ANNEXURE –II
The following standards, as applicable for design of its Boltless MobileShelving System.
SEMA - Code of practice for the design of Mobile Shelving Systems BS: 5950 (V): 1998 – Code of practice for design of cold formed thin gauge sections FEM 10.2.06 – Code of practice for design of hand loaded static steel shelving system.
Load bearing members & accessories are made up of relevant high strength steel & the different types of materials used are:
Steel Type Minimum
guaranteed yield strength
Applicable standards Component Usage
Galvanized 210 Mpa IS:277 D G50 Upright, Shelf Panel, G50 inner cladding,
Galvanized 255 Mpa ASTM A 653M SS GRADE 37 (CLASS 1)
Shelf Clip, Cladding clamp
HR 255 Mpa
IS: 5986 - Fe 410 / Equivalent (or) IS:2062 - E 250/ Equivalent JIS 3101: SS 400 EN 10025 : S 235
Undercarriage ‘C’ Channels
CR 210 Mpa IS:513 D JIS ; G3141
Peripheral Claddings, Top panel
SG 500 500Mpa IS 1865: 1991 Stepped wheel, Plain wheel
In addition to high strength, the raw material used for structural load bearing members posses adequate ductility to ensure toughness. The material also has the necessary impact strength for cold room applications up to -30 deg C.
Technical Specifications – Mobile Boltless System- Modular Type
Design
Raw Material
Fasteners
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Signature of the Contractor
Undercarriage - Movable
Boltless superstructure uses NO bolts for assembly of panels, back tie .Fasteners are used in understructure assembly & cladding assembly. All these fasteners of Grade 8.8.All fasteners are with galvanized finish to suit industrial atmosphere.
All Powder coated components are given a thorough anti-rust treatment. The dry film thickness (DFT) after powder coating would be average 35 microns(Minimum).
All powder coated components are subjected to an elaborate 4 step, six zone anti corrosion treatment, viz. De-greasing as per IS 6005:1970, rinsing, phospating as per IS 3618:1966 and RO water rinsing.
Rails are installed initially then understructures are installed over the rails. Then boltless
superstructure is installed on the undercarriages. Following this, periphery claddings are installed. Since, boltless superstructure is used, assembly of the system takes very minimal time compared to bolted superstructure. No welding will be carried out at site.
Movable undercarriage is provided with high strength, high precision cast iron wheels
which runs on the rails. Drive unit is connected to the undercarriage via sprocket & chain assembly. Undercarriage is made up of ‘C’ Profiles which are assembled together to provide rigid base for the system.
Anti-tipping elements are incorporated in the undercarriage, to provide redundant safety to the operator.
Profile Lipped ‘C’ Channel
Size 1.Front ‘C’ Channel:120x66x66mm 2. ‘C’ Lip beam end: 114x66x60 3.‘C’ Lip beam mid: 114x66x60
Height of undercarriage 120mm
Height of undercarriage from ground
165mm
Usage To hold superstructure & to provide rolling motion on rails.
Guiding of trolley By stepped wheels at extreme rails
Number of guide (step) wheels
5
Mfg Process Forming
Finish Powder coated
Assembly & Installation
Understructure, Rails &Drive unit specification
Surface Finish
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Signature of the Contractor
Rail Assembly
Undercarriage - Fixed
Fixed undercarriage is made up of ‘C’ Profiles which are assembled together to provide
rigid base for the system. Anti-tipping elements are incorporated in the undercarriage, to provide redundant safety
to the operator.
Rails made up of 25x16mm rectangular bars, which enable the undercarriage to move in
a guided path & anti-tilt assembly also takes support from rail assembly. Rails are leveled using shims to maintain uniform level throughout the length. Rails are grouted with the ground using shell expansion anchor bolts. There are ‘12’ bolts per meter length of rail. It is provided with slope plates at both sides to avoid hindrance to people who are walking at the system.
