete kits (shelves and two beams) Frame width ‘W’ Bay length ‘L’ 500mm 600mm 800mm 1000mm

1500mm 450752200 450752205 450752210 450752215 1750mm 450752201 450752206 450752211 450752216 2000mm 450752202 450752207 450752212 450752217 2250mm 450752203 450752208 450752213 450752218 2500mm 450752204 450752209 450752214 450752219

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.


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.


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.


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.


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 E – Accessories Page E.1

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.

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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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).


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.


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 Similar locking 2100 high x 900mm 444050950 444050952 1000 high x 1000mm 444050980 444050982 1600 high x 1000mm 444050990 444050992 2100 high x 1000mm 444050960 444050962 2100 high x 1290mm 444050970 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.


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.


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: Sept 2006 Section H – Low Rise Short Span Applications + Design Page H.1

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.

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.



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. ------------------------------------------------------------------------------------------


New table Table H1: Shelf Capacity in kg.

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

Without bars. With 1 bar. With 2 bars.Shelf size Shelf

t mm Shelf Duty kg kg kg

0.5 N 140 - - 300x900 0.7 H 235 260 300 0.5 N 135 - - 300x1000 0.7 H 235 260 300 0.5 N 70 - - 300x1290 0.7 H 110 235 350

0.5 N 140 - - 0.6 S 160 - - 400x900 0.7 H 235 260 300 0.5 N 140 - - 0.6 S 150 - - 400x1000 0.7 H 235 260 300 0.5 N 75 - - 0.6 S 85 - - 400x1290 0.7 H 110 235 350

0.6 S 160 - - 450x900 0.7 H 235 260 300 0.6 S 150 - - 450x1000 0.7 H 235 260 300 0.6 S 85 - - 450X1290 0.7 H 110 235 350

0.6 S 170 - - 500x900 0.7 H 235 260 300 0.6 S 150 - - 500x1000 0.7 H 235 260 300 0.6 S 85 - - 500x1290 0.7 H 110 235 350

0.6 S 150 - - 600x900 0.7 H 215 290 380 0.6 S 140 - - 600x1000 0.7 H 215 290 380 0.6 S 100 - - 600x1290 0.7 H 120 215 310

800x900 0.7 H 110 290 380

800x1000 0.7 H 110 290 380 800x1290 0.7 H 120 215 310


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’ Upright type ‘K’ Upright type ‘EK’

2 Batten Frames Shelf

spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm 200mm 1057 1163 1774 2034 1774 2034 300mm 1057 1163 1774 2034 1774 2034 400mm 1057 1163 1774 2034 1774 2034 500mm 1057 1163 1774 2034 1774 2034 600mm 1057 1163 1774 2034 1774 2034 700mm 1057 1163 1774 2034 1774 2034 800mm 1057 1163 1774 2027 1774 2027

3 Batten Frames or Fully Clad Frames Shelf

spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths


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


Table H3: Bay Capacity in kg. Rack heights up to 2100mm. All uprights types, 1290mm bay lengths.




spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths



spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths




Table H4: Bay Capacity in kg. Rack heights 2300 and 2500mm. All uprights types, 900 and 1000mm bay

lengths. Minimum 3 bays per rack.



spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths



spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths



spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths




Table H5: Bay Capacity in kg. Rack heights 2300 and 2500mm. All uprights types, 1290mm bay lengths.




spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths



spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths



spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths




Table H6: Bay Capacity in kg. Rack heights 3000mm. All uprights types, 900 and 1000mm bay lengths.




spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths



spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths


4 Batten + 2’X’ Braced Frames (#) or Fully Clad Frames Shelf

spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths


(#) 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


Table H7: Bay Capacity in kg. Rack heights 3000mm. All uprights types, 1290mm bay lengths.




spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths



spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths


4 Batten + 2’X’ Braced Frames (#) or Fully Clad Frames Shelf

spacing Frame

widths 300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths

600-800mm

Frame widths

300-500mm

Frame widths


(#) 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


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.

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.


DESIGN EXAMPLE TWO


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.


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 J – Low Rise Medium Span Applications + Design Page J.1

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.


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.

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.



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.


Table J1: Steel Shelf Capacity. Steel shelves supported by a pair of medium span beams.

Bay length Shelf capacity mm kg

1500 400 1750 400 2000 400 2250 400 2500 350

Table J2: 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 Frame width No of cross mm 500mm 600mm 800mm 1000mm beams

1500 310 370 390 390 4 1750 360 435 520 520 5 2000 415 490 490 490 5 2250 400 400 400 400 6 2500 330 330 330 330 6


Table J3: Bay Capacity Rack heights up to 2100mm, K and EK uprights, 1500mm bay lengths.


Upright type ‘K’ Upright type ‘EK’

2 Batten Frames 2 Batten Frames Shelf

spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

200mm 1774 2034 200mm 1774 2484 300mm 1774 2034 300mm 1774 2484 400mm 1774 2034 400mm 1774 2484 500mm 1774 2034 500mm 1774 2484 600mm 1774 2034 600mm 1774 2484 700mm 1665 1860 700mm 1708 2241 800mm 1556 1686 800mm 1643 1998 900mm 1446 1511 900mm 1577 1754

1000mm 1337 1337 1000mm 1511 1511 1100mm 1219 1219 1100mm 1386 1386 1200mm 1101 1101 1200mm 1261 1261 1300mm 982 982 1300mm 1136 1136 1400mm 864 864 1400mm 1011 1011 1500mm 746 746 1500mm 886 886


spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm





Table J3: Bay Capacity (continued).

Rack heights up to 2100mm, K and EK uprights, 1500mm bay lengths. Minimum 3 bays per rack.


4 Batten Frames or Fully Clad Frames 4 Batten Frames or Fully Clad Frames

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm





Table J4: Bay Capacity Rack heights up to 2100mm, K and EK uprights, 1750 and 2000mm bay lengths.




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm






Rack heights up to 2100mm, K and EK uprights, 1750 and 2000mm bay lengths. Minimum 3 bays per rack.



Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm





Table J5: Bay Capacity Rack heights up to 2100mm, K and EK uprights, 2250 and 2500mm bay lengths.




