Appendix F Pallet Rack.doc

APPENDIX F

FOR

PALLET RACK

AT

EGLIN AIR FORCE BASE, FL.

AMU BUILDING 1417

CSN: AEG0D0

DATE: 15 JULY 2010

PREPARED BY:

Andrew J. Huser

PROJECT ENGINEER

HQ AFMC-LSO/LOE

THIS PAGE LEFT BLANK INTENTIONALLY

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. Decking

3.2.9. Tire support Assembily

3.2.10. Row markers

4. QUALITY ASSURANCE PROVISIONS

4.1. Inspection

4.2. Tests

4.3. certifications 3.1.

autonumlgl General scope This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for pallet rack for the 33rd Fighter Wing, in AMU Building 1417 at Eglin Air Force Base, FL. The work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and Air Force (AF) drawings AEG0D0-01 and AEG0D0-02. This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

The work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and Air Force (AF) Drawing AEG0D0-01. This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

autonumlgl APPLICABLE DOCUMENTS

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

autonumlgl REQUIREMENTS autonumlgl System description The pallet racks will be used to store palletized loads, loose items, aircraft parts and tires in such a manner to permit placement and removal of any individual load without disturbing any other load. The pallet rack shelving system shall interface with warehouse personnel. The rack system Type “F1” shall be capable of supporting a minimum uniformly distributed load of 6,000 pounds per bay. The Type “F” and “F2” pallet rack system shall be capable of supporting a minimum uniformly distributed load of 4,400 pounds per bay. The pallet rack systems shall be designed for use in seismic zone 1. 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 The various rack configurations and locations are shown on AF Drawing AEG0D0-01 and AEG0D0-03. The racks shall be capable of being assembled side-by-side, in a row, using common uprights to support the shelf beams. The racks shall be separated by a flue space, as defined in 3.2.4., when storage locations are back-to-back.

autonumlgl 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 upright frame shall be capable of supporting fully loaded bays without permanent deformation. The upright frames of like racks shall be interchangeable. Upright frames shall meet the following requirements, as a minimum.

Type “F1” Capacity: 18,000 pounds

Safety factor: 1.92 to 1

Type “F” and “F2” Capacity: 17,600 pounds

Safety factor: 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’s 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 six inches above the ground and shall continue upward to the top of the column by 2 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 minimum 2 7/8 inches.

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 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. Each pair of shelf beams for shall provide a bay width of 108 inches. With a uniformly distributed load of 6,000 pounds per bay for Type “F1” and 4,400 pounds per bay for Type “F” and “F2”. 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. If cross-ties are used they shall be the drop-in type, the use of mechanical fasteners or welding is unacceptable.

NOTE ‑ The bay width is not the same thing as the distance from center to center of the upright frames. The center to center distance is usually 111 inches. Check your ACAD drawings.

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 shall be capable of joining the backs of two upright frame sections together to form a double row arrangement. The row spacers shall provide a 6 inch flue space when storage locations are back‑to‑back. 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 2 row spacers for each set of back‑to‑back frames. The top row spacer shall be installed within 12 inches of the top of the frame. The bottom row spacer shall be installed within 12 inches of the bottom of the frame.

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 systemIf you are storing only pallet loads on the pallet rack then pallet supports will be required autonumlgl Decking Wire mesh decking shall be installed in all bays between all parallel shelf beams and uprights. The decking shall be heavy duty welded steel wire with integral support channels capable of supporting a uniformly distributed load of 6,000 pounds per bay for Type “F1” and 4,400 pounds per bay for “F” and “F2”. The decking shall be designed with a safety factor of 1.65 to 1. The decking shall not exhibit permanent deformation and elastic deformations shall not exceed 0.56 percent of the unsupported span. The decking shall be plated or galvanized to protect against corrosion. Decking shall be the appropriate type to interface with the type shelf beam being provided. The ends of the wire mesh decking shall bend over the shelf beam to provide a secure load supporting deck and keep the decking from accidentally disengaging from the shelf beams.

autonumlgl Tire support Assembily Tire support rack Type “F1” shall use two Tire Support Assemblies to support tires and wire mesh decking on the top bay as shown on AEG0D0-02. The tire support assemblies shall be channel and angle iron. The tire supports shall be easily removed and replaced from the storage rack. Tire supports shall be adjustable to accommodate a variety of tire diameters. Tire supports shall have the capability to be adjusted to any storage level configuration that the shelf beams will allow. Each pair of tire supports shall have a minimum load capacity of 3,450 pounds per bay. Tire supports shall be bolted or otherwise connected to front‑to‑back beams or as approved by the COTR (welding is unacceptable).

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.

3.2.3.

Three pallet bays, Type “F1”, picked at random, shall each be loaded with two 3,000-pound pallets (total 6,000 pounds) to ensure the pallet beams are set in place. Three pallet bays, Type “F”or ”F2” picked at random, shall each be loaded with total 4,400 pounds to ensure the pallet beams are set in place. The loads shall then be removed. The distance from the top of each designated shelf beam to the top of the shelf beam above it shall be measured and recorded as M1. The weight 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 designated shelf beams to the top of the next shelf beam shall be measured again and recorded as M2. The following formula shall be used to determine the deflection amount:

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 shall fail.

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 shall fail.

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 F, Pallet Rack, 15 JULY 2010

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.

Manufacturer: _______________________________

3.1.

Dimensions Type “F”:

Width of pallet rack unit:___________ inches

Depth of pallet rack unit:___________ inches

Height of pallet rack unit:__________ inches

Dimensions Type “F1”:

Width of pallet rack unit:___________ inches

Depth of pallet rack unit:___________ inches

Height of pallet rack unit:__________ inches

Dimensions Type “F2”:

Width of pallet rack unit:___________ inches

Depth of pallet rack unit:___________ inches

Height of pallet rack unit:__________ inches

Minimum capacity of upright frame:__________ pounds based on a maximum shelf spacing of ________ inches

Safety factor of: _______ to 1

Upright frame part numbers Type “F1”: ______________

Minimum capacity of upright frame:__________ pounds based on a maximum shelf spacing of ________ inches

Safety factor of: _______ to 1

Upright frame part numbers Type “F2”: ______________

Minimum capacity of upright frame:__________ pounds based on a maximum shelf spacing of ________ inches

Safety factor of: _______ to 1

Vertical center-center spacing of column openings for shelf beam adjustment:___ inches

Type of shelf beam: ______________________________

Bay width provided by shelf beam: _________ inches

Minimum capacity per bay: _________________ pounds

Safety factor of: ___________________________ to 1

Will shelf deflection meet the requirements as specified? YES NO

YES NO

Number of row spacers per set of back-to-back uprights: ________________________________________

YES NO

Length of anchors to be provided: _________ inches

Number of anchors per bearing plate: _____________

YES NO

Part number of decking: __________________________

Capacity of decking: _____________________________

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: