annexure ii technical specifications mobile boltless system- … · 2017-11-21 · the following...

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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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


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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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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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


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



No of bend 14

Mfg Process Press forming

Usage Decking surface

Fasteners No

Mounting Using ‘4’ nos of shelf clips



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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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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


Colour Middle piece: Graphite Grey (RAL 7024) Edge pieces: Light Grey (RAL 7035)

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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



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



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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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



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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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



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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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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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.


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


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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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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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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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

annexure ii technical specifications mobile boltless system- … · 2017-11-21 · the following...

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