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm






Rack heights up to 2100mm, K and EK uprights, 2250 and 2500mm bay lengths. Minimum 3 bays per rack.



Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm





Table J6: Bay Capacity Rack heights of 2300 and 2500mm, K and EK uprights, 1500mm bay lengths.




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm






Rack heights of 2300 and 2500mm, K and EK uprights, 1500mm bay lengths. Minimum 3 bays per rack.



Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm





Table J7: Bay Capacity Rack heights of 2300 and 2500mm, K and EK uprights, 1750 and 2000mm bay




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm






Rack heights of 2300 and 2500mm, K and EK uprights, 1750 and 2000mm bay lengths. Minimum 3 bays per rack.



Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm





Table J8: Bay Capacity Rack heights of 2300 and 2500mm, K and EK uprights, 2250 and 2500mm bay




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm






Rack heights of 2300 and 2500mm, K and EK uprights, 2250 and 2500mm bay lengths. Minimum 3 bays per rack.



Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm





Table J9: Bay Capacity Rack heights of 3000mm, K and EK uprights, 1500mm bay lengths.




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm






Rack heights of 3000mm, K and EK uprights, 1500mm bay lengths. Minimum 3 bays per rack.


4 Batten + 2 ‘X’ Braced Frames (#), or Fully Clad Frames


Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm



(#) 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


Table J10: Bay Capacity Rack heights of 3000mm, K and EK uprights, 1750 and 2000mm bay lengths.




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm






Rack heights of 3000mm, K and EK uprights, 1750 and 2000mm bay lengths. Minimum 3 bays per rack.




Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm





Table J11: Bay Capacity Rack heights of 3000mm, K and EK uprights, 2250 and 2500mm bay lengths.




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm




spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm






Rack heights of 3000mm, K and EK uprights, 2250 and 2500mm bay lengths. Minimum 3 bays per rack.




Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm

Shelf spacing

Frame Widths

500 + 600 mm

Frame Widths

800 + 1000 mm





BASEPLATE and FLOOR FIXING REQUIREMENTS Baseplate Select the required baseplate by checking the load passing through the plate into the floor.


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



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 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.

DESIGN EXAMPLE ONE


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).


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.


DESIGN EXAMPLE TWO


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.


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.


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 K – High Rise Short Span Applications + Design Page K.1

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.


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.

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.



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: Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length. Table K3: Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length. Table K4: Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 900 and 1000mm bay length. Table K5: Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 1290mm bay length. Table K6: Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 900 and 1000mm bay length. Table K7: Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 1290mm bay length. Bay Capacity – ‘Back Bracing Every Third Bay’ Table K8: Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length. Table K9: Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length. Table K10: Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 900 and 1000mm bay length. Table K11: Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 1290mm bay length. Table K12: Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 900 and 1000mm bay length. Table K13: 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: Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length. Table K15: Bay Capacity Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length. Table K16: Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 900 and 1000mm bay length. Table K17: Bay Capacity Rack heights 4100 to 5000mm. K and EK uprights, 1290mm bay length. Table K18: Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 900 and 1000mm bay length. Table K19: Bay Capacity Rack heights 5100 to 5500mm. K and EK uprights, 1290mm bay length.


New table Table K1: Shelf Capacity in kg. Capacity of the shelf and beam using either none, one, or two reinforcing bars.



0.5 N 140 - - 300x900 0.7 H 235 260 300 0.5 N 135 - - 300x1000 0.7 H 235 260 300 0.5 N 70 - - 300x1290 0.7 H 110 235 350

0.5 N 140 - - 0.6 S 160 - - 400x900 0.7 H 235 260 300 0.5 N 140 - - 0.6 S 150 - - 400x1000 0.7 H 235 260 300 0.5 N 75 - - 0.6 S 85 - - 400x1290 0.7 H 110 235 350

0.6 S 160 - - 450x900 0.7 H 235 260 300 0.6 S 150 - - 450x1000 0.7 H 235 260 300 0.6 S 85 - - 450X1290 0.7 H 110 235 350

0.6 S 170 - - 500x900 0.7 H 235 260 300 0.6 S 150 - - 500x1000 0.7 H 235 260 300 0.6 S 85 - - 500x1290 0.7 H 110 235 350

0.6 S 150 - - 600x900 0.7 H 215 290 380 0.6 S 140 - - 600x1000 0.7 H 215 290 380 0.6 S 100 - - 600x1290 0.7 H 120 215 310

800x900 0.7 H 110 290 380

800x1000 0.7 H 110 290 380 800x1290 0.7 H 120 215 310


Table K2: Bay Capacity in kg – ‘Without Back Bracing’. Rack heights 3100 to 4000mm. K and EK uprights, 900 and 1000mm bay length.




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths

600-800mm 200mm 2022 2320 200mm 2106 2961 300mm 2022 2320 300mm 2106 2961 400mm 1896 1896 400mm 2106 2411 500mm 1483 1483 500mm 1950 1950 600mm 1241 1241 600mm 1654 1654 700mm 1119 1119 700mm 1385 1385 800mm 1035 1035 800mm 1267 1267


spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths


5 Batten + 2 ‘X’ Braced Frames or Fully Clad Frames 5 Batten + 2 ‘X’ Braced Frames

or Fully Clad Frames Shelf

spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



Table K3: Bay Capacity in kg – ‘Without Back Bracing’. Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length.




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



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.




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



Table K9: Bay Capacity in kg – ‘Back Bracing Every Third Bay’. Rack heights 3100 to 4000mm. K and EK uprights, 1290mm bay length.




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



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.




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



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.




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths







spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths




spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths



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 1000mm 1000mm 1000mm Bay length 900mm 1000mm 1290mm Hole centres ‘L’ 1328.0mm 1395.5mm 1611.5mm Fixings 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.

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 No. of Dimension Frame No. of Dimension Height Panels ‘A’ ‘B’ Height Panels ‘A’ ‘B’

‘H’ ‘N’ mm mm ‘H’ ‘N’ mm mm

3100mm 3 100 4400mm 4 331 3200mm 3 131 4500mm 4 431 3300mm 3 231 4600mm 4 531 3400mm 3 331 4700mm 5 500 3500mm 3 431 4800mm 5 400 3600mm 3 531 4900mm 5 300 3700mm 4 500 5000mm 5 200 3800mm 4 400 5100mm 5 100 3900mm 4 300 5200mm 5 131 4000mm 4 200 5300mm 5 231 4100mm 4 100 5400mm 5 331 4200mm 4 131 5500mm 5 431 4300mm 4 231


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.



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.


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.


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 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.


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.

DESIGN EXAMPLE 1


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.


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.


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.


DESIGN EXAMPLE 2


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.




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.



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).


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.

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.



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.

______________________________________________________________________________


New table Table K20: Shelf Capacity in kg. Capacity of the shelf and beam using either none, one, or two reinforcing bars.



0.5 N 140 - - 300x900 0.7 H 235 260 300 0.5 N 135 - - 300x1000 0.7 H 235 260 300 0.5 N 70 - - 300x1290 0.7 H 110 235 350

0.5 N 140 - - 0.6 S 160 - - 400x900 0.7 H 235 260 300 0.5 N 140 - - 0.6 S 150 - - 400x1000 0.7 H 235 260 300 0.5 N 75 - - 0.6 S 85 - - 400x1290 0.7 H 110 235 350

0.6 S 160 - - 450x900 0.7 H 235 260 300 0.6 S 150 - - 450x1000 0.7 H 235 260 300 0.6 S 85 - - 450X1290 0.7 H 110 235 350

0.6 S 170 - - 500x900 0.7 H 235 260 300 0.6 S 150 - - 500x1000 0.7 H 235 260 300 0.6 S 85 - - 500x1290 0.7 H 110 235 350

0.6 S 150 - - 600x900 0.7 H 215 290 380 0.6 S 140 - - 600x1000 0.7 H 215 290 380 0.6 S 100 - - 600x1290 0.7 H 120 215 310

800x900 0.7 H 110 290 380

800x1000 0.7 H 110 290 380 800x1290 0.7 H 120 215 310


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.


Rack heights 3100 to 5500mm Rack heights 3100 to 5500mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths


Rack heights 5600 to 8000mm Rack heights 5600 to 8000mm Shelf

spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths


Rack heights 8100 to 12,000mm Rack heights 8100 to 12,000mm Shelf

spacing

Frame Widths

300-500mm

Frame Widths

600-800mm

Shelf spacing

Frame Widths

300-500mm

Frame Widths


For shelving with handling equipment guiding in the rack, the load should be reduced. For further information contact Support Department.

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.



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.


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



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 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.


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.

DESIGN EXAMPLE 3


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.




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.



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: September 2006 Appendix A – Frame Assembly Schedule Page App A.1

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. App A.22 H/D Battens (riveted) 800, and 1000mm widths. App A.33 L/D Battens (swaged or riveted) 300 to 600mm widths. App A.43 H/D Battens (riveted) 800, and 1000mm widths. App A.54 L/D Battens (swaged or riveted) 300 to 600mm widths. App A.64 H/D Battens (riveted) 800, and 1000mm widths. App A.74 L/D Battens (swaged) + 2 ‘X’ braces 300 to 600mm widths. App A.84 L/D Battens (riveted) + 2 ‘X’ braces 300 to 600mm widths. App A.93 H/D Battens (riveted) + 2 ‘X’ braces 800, and 1000mm widths. App A.10 High Rise - Variable Height Frames from 3100 to 5500mm 4 L/D Battens (swaged or riveted) 300 to 600mm widths. App A.11, 124 H/D Battens (riveted) 800, and 1000mm widths. App A.13, 145 L/D Battens (swaged or riveted) 300 to 600mm widths. App A.15, 165 H/D Battens (riveted) 800, and 1000mm widths. App A.17, 184 H/D Battens (riveted) + 2 ‘X’ braces 800, and 1000mm widths. App A.195 L/D Battens (swaged) + 2 ‘X’ braces 300 to 600mm widths. App A.20, 215 L/D Battens (riveted) + 2 ‘X’ braces 300 to 600mm widths. App A.22, 235 H/D Battens (riveted) + 2 ‘X’ braces 800, and 1000mm widths. 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. App A.26, 27, 28Fully braced with L/D battens (riveted) 300 to 600mm widths. App A.29, 30, 31Fully braced with H/D battens (riveted) 800, and 1000mm widths. 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.

LOW RISE - 2 LIGHT DUTY BATTENS (swaged or riveted).

Component take-off Quantity Upright 2 Baseplate 2 Upright to baseplate fixing (when required) 2 Light duty batten 2 Rivet 4.8 x 7mm (only for riveted frames) 8

Frame First Batten Top Height Batten Centres Batten

‘H’ ‘A’ ‘B’ ‘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


LOW RISE - 2 HEAVY DUTY BATTENS (riveted).

Component take-off Quantity Upright 2 Baseplate 2 Upright to baseplate fixing (when required) 2 Heavy duty batten 2 Rivet 4.8 x 7mm 12

Frame First Batten Top Height Batten Centres Batten

‘H’ ‘A’ ‘B’ ‘C’

1000mm 211 600 189 1600mm 211 900 489 2100mm 311 1300 489 2300mm 311 1500 489 2500mm 311 1700 489




Frame First Batten Batten Top Height Batten Centres Centres Batten

‘H’ ‘A’ ‘B’ ‘C’ ‘D’

2100mm 311 600 700 489 2300mm 311 600 900 489 2500mm 311 700 1000 489 3000mm 311 900 1300 489





Frame First Batten Batten Top Height Batten Centres Centres Batten

‘H’ ‘A’ ‘B’ ‘C’ ‘D’

2100mm 311 600 700 489 2300mm 311 600 900 489 2500mm 311 700 1000 489 3000mm 311 900 1300 489




Frame First Batten Batten Batten Top Height Batten Centres Centres Centres Batten

‘H’ ‘A’ ‘B’ ‘C’ ‘D’ ‘E’

2100mm 211 300 500 600 489 2300mm 211 400 500 700 489 2500mm 211 400 600 800 489 3000mm 211 500 800 1000 489






‘H’ ‘A’ ‘B’ ‘C’ ‘D’ ‘E’

2100mm 211 300 500 600 489 2300mm 211 400 500 700 489 2500mm 211 400 600 800 489 3000mm 211 500 800 1000 489


LOW RISE - 4 LIGHT DUTY BATTENS (swaged) + 2 ‘X’ BRACES.

