Appendix B - Pallet Rack PD.doc

APPENDIX B

FOR

PALLET RACK

AT

RAF MILDENHALL UK

BUILDING 719

CSN: UML285

DATE: 20 August 2009

PREPARED BY:

LARRY HEAD

PROJECT ENGINEER

403 SCMS/GUEC

Table of Contents

11. General scope

1.1. 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. Row spacers

3.2.5. Leveling shims

3.2.6. Anchoring the structure

3.2.7. Assembly

3.2.8. Pallet supports

3.2.9. Pallet supports WITH WIRE DECKING

3.2.10. Row markers

3.2.11. Forklift guard posts

4. QUALITY ASSURANCE PROVISIONS

4.1. Inspection

4.2. Tests

4.3. certifications autonumlgl General scope

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for pallet rack for Building 719 at RAF Mildenhall UK. The work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and AF Figures 4 and 5. This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

autonumlgl Definitions

Bay ‑ A storage location in the pallet rack which measures from the front shelf beam to the back shelf beam in depth, and from the inside of the upright frame to the inside of the opposite upright frame in width, and from the top of the shelf beam to the bottom of the next shelf beam above in height. The positions on the top level are considered bays even though they are not fully enclosed.

Pallet rack unit ‑ A unit is an assembly of two upright frames and all shelf beams joining those two upright frames; plus pallet supports or decking.

Pallet support ‑ Short beam which runs from the front to the back shelf beam used to help support pallets.

autonumlgl APPLICABLE DOCUMENTS

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

autonumlgl REQUIREMENTS autonumlgl System description The pallet racks will be used to store palletized loads in such a manner to permit placement and removal of any individual load without disturbing any other load. The pallet rack shall interface with rail-guided, man-up, turret trucks/orderpickers described in Appendix A. The pallet rack system shall be capable of supporting a minimum uniformly distributed load of 6,000 pounds per bay. The pallet rack system shall be designed for use in seismic zone 2. The pallet rack shall conform to the requirements of the Rack Manufacturers Institute (RMI) June 1990 Specification for the Design, Testing, and Utilization of Industrial Steel Storage Racks.

autonumlgl Physical and Performance Characteristics autonumlgl Configuration requirements Three new rows of pallet rack shall be installed in Bldg 719 as shown on Figures 4 and 5. The racks shall be capable of being assembled side‑by‑side, in a row, using common uprights to support the shelf beams. Row 8 shall have five levels of shelf beams installed at the following heights: 6 inches, 5 feet, 10 feet, 15 feet, and 20 feet. Rows 9 and 10 shall have four levels of shelf beams installed at the following heights: 6 inches, 5 feet, 10 feet, and 16 feet.

autonumlgl Upright frames New upright frames shall be provided, which are 20 feet high for Row 8 and 16 feet high for Rows 9 and 10. All uprights shall be 48 inches deep. The upright frames shall be of steel, all welded construction consisting of two columns, diagonal and horizontal braces, and floor bearing plates. Each upright frame shall be capable of supporting fully loaded bays without permanent deformation. The upright frames of like racks shall be interchangeable. Upright frames in Row 8 shall have a capacity of 30,000 pounds. Upright frames in Rows 9 and 10 shall have a capacity of 24,000 pounds. Both types shall have a safety factor of 1.92 to 1.

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

Contracting Officer or technical representative (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 6 inches above the ground and shall continue upward to the top of the column by maximum 4 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 1/2 inch, with the top of the column.

autonumlgl 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 1/2-inch anchor bolts in accordance with 3.2.6.

autonumlgl Diagonal/horizontal bracing The columns shall be braced by horizontal and diagonal braces. 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.

autonumlgl Shelf beams New pairs of shelf beams shall be provided, which have a bay width of 108 inches. Shelf beams shall be the box or step 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. With a uniformly distributed load of 6,000 pounds per bay, there shall be no permanent deformations, and elastic deflections shall not exceed 0.56 percent of the unsupported span, measured with respect to the two ends of the beam. Shelf beams shall be designed with a safety factor of 1.65 to 1.