Profile Lipped ‘C’ Channel
Size 1. Front ‘C’ Channel: 120x66x66mm
2. ‘C’ Lip beam end: 114x66x60 3. ‘C’ Lip beam mid: 114x66x60
Height of undercarriage 120mm
Height of undercarriage from ground
165mm
Usage To hold superstructure & to support moving units
Mfg Process Forming
Finish Powder coated
Profile Rectangular Bar
Size of bar 25 x 16
Material IS 2062
Bottom width of rail 100mm
Slope plate Thickness 2mm
Usage Trolley path
Mfg Process Forming and Welding
Finish
Power Coated. (Top surface of the rails are without powder coating)
Colour Graphite Gray (RAL 7024)
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Signature of the Contractor
Drive unit Assembly
Upright
Drive unit assembly is a chain mechanism by proper reduction that will reduce the efforts
of the operator. Drive unit is provided with innovative handle mechanism which will always in downwards position, to improve the overall aesthetics of the system & hassle free operation.
Upright is roll-formed construction made up of single piece having slots at 25mm pitch.Uprights are inserted & bolted to the undercarriage.
The manufacturing process of punching and forming is in one flow and a synchronized operation, thereby providing dimensional accuracy and contour uniformity consistently.
Hand wheel type Single Handle
Effort Reduction Ratio 1:2.29 (34Teeth : 14Teeth)
Locking mechanism Lock handle (Kept horizontal means locked & vertically downward means free to move)
Drive force transfer Through chain (RS40)
Chain pitch ½” (12.7mm)
Reverse movement Yes
Material of handle ABS (Acrylonitrile Butadiene Styrene) Plastic.
Finish of handle Molded Mat finish
Profile width 50 mm
Profile depth 37 mm
No of pieces Single
Panel adjustability
25 mm
Material quality
Min Ys=210Mpa
Boltless Superstructure Components specification
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Signature of the Contractor
Bracing
Shelf Panel
Bracing type is battened type. Bracing is a formed single piece section which connects two
vertical uprights & makes a frame. These are hooked into upright & two plastic rivet pins used for fastening.
Shelf panels are the load carrying members which are hooked into the uprights via shelf clips. ‘4’ nos of clips are used per panel. Panel levels can be adjusted in the pitch of 25mm. It is a roll-formed section with 14 bends. There are slots for mounting dividers at the pitch of 50mm.
Shelf Panel Depth Side –Cross Section
Mfg process Roll forming
Finish Powder coated
Colour Light Grey (RAL 7035)
Thickness 1.0mm (Min)
Section Flat with edge bend and middle rib
Material thickness 1.2mm
Mfg process Forming
Connectivity Hooking & Pin assembly
No of fasteners 2 nos of M6x10 plastic rivet pin
Finish Powder coated
Colour Light Grey (RAL 7035)
No of bend 14
Mfg Process Press forming
Usage Decking surface
Fasteners No
Mounting Using ‘4’ nos of shelf clips
Finish Powder coated
Colour Light Grey (RAL 7035)
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Signature of the Contractor
Shelf Clip
Back tie
Upright Connector
Shelf panels are mounted on the upright using this clip. These are replacing the fasteners to mount panels with upright and while changing the levels of panels, these clips can be placed into the upright without any additional tools.
Back tie rod cleat (RH) is inserted into upright& then turn buckle is hooked to it. Then back tie rod is hooked to turn buckle & back tie rod cleat (LH).
Usage Stability
Dia of tie rod 5mm
Size of turn buckle 90mm
Connectivity – tie rod cleat Hooking
Fasteners ‘1’ no of plastic rivet pin / cleat
Mfg process – tie rod Forming
Finish Galvanized
Profile section 70x 17 x 12mm
Material thickness
2.3mm
Mfg process Blanking & Punching
No of bend 2
Connectivity Insertion
Finish Galvanized
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Signature of the Contractor
Front Box Cladding (FBC) Assembly
Rear Box Cladding (RBC) Assembly
This component used to connect two Uprights back to back when configured as a DF system. Default gap to maintained between two SF system is ‘1’mm.
It is an assembly of either single / ‘3’ pieces / ‘6’ pieces together to form a front fascia.
It comprises either single / ‘3’ pieces / ‘6’ pieces together to form a rear fascia.
Profile Hat Section
Material thickness 1.2 mm
Mfg process Forming
Connectivity Bolting
Fastener ‘2’ Nos of M6x15 Hex bolt & Nut / pair of connector
Finish Galvanized
Mfg Process Forming
Fixity Bolted to frame via cladding connector
Material CR Material thickness 1 mm
Fastener
1. M6x15 Hex Bolt, Nut & Washer – with cladding connector
2. M8x20 Hex Bolt, Nut & Washer – For interbolting Finish Powder coated
Colour Middle piece: Graphite Grey (RAL 7024) Edge pieces: Light Grey (RAL 7035)
Mfg Process Forming
Fixity Bolted to frame via cladding connector
Material CR Material thickness
1 mm
Fastener 1. M6x15 Hex Bolt, Nut & Washer – with cladding connector 2. M8x20 Hex Bolt, Nut & Washer – For interbolting
Finish Powder coated
Colour Middle piece: Graphite Grey (RAL 7024) Edge pieces: Light Grey (RAL 7035)
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Signature of the Contractor
End Cladding (EBC) Assembly
Manual Locking Stiffener
Anti-Toppling Assembly
End cladding is provided at the extreme sides ( i.e. Sides of the SFF (Single Faced
Fixed) unit & SFM (Single Faced Movable) Unit) of the block.
Locking stiffener is a mechanism used to lock the overall block. Once the aisle is closed & locking stiffener is locked, the system becomes a block and no access to material is possible. This gives access control to the material in the system. Lock comes with ‘2’ keys. This is over and above the Electronic Pin Lock .
Usage Centralized Locking of the system
Lock type Recess Handle Lock
Stiffener Body thickness
1mm
Rod diameter 9mm
Mfg Process Forming & welding
Finish Powder coated
Colour Light Grey (RAL 7035)
Mfg Process Forming
Fixity Bolted to frame via EBC Locking Beam
Material CR
Material thickness 1 mm
Fastener M8x20 Hex Bolt, Nut & Washer – for connecting with EBC locking beam & for inter bolting
Finish Powder coated
Colour Light Grey (RAL 7035)
Usage Stability
Dia of the tube 38mm
Material thickness 2mm
Mfg Process Forming & welding
Finish of pipe Galvanized
Finish of housing Powder coated
Colour of housing Light Grey (RAL 7035)
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Signature of the Contractor
Inner side Plain Cladding
Label Holder
Label shall be inserted from top of the holder. One label holder is provided to SF / DF unit.
Inner side plain claddings are most common cladding type & assembled in between two units.
Type of profile Plain sheet
Thickness 0.6 mm
Mfg process Forming
Fixity Bolted to upright
Fasteners ‘4’ nos of M6x15
Fastener type Hex. Bolt & nut
Finish Powder coated
Colour Light Grey (RAL 7035)
Paper Size A4
Label holder size 315x250x6
Connectivity Bolted
Fastener ‘3’ nos of M4x16
Type Slotted round head screw & Nut
Material Acrylic
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Signature of the Contractor
Back cladding clip
End back plain Cladding
Electronic pin Lock Electronic pin lock
End back plain claddings are located at the back of the unit.
This clip is used to connect end back cladding with G50 upright. This clip is common for end back plain & end back mesh claddings.
Electronic pin lock is a mechanism used to lock the overall system (Block). Electronic pin
Lock will be locked automatically, while closing the aisle. The lock can be opened with preset pin numbers for accessing the material.
Type of profile Plain
Thickness 0.8 mm
Mfg process Forming
Fixity Using ‘4’ nos of ‘back cladding clip’ & Bolting
Fasteners ‘4’ nos of M5x15 & ‘1’ no of M5x10 pan head self tap screw
Fastener type Slotted round head screw
Finish Powder coated
Colour Light Grey (RAL 703)
Size 30 x 27 x 25mm
Thickness 1.2 mm
Mfg process Forming
Surface finish Galvanized
Usage Centralized Locking of the system
Lock type Electronic pin Lock
Total no of user codes 9 (One master code and eight user codes)
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Signature of the Contractor
Possible lock code combinations
One million
Power source Battery
No of batteries 2
Battery type 9V,Alkaline battery
Battery make Duracell
Low power indication sound beeps
Battery operating cycle
New batteries will power lock for approximately 8000 openings when used without the time delay feature
Type of mechanism Motor drive
Mechanical override In case of maintenance, a Unique mechanical bypass key can be used.
Pin lock Certifications
UL
Electronic pin lock Colour Bright Chrome
Assembly Body thickness 1.25mm
Assembly Mfg Process Forming & welding
Assembly Finish Powder coated
Assembly Colour RAL 7035
Electronic pin lock assembly
Keypad Lock
Electronic pin Lock integration with Mobistack Neo
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Signature of the Contractor
1 The Working Aisle of Minimum 800mm to maintain in Design
2 Load per level carrying capacity = 70kgs minimum (Uniformly distributed load).
3 The Mobile Shelving system is completely knock down construction. No welding will be carried out at site.
4 Mobile shelving can be dismantled component wise for future relocation Requirements.
5 The Mobile Shelving system should be provided with totally boltless superstructure assembly.
6 Superstructure:-
6.1 Superstructure of the system is the integrated storage units having multiple loading levels on each unit with boltless assembly.
6.2 Assembled superstructure has to be mounted on the modular undercarriage with a typical base plate.
7 Upright (Verticals Member):-
7.1
Upright used in the system as main vertical members are of T profile only where loading shelves/panels are mounted and should be of section 50mm(W)x37mm(D) of 1.0mmThickness (Min). Slotted L Angle constructions not acceptable
7.2 Upright must have holes at a minimum pitch of ¾ to an inch maximum to an inch for flexible re-adjustment of the load levels’ height as and when required.
7.3 Upright used must be of single piece of required length without joint.
7.4 Materials of construction: IS: 277 D. Minimum yield strength 210 Mpa.
7.5 Process of manufacturing: Roll formed.
7.6 Finish: Epoxy powder coated
7.7 Colour: Light Grey(RAL 7035).
8 Shelf Panels :-
8.1 Panels are hooked into uprights with '4' Shelf clips per panel .
8.2 Size of the Panels shall be 1300mm W X 400mm D and should be as per Drawing.
8.3 No of Bend : 14 Bends with construction as shown in Technical Specifications.
8.4 Material of construction conform CR ; IS 277 D ,Minimum yield strength 210Mpa.
8.5 Mounting : Using '4' Shelf Clips for Easy Adjustability whenever required.
8.6 Process of manufactured: press forming.
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8.7 Finish: Epoxy powder coated.
8.8 Colour: Light Grey(RAL 7035).
9 Bracing :
9.1 Section : Flat with Edge Bend without sharp edges and middle Rib .
9.2 Size & Thickness of Bracings shall be minimum 399mm(L)x 139(H)x1.2mm Thick .
9.3 Manufacturing Process : Forming
9.4 Connectivity : Hooked & Pin Assembly
9.5 Finish: Epoxy powder coated
9.6 Colour: Light Grey(RAL 7035).
10 Back Tie :
10.1 Dia of Tie Rod : 5 mm'
10.2 Size of Turn Buckle : 90mm
10.3 Connectivity : Hooking
10.4 Manufacturing : Forming
10.5 Finish : Galvanized
11 Fastners:-Modular Boltless system uses NO Nut & Bolts for Panel assembly, backtie. Fastners are used in Under structure assembly and cladding assembly are of grade 8.8 and Galvanized.
12 Inner /Mid /End Claddings
12.1 Inner cladding to be provided at the inner common sides to separate the bodies and mix up of storage materials
12.2 Plain Mid claddings are to be provided at the inner common backs of Double Faced to separate the bodies and of minimum 0.65mm
12.3 End cladding to be Provided at the Ends and of Minimum 0.8mm (sheets or panels can be provided)
12.4 Material of construction confirming to CR ; IS: 513 grade ‘D’,JIS;G3141
12.5 Process of Manufactured: press forming
12.6 Finish: All the inner/Mid/End cladding has to be epoxy powder coated
12.7 Colour :Light grey (RAL 7035).
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Signature of the Contractor
13 Front/Rear Box Cladding :
13.1 Peripheries of the system have to be covered with claddings, which must be of Box Type Claddings of suitable & required combination at the front and Rear. No plain claddings are acceptable at front/rear peripheries of the system.