Component take-off Quantity Upright 2 Baseplate 2 Upright to baseplate fixing (when required) 2 Light duty batten (swage holes) 4 Frame brace 4 Rivet 4.8 x 7mm 8


LOW RISE - 4 LIGHT DUTY BATTENS (riveted) + 2 ‘X’ BRACES.

Component take-off Quantity Upright 2 Baseplate 2 Upright to baseplate fixing (when required) 2 Light duty batten (rivet holes) 4 Frame brace 4 Rivet 4.8 x 7mm 24


LOW RISE - 3 HEAVY DUTY BATTENS (riveted) + 2 ‘X’ BRACES.

Component take-off Quantity Upright 2 Baseplate 2 Upright to baseplate fixing (when required) 2 Heavy duty batten 3 Frame brace 4 Rivet 4.8 x 7mm 26


HIGH RISE - 4 LIGHT DUTY BATTENS (swaged or riveted).


The chart containing the schedule of dimensions is shown on the following page.



HIGH RISE - 4 LIGHT DUTY BATTENS (swaged or riveted) (continued).


‘H’ ‘A’ ‘B’ ‘C’ ‘D’ ‘E’

3100mm 211 600 900 900 489 3200mm 211 600 1000 900 489 3300mm 211 600 1000 1000 489 3400mm 211 700 1000 1000 489 3500mm 211 700 1000 1100 489 3600mm 211 700 1100 1100 489 3700mm 211 700 1100 1200 489 3800mm 211 800 1100 1200 489 3900mm 211 800 1100 1300 489 4000mm 211 800 1200 1300 489 4100mm 211 800 1300 1300 489 4200mm 211 900 1200 1400 489 4300mm 211 900 1300 1400 489 4400mm 211 900 1300 1500 489 4500mm 211 900 1400 1500 489 4600mm 211 1000 1300 1600 489 4700mm 211 1000 1400 1600 489 4800mm 211 1000 1400 1700 489 4900mm 211 1000 1500 1700 489 5000mm 211 1100 1500 1700 489 5100mm 211 1100 1500 1800 489 5200mm 211 1100 1600 1800 489 5300mm 211 1100 1600 1900 489 5400mm 211 1200 1600 1900 489 5500mm 211 1200 1600 2000 489


HIGH RISE - 4 HEAVY DUTY BATTENS (riveted).





HIGH RISE - 4 HEAVY DUTY BATTENS (riveted) (continued).


‘H’ ‘A’ ‘B’ ‘C’ ‘D’ ‘E’

3100mm 211 600 900 900 489 3200mm 211 600 1000 900 489 3300mm 211 600 1000 1000 489 3400mm 211 700 1000 1000 489 3500mm 211 700 1000 1100 489 3600mm 211 700 1100 1100 489 3700mm 211 700 1100 1200 489 3800mm 211 800 1100 1200 489 3900mm 211 800 1100 1300 489 4000mm 211 800 1200 1300 489 4100mm 211 800 1300 1300 489 4200mm 211 900 1200 1400 489 4300mm 211 900 1300 1400 489 4400mm 211 900 1300 1500 489 4500mm 211 900 1400 1500 489 4600mm 211 1000 1300 1600 489 4700mm 211 1000 1400 1600 489 4800mm 211 1000 1400 1700 489 4900mm 211 1000 1500 1700 489 5000mm 211 1100 1500 1700 489 5100mm 211 1100 1500 1800 489 5200mm 211 1100 1600 1800 489 5300mm 211 1100 1600 1900 489 5400mm 211 1200 1600 1900 489 5500mm 211 1200 1600 2000 489

HIGH RISE - 5 LIGHT DUTY BATTENS (swaged or riveted).





HIGH RISE - 5 LIGHT DUTY BATTENS (swaged or riveted) (continued).

Frame First Batten Batten Batten Batten Top Height Batten Centres Centres Centres Centres Batten

‘H’ ‘A’ ‘B’ ‘C’ ‘D’ ‘E’ ‘F’

3100mm 211 400 600 700 700 489 3200mm 211 400 600 700 800 489 3300mm 211 500 600 700 800 489 3400mm 211 500 600 700 900 489 3500mm 211 500 600 800 900 489 3600mm 211 500 700 800 900 489 3700mm 211 500 700 800 1000 489 3800mm 211 600 600 900 1000 489 3900mm 211 600 700 800 1100 489 4000mm 211 600 700 900 1100 489 4100mm 211 600 800 900 1100 489 4200mm 211 600 800 900 1200 489 4300mm 211 700 700 1000 1200 489 4400mm 211 700 800 900 1300 489 4500mm 211 700 800 1000 1300 489 4600mm 211 700 800 1100 1300 489 4700mm 211 700 900 1000 1400 489 4800mm 211 800 800 1100 1400 489 4900mm 211 800 900 1000 1500 489 5000mm 211 800 900 1100 1500 489 5100mm 211 800 900 1200 1500 489 5200mm 211 800 1000 1100 1600 489 5300mm 211 900 900 1200 1600 489 5400mm 211 900 1000 1100 1700 489 5500mm 211 900 1000 1200 1700 489


HIGH RISE - 5 HEAVY DUTY BATTENS (riveted).

Component take-off Quantity Upright 2 Baseplate 2 Upright to baseplate fixing (when required) 2 Heavy duty batten 5 Rivet 4.8 x 7mm (only for riveted frames) 30




HIGH RISE - 5 HEAVY DUTY BATTENS (riveted) (continued).

Frame First Batten Batten Batten Batten Top Height Batten Centres Centres Centres Centres Batten

‘H’ ‘A’ ‘B’ ‘C’ ‘D’ ‘E’ ‘F’

3100mm 211 400 600 700 700 489 3200mm 211 400 600 700 800 489 3300mm 211 500 600 700 800 489 3400mm 211 500 600 700 900 489 3500mm 211 500 600 800 900 489 3600mm 211 500 700 800 900 489 3700mm 211 500 700 800 1000 489 3800mm 211 600 600 900 1000 489 3900mm 211 600 700 800 1100 489 4000mm 211 600 700 900 1100 489 4100mm 211 600 800 900 1100 489 4200mm 211 600 800 900 1200 489 4300mm 211 700 700 1000 1200 489 4400mm 211 700 800 900 1300 489 4500mm 211 700 800 1000 1300 489 4600mm 211 700 800 1100 1300 489 4700mm 211 700 900 1000 1400 489 4800mm 211 800 800 1100 1400 489 4900mm 211 800 900 1000 1500 489 5000mm 211 800 900 1100 1500 489 5100mm 211 800 900 1200 1500 489 5200mm 211 800 1000 1100 1600 489 5300mm 211 900 900 1200 1600 489 5400mm 211 900 1000 1100 1700 489 5500mm 211 900 1000 1200 1700 489

HIGH RISE - 4 HEAVY DUTY BATTENS (riveted) + 2 ‘X’ BRACES.


Frame Height 3100mm 3200mm 3300mm 3400mm Dimension ‘A’ 300mm 400mm 400mm 400mm Dimension ‘B’ 189mm 189mm 289mm 389mm


HIGH RISE - 5 LIGHT DUTY BATTENS (swaged) + 2 ‘X’ BRACES.

Component take-off Quantity Upright 2 Baseplate 2 Upright to baseplate fixing (when required) 2 Light duty batten (swage holes) 5 Frame brace 4 Rivet 4.8 x 7mm 8




HIGH RISE - 5 LIGHT DUTY BATTENS (swaged) + 2 ‘X’ BRACES (continued).

Frame Batten Batten Height Centres Centres

‘H’ ‘A’ ‘B’


HIGH RISE - 5 LIGHT DUTY BATTENS (riveted) + 2 ‘X’ BRACES.

Component take-off Quantity Upright 2 Baseplate 2 Upright to baseplate fixing (when required) 2 Light duty batten (rivet holes) 5 Frame brace 4 Rivet 4.8 x 7mm 28




HIGH RISE - 5 LIGHT DUTY BATTENS (riveted) + 2 ‘X’ BRACES (continued).

Frame Batten Batten Height Centres Centres

‘H’ ‘A’ ‘B’


HIGH RISE - 5 HEAVY DUTY BATTENS (riveted) + 2 ‘X’ BRACES.





HIGH RISE - 5 HEAVY DUTY BATTENS (riveted) + 2 ‘X’ BRACES (continued).

Frame Batten Batten Top Height Centres Centres Batten

‘H’ ‘A’ ‘B’ ‘C’

3500mm 300 400 189 3600mm 400 400 189 3700mm 400 400 289 3800mm 400 500 289 3900mm 500 400 389 4000mm 500 500 389 4100mm 500 600 389 4200mm 600 500 489 4300mm 600 600 489 4400mm 700 600 489 4500mm 700 700 489 4600mm 700 800 489 4700mm 800 800 489 4800mm 800 900 489 4900mm 900 900 489 5000mm 900 1000 489 5100mm 1000 1000 489 5200mm 1000 1100 489 5300mm 1100 1100 489 5400mm 1100 1200 489 5500mm 1200 1200 489

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.



HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (swaged) (continued).

Frame No. of No. of Batten centres (mm) Material take-off height panels extra battens braces rivets

‘H’ ‘N’ battens ‘A’ ‘B’ ‘C’

3100mm 2 2 89 5 4 8 3200mm 2 2 189 5 4 8 3300mm 3 - 89 4 6 12 3400mm 3 - 189 4 6 12 3500mm 3 - 289 4 6 12 3600mm 3 - 389 4 6 12 3700mm 3 1 89 5 6 12 3800mm 3 1 189 5 6 12 3900mm 3 1 289 5 6 12 4000mm 3 1 389 5 6 12 4100mm 3 2 89 6 6 12 4200mm 3 2 189 6 6 12 4300mm 4 - 89 5 8 16 4400mm 4 - 189 5 8 16 4500mm 4 - 289 5 8 16 4600mm 4 - 389 5 8 16 4700mm 4 1 89 6 8 16 4800mm 4 1 189 6 8 16 4900mm 4 1 289 6 8 16 5000mm 4 1 389 6 8 16 5100mm 4 2 89 7 8 16 5200mm 4 2 189 7 8 16 5300mm 5 - 89 6 10 20 5400mm 5 - 189 6 10 20 5500mm 5 - 289 6 10 20 5600mm 5 - 389 6 10 20 5700mm 5 1 89 7 10 20 5800mm 5 1 189 7 10 20 5900mm 5 1 289 7 10 20 6000mm 5 1 389 7 10 20 6100mm 5 2 89 8 10 20 6200mm 5 2 189 8 10 20 6300mm 6 - 89 7 12 24 6400mm 6 - 189 7 12 24 6500mm 6 - 289 7 12 24 6600mm 6 - 389 7 12 24 6700mm 6 1 89 8 12 24 6800mm 6 1 189 8 12 24 6900mm 6 1 289 8 12 24 7000mm 6 1 389 8 12 24 7100mm 6 2 89 9 12 24 7200mm 6 2 189 9 12 24 7300mm 7 - 89 8 14 28 7400mm 7 - 189 8 14 28 7500mm 7 - 289 8 14 28


HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (swaged) (continued).