autonumlgl 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.

autonumlgl 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.

autonumlgl Row spacers Row spacers between Rows 8 and 9 shall join the backs of two upright frame sections together to form a double row arrangement. The row spacers shall provide a 6 inch flue space. Each end shall firmly and securely attach to the column and prevent unintentional disengagement. The row 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 row spacers for each set of back‑to‑back frames.

autonumlgl 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.

autonumlgl Anchoring the structure The rack system shall be anchored to resist all design shear and uplift forces. The 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 1/2-inch diameter anchor bolt. The minimum embedment of the anchor shall be in accordance with 3.3.2.3 of the Cover PD.

autonumlgl Assembly The assembled 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 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.

autonumlgl Pallet supports A minimum of four steel pallet supports per bay shall be installed in Rows 9 and 10. The top of each pallet support shall be flush with the tops of the front and back shelf beams to within 1/8 inch. Each pallet support shall be capable of supporting a minimum safe load of 1,500 pounds. All pallet supports shall be flanged at the front and back of the support to inhibit accidental dislodging of pallet supports. Pallet supports shall be designed with a safety factor of 1.65 to 1.

autonumlgl Pallet supports WITH WIRE DECKING A minimum of four steel pallet supports per bay, with integrated wire decking, shall be installed in Row 8. Each pallet support shall be capable of supporting a minimum safe load of 1,500 pounds. Pallet supports shall be designed with a safety factor of 1.65 to 1. Row 8 can be used for pallet storage or large handliftable items.

autonumlgl Row markers Card holders shall be installed on the end of each pallet rack section for row identification. Two card holders shall be mounted on each end of rows with back to back pallet rack, while one is required for a single row of pallet rack. The card holders shall be large enough for a minimum 8 inch by 8 inch card to be displayed. The card holders shall be mounted between 7 feet and 10 feet from the floor. Row identification cards will be made up by the warehouse personnel according to their established location assignment practices. A blank card will be provided by the Contractor for each card holder.

autonumlgl Forklift guard posts Steel pipe forklift guard posts shall be provided at the end of each row as shown on AF Figure 4. The guard posts shall extend a minimum 3 feet above the floor and shall be installed so 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. Each guard post shall be anchored to the floor with a minimum of four anchor bolts in accordance with 3.3.2.3 of the Cover PD. The guard post shall be painted safety yellow.

autonumlgl QUALITY ASSURANCE PROVISIONS autonumlgl 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.

autonumlgl 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.

Deflection = [(M1 - M2) /108] * 100

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

autonumlgl 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.

PALLET RACK

Offeror:

-R-

Appendix B, Pallet Rack, 20 August 2009

This questionnaire shall be completed by the Offeror. 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. Please attach product literature/cut sheets for all equipment detailed in this questionnaire and attach any exceptions to the Purchase Description Appendix or recommendations/design alternatives as detailed below.

Pallet Rack Manufacturer: _____________________________________

Row 8: ________ Row 9: ________ Row 10: _________

Row 8: _____ feet, _______ pounds, and ____________ Row 9: _____ feet, _______ pounds, and ____________ Row 10: _____ feet, _______ pounds, and ___________ Depth of upright frames: ___________________ inches

Type of shelf beam: _______________________________

Minimum capacity per bay: __________________ pounds

Length of anchor bolt: _____________________ inches

Number of steel pallet supports per bay: __________

Capacity of each pallet support: ___________ pounds

EXCEPTIONS/RECOMMENDATIONS/DESIGN ALTERNATIVES

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?

Number of pages attached: ____________________________________

Attach any recommendations or design alternatives you feel may enhance operation, maintainability, or reduce system cost. Your recommendations and design alternatives will be reviewed to determine acceptability.

Are recommendations/design alternatives attached?

Number of pages attached: ____________________________________

We have read the requirements of the Purchase Description Appendix and will comply with all paragraphs as written, with exceptions taken only to those items indicated on the attached exception sheet.

Offeror's Signature Date

TYPED NAME:

COMPANY NAME:

ADDRESS:

PHONE:

FAX: