Appendix F Pallet Rack 463L.pdf

APPENDIX F

FOR

463L PALLET RACK

AT

JOINT BASE CHARLESTON, SOUTH CAROLINA

FLIGHT LINE SUPPORT FACILITY

CSN: BCH205

DATE: 10 JANUARY 2024

PREPARED BY:

Ashley Ambrose

ASHLEY AMBROSE

PROJECT ENGINEER

AFLCMC/EZPAE

Ronald Parsons

RONALD PARSONS

REVIEWER

AFLCMC/EZPAE

FA860424RB005 ATTACHMENT 7

THIS PAGE LEFT BLANK INTENTIONALLY

Joint Base Charleston – App F – Page i

Table of Contents

1. SCOPE

1.1. GENERAL SCOPE

1.2. DEFINITIONS

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. CONFIGURATION REQUIREMENTS

3.2.2. UPRIGHT FRAMES

3.2.2.1. COLUMNS

3.2.2.2. BEARING PLATES

3.2.2.3. DIAGONAL/HORIZONTAL BRACING

3.2.3. SHELF BEAMS

3.2.3.1. CONNECTORS

3.2.3.2. SHELF BEAM-TO-COLUMN SAFETY LOCK

3.2.4. FLUE SPACERS

3.2.5. LEVELING SHIMS

3.2.6. ANCHORING THE STRUCTURE

3.2.7. ASSEMBLY

3.2.8. FORKLIFT GUARD POSTS

3.2.9. CAPACITY MARKINGS

3.2.10. PALLET SCALE

3.2.10.1. SCALE DISPLAY

3.2.10.2. LOAD CELLS

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTION

4.2. TESTS

4.3. EQUIPMENT CERTIFICATIONS

THIS PAGE LEFT BLANK INTENTIONALLY

Joint Base Charleston – App F - Page 1

1. SCOPE

1.1. GENERAL SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for 463L pallet rack for the 628th Logistics Readiness Squadron (LRS) the Flight

Line Support Facility (FLSF), at Joint Base Charleston, South

Carolina. The work shall be completed in accordance with this appendix, Air Force (AF) Drawing BCH205-01, and the Cover

Purchase Description (PD). This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

1.2. DEFINITIONS

- 463L pallet rack unit - A unit is an assembly of four upright frames, four shelf beams, four flue spacers, three pieces of dunnage, and the hardware connecting all the components together.

- 463L pallets - The 463L pallet is used to transport air cargo on military aircraft. The 463L pallet consists of an end-grain balsa-wood or redwood core sandwiched between two sheets of aluminum with frames on all sides consisting of extruded aluminum edge rails. Steel tie-down rings are distributed around the perimeter of the pallet to secure nets and to facilitate handling. The entire pallet measures 108 inches wide by 88 inches long by 2.25 inches thick. Cargo on 463L pallets may be stacked up to 114 inches high on a single pallet. The pallet has a rated capacity of 10,000 pounds and weighs approximately 355 pounds. The 463L pallet is normally transferred with the 108-inch edge leading.

- The ISU pallet base is the same as the 463L pallet base.

Steel tie-down rings are distributed around the perimeter of the pallet to secure nets and to facilitate handling. The ISU pallet weight is between 1,400 and 1,700 pounds with a payload capacity of 10,000 pounds. Dimensions of the ISU

70/90 is 108 inches wide by 88 inches deep and either 70 or

90 inches high.

- Bay - is the area between two pair of adjacent uprights.

Joint Base Charleston – App F - Page 2

2. APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with Section 2 of the Cover PD.

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

463L pallet racks will be used to store fully loaded 463L pallets in such a manner to permit placement and removal of any individual load without disturbing any other load. 463L pallet rack shall interface with 10K forklifts. 463L pallet rack shelves shall be capable of supporting a minimum uniformly distributed load of 12,000 pounds. The pallet rack system shall be designed to comply with seismic requirements at Joint Base

Charleston. The pallet rack shall conform to the requirements of the Rack Manufacturers Institute (RMI) 2012 Specification for the Design, Testing, and Utilization of Industrial Steel Storage

Racks.

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. CONFIGURATION REQUIREMENTS

463L pallet rack shall be capable of being assembled side-by-side, in a row, using common uprights to support the shelf beams. 463L pallet racks shall be located as shown in AF

Drawing BCH205-01. A starter unit of 463L pallet rack shall be assembled using (4) 120” H x 36” D uprights, (4) 120” W beams,

(4) flue spacers, (3) pieces of dunnage (if applicable) and the hardware to attach the dunnage to the beams and anchor the racking. See Figure 1 for additional details. The racks shall be separated by a flue for back-to-back rows, as defined in

3.2.4.