‘H’ ‘N’ battens ‘A’ ‘B’ ‘C’

7600mm 7 - 389 8 14 28 7700mm 7 1 89 9 14 28 7800mm 7 1 189 9 14 28 7900mm 7 1 289 9 14 28 8000mm 7 1 389 9 14 28 8100mm 7 2 89 10 14 28 8200mm 7 2 189 10 14 28 8300mm 8 - 89 9 16 32 8400mm 8 - 189 9 16 32 8500mm 8 - 289 9 16 32 8600mm 8 - 389 9 16 32 8700mm 8 1 89 10 16 32 8800mm 8 1 189 10 16 32 8900mm 8 1 289 10 16 32 9000mm 8 1 389 10 16 32 9100mm 8 2 89 11 16 32 9200mm 8 2 189 11 16 32 9300mm 9 - 89 10 18 36 9400mm 9 - 189 10 18 36 9500mm 9 - 289 10 18 36 9600mm 9 - 389 10 18 36 9700mm 9 1 89 11 18 36 9800mm 9 1 189 11 18 36 9900mm 9 1 289 11 18 36 10000mm 9 1 389 11 18 36 10100mm 9 2 89 12 18 36 10200mm 9 2 189 12 18 36 10300mm 10 - 89 11 20 40 10400mm 10 - 189 11 20 40 10500mm 10 - 289 11 20 40 10600mm 10 - 389 11 20 40 10700mm 10 1 89 12 20 40 10800mm 10 1 189 12 20 40 10900mm 10 1 289 12 20 40 11000mm 10 1 389 12 20 40 11100mm 10 2 89 13 20 40 11200mm 10 2 189 13 20 40 11300mm 11 - 89 12 22 44 11400mm 11 - 189 12 22 44 11500mm 11 - 289 12 22 44 11600mm 11 - 389 12 22 44 11700mm 11 1 89 13 22 44 11800mm 11 1 189 13 22 44 11900mm 11 1 289 13 22 44 12000mm 11 1 389 13 22 44

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.



HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (riveted) (continued).


‘H’ ‘N’ battens ‘A’ ‘B’ ‘C’ ‘D’

3100mm 2 2 300 139 5 4 28 3200mm 2 2 300 239 5 4 28 3300mm 2 2 300 339 5 4 28 3400mm 2 2 400 239 5 4 28 3500mm 2 2 400 339 5 4 28 3600mm 3 - 139 4 6 28 3700mm 3 - 239 4 6 28 3800mm 3 - 339 4 6 28 3900mm 3 1 139 5 6 32 4000mm 3 1 239 5 6 32 4100mm 3 1 339 5 6 32 4200mm 3 2 300 139 6 6 36 4300mm 3 2 300 239 6 6 36 4400mm 3 2 300 339 6 6 36 4500mm 3 2 400 239 6 6 36 4600mm 3 2 400 339 6 6 36 4700mm 4 - 139 5 8 36 4800mm 4 - 239 5 8 36 4900mm 4 - 339 5 8 36 5000mm 4 1 139 6 8 40 5100mm 4 1 239 6 8 40 5200mm 4 1 339 6 8 40 5300mm 4 2 300 139 7 8 44 5400mm 4 2 300 239 7 8 44 5500mm 4 2 300 339 7 8 44 5600mm 4 2 400 239 7 8 44 5700mm 4 2 400 339 7 8 44 5800mm 5 - 139 6 10 44 5900mm 5 - 239 6 10 44 6000mm 5 - 339 6 10 44 6100mm 5 1 139 7 10 48 6200mm 5 1 239 7 10 48 6300mm 5 1 339 7 10 48 6400mm 5 2 300 139 8 10 52 6500mm 5 2 300 239 8 10 52 6600mm 5 2 300 339 8 10 52 6700mm 5 2 400 239 8 10 52 6800mm 5 2 400 339 8 10 52 6900mm 6 - 139 7 12 52 7000mm 6 - 239 7 12 52 7100mm 6 - 339 7 12 52 7200mm 6 1 139 8 12 56 7300mm 6 1 239 8 12 56 7400mm 6 1 339 8 12 56 7500mm 6 2 300 139 9 12 60


HIGH RISE – FULLY BRACED with LIGHT DUTY BATTENS (riveted) (continued).



7600mm 6 2 300 239 9 12 60 7700mm 6 2 300 339 9 12 60 7800mm 6 2 400 239 9 12 60 7900mm 6 2 400 339 9 12 60 8000mm 7 - 139 8 14 60 8100mm 7 - 239 8 14 60 8200mm 7 - 339 8 14 60 8300mm 7 1 139 9 14 64 8400mm 7 1 239 9 14 64 8500mm 7 1 339 9 14 64 8600mm 7 2 300 139 10 14 68 8700mm 7 2 300 239 10 14 68 8800mm 7 2 300 339 10 14 68 8900mm 7 2 400 239 10 14 68 9000mm 7 2 400 339 10 14 68 9100mm 8 - 139 9 16 68 9200mm 8 - 239 9 16 68 9300mm 8 - 339 9 16 68 9400mm 8 1 139 10 16 72 9500mm 8 1 239 10 16 72 9600mm 8 1 339 10 16 72 9700mm 8 2 300 139 11 16 76 9800mm 8 2 300 239 11 16 76 9900mm 8 2 300 339 11 16 76 10000mm 8 2 400 239 11 16 76 10100mm 8 2 400 339 11 16 76 10200mm 9 - 139 10 18 76 10300mm 9 - 239 10 18 76 10400mm 9 - 339 10 18 76 10500mm 9 1 139 11 18 80 10600mm 9 1 239 11 18 80 10700mm 9 1 339 11 18 80 10800mm 9 2 300 139 12 18 84 10900mm 9 2 300 239 12 18 84 11000mm 9 2 300 339 12 18 84 11100mm 9 2 400 239 12 18 84 11200mm 9 2 400 339 12 18 84 11300mm 10 - 139 11 20 84 11400mm 10 - 239 11 20 84 11500mm 10 - 339 11 20 84 11600mm 10 1 139 12 20 88 11700mm 10 1 239 12 20 88 11800mm 10 1 339 12 20 88 11900mm 10 2 300 139 13 20 92 12000mm 10 2 300 239 13 20 92

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.



HIGH RISE – FULLY BRACED with HEAVY DUTY BATTENS (riveted) (continued).