13.2 Connectivity: Bolted to frame via cladding connector. Riveting not acceptable as due to future relocation possibility
13.3 Material : Cold Rolled Steel with 1mm Thickness
13.4 Finish : Epoxy Powder Coated
13.5 Colour: Middle piece- Graphite Grey (RAL 7024) & Edge Pieces- Light Grey (RAL 7035)
14 Manual Lock Stiffener to be provided for access control with 2keys with powder coated of Light Grey ( RAL 7035) and in addition to the Electronic Pin Lock
15 Anti-Toppling Assembly to be provided for Stability purpose.
16 Undercarriage :
16.1 Under structure should comprised three varieties of undercarriages as Single faced Fixed/Single Faced Mobile/Double Faced Mobile
16.2
Under structures used in the system are required be completely modular knockdown frame with bolted assembly of multiple sections of Lipped “C” channels of required section without welding and to be dismantled for future relocation Requirements Size : 1)Front "C" channel 100 to 120 x66x66 mm. 2)'C' Lip Beam Mid &End 114x66x60 mm.
16.3 Height of Undercarriage from ground 165mm Max , as due to civil clear height availability and storage capacity achievement.
16.4 Under structures for Movable Units has to be fitted with stepped & flat cast wheels for noiseless movement of undercarriages, assembled with suitable teeth sprockets at required dia of shaft for necessary load bearing. Chain construction on rails not acceptable
16.5 Materials of construction has to confirm HR ; IS 2062
16.6 Finish : Epoxy powder coated.
17 Rails :-
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Signature of the Contractor
17.1 Sides of the rails must be made with slanted sloped surface allowing movement of trolley inside as well as to ensure smooth walk throughProfile : Rectangular Bar. Size 25x16. Bottom Width :100mm. Slope plate Thickness : 2mm.
17.2 Material of construction has to confirm to IS 2062
17.3 Finish : Epoxy powder coated
18 Drive Mechanism:-
18.1 Single Handle Type or Tri Star Handles can be provided
18.2 Drive force Transfer : Through Chain with Chain pitch
18.3 Effort Reduction Ratio :1:2.29
18.4 Reverse Movement: Yes.
18.5 Finish of Handle: Molded Mat Finish or machined handles to be provided
19
Electronic Pin Lock :
19.1 Locking Type : Centralized Locking of System
19.2 No of User Codes : 9 nos with One Million combinations
19.3 Power Sources : Battery (2 nos) with 9 v Alkaline Battery
19.4 Low Power Indication : Sound Beeps
19.5 Battery Openning Cycle : Minimum 8000 openings without the Time Delay Feature
19.6 Mechanism Type : Motor Drive
19.7 Colour : Bright Chrome
20 Safety Locking arrangement: Safety locking arrangement must be provided along with hand wheel drive assembly in order to provide safety during operation inside the system.
21 Safety & stability arrangement:- In order to provide safety & stability to the system necessary stability arrangement both on the superstructure as well as in the undercarriage must be provided to the system
22 Pre treatment and Final Finish of the System:-
22.1 For long life and protection from corrosion, All Powder coated components are given a thorough anti-rust treatment. The dry film thickness (DFT) after powder coating would be average 35 microns.
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Signature of the Contractor
22.2
All powder coated components are subjected to an elaborate 4 step, six zone anti corrosion treatment, viz. De-greasing as per IS 6005:1970, rinsing, phospating as per IS 3618:1966 and De-mineralized water rinsing. Furthermore, the testing of paint for various physical and chemical properties is done as per IS 101: 1964.
22.3 The paint used in the system shall be of Lead free composition
23 Raw material proof from major Steel Suppliers like Tata/ Jindal ,used in production ,to be submitted
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