3.2.2. UPRIGHT FRAMES

The upright frames shall be of steel, all welded construction consisting of two columns, diagonal and horizontal braces, and floor bearing plates. Each set of upright frame shall be capable of supporting fully loaded bays without permanent deformation. Upright frames shall have a minimum capacity of

12,000 pounds with a safety factor of 1.92 to 1.

Joint Base Charleston – App F - Page 3

3.2.2.1. COLUMNS

The columns shall be a continuous channel, box channel, rectangular, square or other formation approved by the

Contracting Officers Technical Representative (COTR). The columns facing the aisle shall be reinforced using a double post or other means as approved by the COTR. Each column shall have openings to readily accommodate beam connectors, end-to-end, at corresponding heights through the height range of the column openings. The openings at the bottom shall allow for the tops of shelf beams to be installed at six inches above the ground

Joint Base Charleston – App F - Page 4 and shall continue upward to the top of the column with maximum

3-inch increments. All openings of each column shall be identical to each other and identical to the openings of all other columns. The position of all corresponding openings of the columns shall not vary more than 3/32 inch as measured from the bottom of the bearing plates. The arrangement of the openings and the fastening devices of the beams shall be such that the tops of the beams are flush, within 3/8 inch, with the top of the column. The width of the column, facing the aisle, shall be a nominal 3 inches.

3.2.2.2. BEARING PLATES

The bottom of each column shall have a load bearing plate securely attached. Each bearing plate shall be sufficiently sized to disperse the maximum load imposed by the column. Each bearing plate shall have a minimum of two punched holes to accept minimum 3/8-inch anchor bolts in accordance with 3.2.6.

3.2.2.3. DIAGONAL/HORIZONTAL BRACING

Horizontal and diagonal braces shall brace the columns. Each end of all braces shall be securely welded to the columns. The braces shall not protrude beyond the sides of the columns or obstruct the attachment of the shelf beams to the columns, at any height on the columns. The centerline of the bottom horizontal brace shall not be located more than 12 inches from the bottom of the upright frame, and the centerline of the top horizontal brace shall be located not farther than 12 inches from the top of the upright frame. Other diagonal and horizontal braces shall be uniformly spaced between the top and bottom horizontal braces.

3.2.3. SHELF BEAMS

Shelf beams shall be the box type. Any openings in the shelf beam construction shall face inward; they shall not face the aisle. The connector shall not be welded to the column. Shelf beam-to-column connection shall be of the locking type. Shelf beams shall provide a bay width of 120 inches and a capacity of

6,000 pounds. When loaded to capacity, shelf beams elastic deformation shall not exceed 0.56 percent of the unsupported span, measured with respect to the two ends of the beam and shall not exhibit permanent deformation. Shelf beams shall be designed with a safety factor of 1.65 to 1.

Joint Base Charleston – App F - Page 5

3.2.3.1. CONNECTORS

Each end of the shelf beams shall have a multiple prong slip-fit or slip-joint type shelf beam-to-column connector. Separate shelf beams and connectors are unacceptable. The connectors shall be adjustable, allowing the shelf beams to be moved with no more than the use of a soft hammer. The connector shall be capable of transferring all loads and external forces of the shelf beam to the column without failure of the connection, or damage to the column or connector. The prongs shall be of sufficient number, size, and strength to withstand repeated loading and unloading of the rack, and to continually sustain the rated shelf beam load. The prongs shall engage with the openings of the columns in such a manner to prevent lateral rotation of the beam, with each prong contributing to the support of the beam. The prongs shall engage with the openings of the columns to ensure a snug metal-to-metal fit between the horizontal and vertical load carrying members. The prongs shall be of the same design as the opening.

3.2.3.2. SHELF BEAM-TO-COLUMN SAFETY LOCK

Each shelf beam-to-column connection shall have a safety lock, which shall lock the shelf beam to the column. The design and manner of construction of the device shall prevent accidental disengagement of the shelf beam-to-column connection during movement or shifting of the assembled rack unit due to impact to the upright frame or shelf beam from horizontal or vertical directions. The safety-locking device shall be an integral, attached part of the shelf beam. The safety lock shall be employed without the use of tools, and no part thereof shall obstruct or restrict the loading or unloading of the racks.

3.2.4. FLUE SPACERS

Flue spacers shall be capable of joining the backs of two upright frame sections together. Flue spacers installed to create a single bay of 463L pallet rack shall provide a 24-inch flue space. Flue spacers installed for back-to-back bays of

463L pallet rack shall provide a minimum 6-inch flue space.

Each end shall firmly and securely attach to the column and prevent unintentional disengagement. The flue spacer shall be of sufficient size and strength to withstand all forces applied to the connected upright frames during normal loading and unloading operations without deformation or failure. The

Contractor shall supply and install a minimum of two flue spacers for each set of back-to-back uprights when applicable.

The top flue spacer shall be installed within 12 inches of the

Joint Base Charleston – App F - Page 6 top of the frame. The bottom flue spacer shall be installed within 12 inches of the bottom of the frame.

3.2.5. LEVELING SHIMS

Leveling shims shall be provided with the rack units where necessary. The shims shall have holes corresponding to the holes in the bearing plate, and shall anchor or lock with the bearing plate when the rack is erected. Shims shall be equal in width and length to the bearing plate under which it is installed. Shims shall be of varying thickness so no more than five shims are installed at any point. Slotted shims shall be unacceptable.

3.2.6. ANCHORING THE STRUCTURE

The 463L rack system shall be anchored to resist all design shears and uplift forces. The 463L rack units shall be designed to be a rigid freestanding structure and shall not be connected to any existing building structure except the floor. Each bearing plate shall be securely anchored to the floor with minimum one 3/8-inch diameter anchor bolt. The minimum embedment of the anchor shall be 4 inches.

3.2.7. ASSEMBLY

The assembled 463L pallet rack system shall be rigid, stable, and without deformation or skewing when each bay is loaded to the capacity of the design loads. The 463L pallet rack system shall assemble so that the columns are perpendicular to the beams and parallel to each other. Shelf frames shall be straight and square. All horizontal members shall be level to within 1/8 inch per 10 feet measured over any distance in the rack system.

3.2.8. FORKLIFT GUARD POSTS

Steel pipe forklift guard posts shall be provided at the end of the rows as shown on AF Drawing BCH205-01. The guard posts shall extend a minimum 3 feet above the floor and shall be installed in such a manner that they do not interfere with the normal usage of the pallet rack. A cap shall be installed on the top of the guard post. The guard posts shall not interfere with the normal movement of the trucks and shall protect the corner upright frame at each aisle entry from an accidental impact with a 10,000-pound capacity forklift. Each forklift guard post shall be anchored to the floor with a minimum of four

Joint Base Charleston – App F - Page 7 anchor bolts in accordance with 3.3.2.3 of the Cover PD. The guard post shall be painted safety yellow.

3.2.9. CAPACITY MARKINGS

Load capacity labels or markings shall be displayed on the front shelf beam of each bay. Every shelf beam shall be labeled with:

Manufacturer, Part #, and Capacity. The labels shall be approximately 2” x 4” with the font size easy enough to read from 5 feet away.

3.2.10. PALLET SCALE

One pallet scale shall be provided at the location shown on AF

Drawing BCH205-01. The scale shall be the low profile, platform type and shall be used to weigh 463L pallets and ISU containers. The scale platform shall be 120 inches wide by 96 inches deep and shall have an impact protection angle installed on the forklift approach side. The scale shall be accurate to within 0.5 percent at maximum rated load. The contractor shall provide independent verification and certification of this accuracy, including the certifications of the load cells used in the system. Detailed calibration procedures shall be provided with the scale. Calibrating the scale shall not void the warranty.

3.2.10.1. SCALE DISPLAY

The scale display shall be mounted on a pedestal to the side of the scale, near to the wall located behind the scale. The scale display shall consist of a digital readout with numbers at least

1 inch high. The scale display shall stabilize in less than 3 seconds. The scale display shall have a zero button to reset the weight to zero, a tare button and a tare indicator to show the tare mode has been selected, and a button to toggle the displayed weight between pounds and kilograms and shall default to pounds. The scale display shall have a RS-232 port. The scale display shall be designed so an operator cannot inadvertently change the scale calibration. The scale display shall reset, but not lose calibration, by powering the display off and on without any other form of human intervention. All scale display controls shall be clearly labeled.

3.2.10.2. LOAD CELLS

The scale shall have a minimum of four electronic shear beam load cells, each having a minimum capacity of 10,000 pounds. Repeated loading/unloading of fully loaded pallets on

Joint Base Charleston – App F - Page 8 the scale shall not harm the load cells. All shear beam load cells shall be dust proof and watertight. Damage to the load cells due to impacts from pallets and other normal use shall be prevented by the design of the load cells. Provisions for load call replacement shall be provided.

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTION

The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of this appendix and the

Cover PD. These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

4.2. TESTS

The following tests shall be performed on the system as part of the system checkout test and again as a part of the quality conformance test.

No. Paragraph Description

1. 3.1. and

3.2.3.

Three 463L top-level pallet bays, picked at random, shall each be loaded to full capacity to ensure the pallet beams are set in place.

The loads shall then be removed. The distance from the floor to the bottom of the shelf beam shall be measured and recorded as M1. The loads shall then be put back into the designated pallet bays. The loads shall be left for a minimum of four continuous hours.

The distance from the floor to the bottom of the shelf beam shall be measured again and recorded as M2. The following formula shall be used to determine the deflection amount for

463L pallet rack:

Deflection = [(M1 - M2) / 120] * 100

If the deflection is greater than 0.56 or if permanent deformation exists when the loads are removed, the system shall fail.

Joint Base Charleston – App F - Page 9

2. 3.2.3.2. The shelf-to-column safety lock shall be tested at a minimum of ten random locations.

Personnel shall attempt to separate empty shelf beams from the column without disabling the shelf-to-beam safety lock. If a shelf separates from a column then, the system fails the test.

4.3. EQUIPMENT CERTIFICATIONS

The Contractor shall provide certification that the following requirements have been met. All certifications shall be provided in accordance with the Contract Data Requirements List.

No. Paragraph Certifications

1. 3.1. The pallet rack conforms to the requirements the Rack Manufacturers Institute (RMI) 2012

Specification for the Design, Testing, and

Utilization of Industrial Steel Storage Racks.

2. 3.2.2. Each 463L-pallet rack upright frame shall have a minimum safe load capacity of 12,000 pounds with a safety factor of at least 1.92 to 1.

3. 3.2.2.2. The bearing plates are of sufficient size to disperse the maximum load imposed on the column.

4. 3.2.3. All shelf beams are designed for, constructed to, and capable of sustaining the minimum safe load with a safety factor of at least 1.65 to

1.

TECHNICAL PROPOSAL QUESTIONNAIRE

FOR

Joint Base Charleston – TPQ for 463L Pallet Rack - Page 1 of 3

463L PALLET RACK

Solicitation Number: FA8604- -R-

Project Title: Storage Aids System

Base: Joint Base Charleston, SC CSN: BCH205

Appendix F – 463L Pallet Rack: 10 January 2024

The Offeror shall complete this questionnaire. All entries to this questionnaire shall be typed. The questionnaire will be used to determine the Offeror’s understanding of the requirements and acceptability of the proposed equipment.

Attach product literature/cut sheets for all equipment detailed in this Purchase Description and attach any exceptions to the

Purchase Description as detailed below.

Pallet Rack Manufacturer: ____________________________________

No. Paragraph Characteristics

1. 3.2.1. Upright Frames: _______ by _______ inches

2. 3.2.2. Minimum capacity of upright frames:

_________ pounds

Safety factor of: ____________________ to 1

3. 3.2.2.1. Width of column facing the aisle: __________ inches

Explain means of column reinforcement:

4. 3.2.2.2. Number of punched holes per bearing plate:

Solicitation Number: FA8604- -R-

Joint Base Charleston – TPQ for 463L Pallet Rack - Page 2 of 3

5. 3.2.3. Shelf beam length: __________________ inches

Shelf beam capacity: ________________ pounds

Safety factor of: _____________________ to 1

Will shelf deflection meet the requirements as specified?

YES NO

6. 3.2.3.2. Will shelf beam-to-column safety locks be provided as specified?

7. 3.2.5. Will leveling shims be provided as specified?

8. 3.2.6. Diameter of anchors to be provided: ________

Length of anchors to be provided: __________

Number of anchors per bearing plate: _______

9. 3.2.8. Quantity of guard posts provided? __________

10. 3.2.9. Will capacity markings be provided as specified?

11. 3.2.9. Platform Scale Manufacturer: _____________

Platform Scale Model Number: _____________

Each scale system shall be accurate to within _______ percent a maximum rated load.

Solicitation Number: FA8604- -R-

Joint Base Charleston – TPQ for 463L Pallet Rack - Page 3 of 3

EXCEPTIONS

Attach any exceptions taken to the Purchase Description

Appendix. Please outline those concerns in detail. Your exceptions will be reviewed to determine acceptability.

Are exceptions taken? YES NO

Number of pages attached: ____________________________________