3100mm 2 1 189 300 4 4 32 3200mm 2 1 189 400 4 4 32 3300mm 2 1 289 400 4 4 32 3400mm 2 1 389 400 4 4 32 3500mm 2 1 489 400 4 4 32 3600mm 2 2 189 5 4 38 3700mm 2 2 289 5 4 38 3800mm 2 2 389 5 4 38 3900mm 2 2 489 5 4 38 4000mm 3 - 189 4 6 36 4100mm 3 - 289 4 6 36 4200mm 3 - 389 4 6 36 4300mm 3 1 189 300 5 6 42 4400mm 3 1 189 400 5 6 42 4500mm 3 1 289 400 5 6 42 4600mm 3 1 389 400 5 6 42 4700mm 3 1 489 400 5 6 42 4800mm 3 2 189 6 6 48 4900mm 3 2 289 6 6 48 5000mm 3 2 389 6 6 48 5100mm 3 2 489 6 6 48 5200mm 4 - 189 5 8 46 5300mm 4 - 289 5 8 46 5400mm 4 - 389 5 8 46 5500mm 4 1 189 300 6 8 52 5600mm 4 1 189 400 6 8 52 5700mm 4 1 289 400 6 8 52 5800mm 4 1 389 400 6 8 52 5900mm 4 1 489 400 6 8 52 6000mm 4 2 189 7 8 58 6100mm 4 2 289 7 8 58 6200mm 4 2 389 7 8 58 6300mm 4 2 489 7 8 58 6400mm 5 - 189 6 10 56 6500mm 5 - 289 6 10 56 6600mm 5 - 389 6 10 56 6700mm 5 1 189 300 7 10 62 6800mm 5 1 189 400 7 10 62 6900mm 5 1 289 400 7 10 62 7000mm 5 1 389 400 7 10 62 7100mm 5 1 489 400 7 10 62 7200mm 5 2 189 8 10 68 7300mm 5 2 289 8 10 68 7400mm 5 2 389 8 10 68 7500mm 5 2 489 8 10 68


HIGH RISE – FULLY BRACED with HEAVY DUTY BATTENS (riveted) (continued).



7600mm 6 - 189 7 12 66 7700mm 6 - 289 7 12 66 7800mm 6 - 389 7 12 66 7900mm 6 1 189 300 8 12 72 8000mm 6 1 189 400 8 12 72 8100mm 6 1 289 400 8 12 72 8200mm 6 1 389 400 8 12 72 8300mm 6 1 489 400 8 12 72 8400mm 6 2 189 9 12 78 8500mm 6 2 289 9 12 78 8600mm 6 2 389 9 12 78 8700mm 6 2 489 9 12 78 8800mm 7 - 189 8 14 76 8900mm 7 - 289 8 14 76 9000mm 7 - 389 8 14 76 9100mm 7 1 189 300 9 14 82 9200mm 7 1 189 400 9 14 82 9300mm 7 1 289 400 9 14 82 9400mm 7 1 389 400 9 14 82 9500mm 7 1 489 400 9 14 82 9600mm 7 2 189 10 14 88 9700mm 7 2 289 10 14 88 9800mm 7 2 389 10 14 88 9900mm 7 2 489 10 14 88 10000mm 8 - 189 9 16 86 10100mm 8 - 289 9 16 86 10200mm 8 - 389 9 16 86 10300mm 8 1 189 300 10 16 92 10400mm 8 1 189 400 10 16 92 10500mm 8 1 289 400 10 16 92 10600mm 8 1 389 400 10 16 92 10700mm 8 1 489 400 10 16 92 10800mm 8 2 189 11 16 98 10900mm 8 2 289 11 16 98 11000mm 8 2 389 11 16 98 11100mm 8 2 489 11 16 98 11200mm 9 - 189 10 18 96 11300mm 9 - 289 10 18 96 11400mm 9 - 389 10 18 96 11500mm 9 1 189 300 11 18 102 11600mm 9 1 189 400 11 18 102 11700mm 9 1 289 400 11 18 102 11800mm 9 1 389 400 11 18 102 11900mm 9 1 489 400 11 18 102 12000mm 9 2 189 12 18 108

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.



FULLY SOLID CLAD FRAMES (continued).

Frame No. of No. of No. of Quantity of each cladding sheet type height clad clad swage 900 1000 1600 2100 2300 2500

‘H’ sheets trim fixings mm mm mm mm mm mm

1000mm 1 - 8 1 1600mm 1 - 10 1 2100mm 1 - 12 1 2300mm 1 - 14 1 2500mm 1 - 14 1 3000mm 2 1 18 1 1

3100mm 2 1 20 1 1 3200mm 2 1 20 2 3300mm 2 1 22 1 1 3400mm 2 1 20 1 1 3500mm 2 1 22 1 1 3600mm 3 2 26 2 1 3700mm 2 1 22 1 1 3800mm 4 3 28 2 2 3900mm 2 1 24 1 1 4000mm 3 2 26 1 1 1 4100mm 2 1 24 1 1 4200mm 2 1 24 2 4300mm 3 2 30 2 1 4400mm 2 1 26 1 1 4500mm 3 2 30 2 1 4600mm 2 1 26 1 1 4700mm 3 2 30 1 1 1 4800mm 2 1 28 1 1 4900mm 3 2 32 1 1 1 5000mm 2 1 28 2 5100mm 3 2 32 1 1 1 5200mm 3 2 32 1 2 5300mm 3 2 32 2 1 5400mm 3 2 34 1 1 1 5500mm 3 2 34 2 1 5600mm 3 2 36 1 2 5700mm 3 2 34 2 1 5800mm 3 2 36 1 1 1 5900mm 3 2 34 1 2





6000mm 3 2 36 1 2 6100mm 4 3 40 2 1 1 6200mm 3 2 36 1 1 1 6300mm 3 2 36 3 6400mm 3 2 38 1 1 1 6500mm 4 3 40 1 1 1 1 6600mm 3 2 38 1 2 6700mm 3 2 38 2 1 6800mm 4 3 44 2 1 1 6900mm 3 2 42 3 7000mm 4 3 44 2 2 7100mm 3 2 40 1 2 7200mm 4 3 46 1 1 2 7300mm 3 2 42 1 2 7400mm 4 3 46 1 1 1 1 7500mm 3 2 42 3 7600mm 4 3 46 1 1 2 7700mm 4 3 46 1 2 1 7800mm 4 3 48 1 3 7900mm 4 3 50 1 3 8000mm 4 3 48 2 1 1 8100mm 4 3 50 1 2 1 8200mm 4 3 48 2 2 8300mm 4 3 50 1 1 2 8400mm 4 3 48 4 8500mm 4 3 50 1 3 8600mm 4 3 50 3 1 8700mm 4 3 52 1 2 1 8800mm 4 3 50 3 1 8900mm 4 3 52 1 1 2 9000mm 4 3 54 1 3 9100mm 4 3 52 1 3 9200mm 4 3 56 4 9300mm 5 4 54 1 4 9400mm 4 3 56 3 1 9500mm 5 4 58 2 3 9600mm 4 3 54 1 3 9700mm 5 4 58 2 2 1 9800mm 4 3 56 1 3 9900mm 5 4 60 2 1 2





10000mm 4 3 56 4 10100mm 5 4 62 1 4 10200mm 5 4 64 1 4 10300mm 5 4 62 1 3 1 10400mm 5 4 62 1 2 2 10500mm 5 4 60 5 10600mm 5 4 64 1 1 3 10700mm 5 4 62 4 1 10800mm 5 4 66 1 4 10900mm 5 4 62 1 4 11000mm 5 4 64 1 4 11100mm 5 4 66 2 3 11200mm 5 4 64 1 1 3 11300mm 5 4 68 1 4 11400mm 5 4 66 1 1 3 11500mm 5 4 70 5 11600mm 5 4 66 1 4 11700mm 5 4 70 4 1 11800mm 6 5 70 2 3 1 11900mm 5 4 70 3 2 12000mm 6 5 72 2 2 2

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 No. of No. of No. of Quantity of each cladding sheet type height cladding cladding cladding 800 1000 1200 1300

‘H’ sheets trims clips mm mm mm mm

1000mm 1 - 6 1 1600mm 2 1 12 2 2100mm 2 1 12 1 1 2300mm 2 1 12 1 1 2500mm 2 1 12 1 1 3000mm 3 2 18 3

3100mm 3 2 18 1 1 1 3200mm 3 2 18 2 1 3300mm 3 2 18 2 1 3400mm 3 2 18 1 2 3500mm 3 2 18 1 1 1 3600mm 3 2 18 3 3700mm 3 2 18 2 1 3800mm 3 2 18 1 2 3900mm 3 2 18 3 4000mm 4 3 24 4 4100mm 4 3 24 1 2 1 4200mm 4 3 24 3 1 4300mm 4 3 24 3 1 4400mm 4 3 24 2 2 4500mm 4 3 24 2 1 1 4600mm 4 3 24 1 3 4700mm 4 3 24 1 2 1 4800mm 4 3 24 4 4900mm 4 3 24 3 1 5000mm 4 3 24 2 2 5100mm 4 3 24 1 3 5200mm 4 3 24 4 5300mm 5 4 30 4 1 5400mm 5 4 30 3 2 5500mm 5 4 30 3 1 1 5600mm 5 4 30 2 3 5700mm 5 4 30 2 2 1 5800mm 5 4 30 1 4 5900mm 5 4 30 1 3 1





6000mm 5 4 30 5 6100mm 5 4 30 4 1 6200mm 5 4 30 3 2 6300mm 5 4 30 2 3 6400mm 5 4 30 1 4 6500mm 5 4 30 5 6600mm 6 5 36 3 3 6700mm 6 5 36 3 2 1 6800mm 6 5 36 2 4 6900mm 6 5 36 2 3 1 7000mm 6 5 36 1 5 7100mm 6 5 36 1 4 1 7200mm 6 5 36 6 7300mm 6 5 36 5 1 7400mm 6 5 36 4 2 7500mm 6 5 36 3 3 7600mm 6 5 36 2 4 7700mm 6 5 36 1 5 7800mm 6 5 36 6 7900mm 7 6 42 3 3 1 8000mm 7 6 42 2 5 8100mm 7 6 42 2 4 1 8200mm 7 6 42 1 6 8300mm 7 6 42 1 5 1 8400mm 7 6 42 7 8500mm 7 6 42 6 1 8600mm 7 6 42 5 2 8700mm 7 6 42 4 3 8800mm 7 6 42 3 4 8900mm 7 6 42 2 5 9000mm 7 6 42 1 6 9100mm 7 6 42 7 9200mm 8 7 48 2 6 9300mm 8 7 48 2 5 1 9400mm 8 7 48 1 7 9500mm 8 7 48 1 6 1 9600mm 8 7 48 8 9700mm 8 7 48 7 1 9800mm 8 7 48 6 2 9900mm 8 7 48 5 3





10000mm 8 7 48 4 4 10100mm 8 7 48 3 5 10200mm 8 7 48 2 6 10300mm 8 7 48 1 7 10400mm 8 7 48 8 10500mm 9 8 54 2 6 1 10600mm 9 8 54 1 8 10700mm 9 8 54 1 7 1 10800mm 9 8 54 9 10900mm 9 8 54 8 1 11000mm 9 8 54 7 2 11100mm 9 8 54 6 3 11200mm 9 8 54 5 4 11300mm 9 8 54 4 5 11400mm 9 8 54 3 6 11500mm 9 8 54 2 7 11600mm 9 8 54 1 8 11700mm 9 8 54 9 11800mm 10 9 60 1 9 11900mm 10 9 60 1 8 1 12000mm 10 9 60 10

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 backdividers

Left to rightdividers

Clear front flap

Label facility Colours

ARCA Series 45 storage trays B Series 91 storage trays B,ESD Series 92 storage trays B,ESD Modular bins (9068-9070) B,R,Y Storage bins (9071-9072) B,G,R,Y

Colours: B = Blue, G = Green, R = Red, Y = Yellow. ESD = Specialist trays made of conductive material.



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 Height Unit width 62mm 80mm 100mm 150mm 200mm 250mm

400mm shelf width (front to back).

94mm 4532.760 115mm 9111.760 188mm 4530.760 230mm 9113.760 9068.000


94mm 4537.760 115mm 9221.760 9121.760 188mm 4536.760 230mm 9223.760 9123.760 9069.000 310mm 9071.000 9072.000


115mm 9231.760 9131.760 230mm 9233.760 9133.760 9070.000

Recommended HI280 Shelf Pitch (top of shelf to top of shelf). 100mm 125mm 150mm 200mm 250mm 300mm

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.


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 Shelf width (front to back) 300mm 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.

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

Documents

section contents page

section c pages

section h pages

contents pages

existing page

page basic system

design manual

following pages