LUKE Appendix A- Pallet Rack REV-1 reduced.pdf

APPENDIX A

FOR

PALLET RACK

AT

LUKE AIR FORCE BASE, ARIZONA

BUILDING 945 and 296

CSN: ALK906

DATE: 10/28/2021

Rev 1 07/18/2022

PREPARED BY:

Joshua A Payne

PROJECT ENGINEER

AFLCMC/EZPAE

LUKE AFB - App A - Page i

Table of Contents

1. GENERAL SCOPE

1.1. DEFINITIONS (REV 1)

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION (REV 1)

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 (REV 1)

3.2.3.1. CONNECTORS

3.2.4. ROW SPACERS (REV 1)

3.2.5. LEVELING SHIMS

3.2.6. ANCHORING THE STRUCTURE

3.2.7. ASSEMBLY

3.2.8. DECKING

3.2.9. TIRE SUPPORTS (REV 1)

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTION

4.2. TESTS

4.3. CERTIFICATIONS

LUKE AFB - App A - Page 1

1. GENERAL SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for pallet rack in Bldg 945 and 298, at Luke Air Force Base, Arizona. The work shall be completed in accordance with this appendix, the Cover

Purchase Description (PD), and Air Force (AF) Drawing ALK906-01.

This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

1.1. DEFINITIONS (REV 1)

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.

Decking - A wire mesh surface spanning the area between two parallel shelf beams for the storage of loose or boxed items.

Pallet rack unit - A unit is an assembly of two upright frames and all shelf beams joining those two upright frames; decking and tire supports.

Tire Support (rev 1) - Angular shaped members attached to front-to- back supports to span the bay from the inside of one upright to the inside of the opposite upright column. Tire supports are used to facilitate tire storage by cradling them while they rest in a vertical position.

2. APPLICABLE DOCUMENTS

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

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION (REV 1)

The pallet racks will be used to store palletized and small, medium and large sized loads and loose items in such a manner to permit placement and removal of any individual load without disturbing any other load. Tire rack inserts shall be installed in pallet rack types as shown in drawings ALK906-01 and shall be

LUKE AFB - App A - Page 2 provided to facilitate storage of tires. Wire decking shall be provided to facilitate storage of loose or boxed items for pallet rack types as shown in drawings ALK906-01. The pallet rack shall be installed in buildings 945 and 296 as shown in drawings ALK906-1. The pallet rack system shall be capable of supporting a minimum uniformly distributed load of 1100 pounds.

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.

3.1.2

Pallet Rack Type A shall be no more than 108 inches tall, 48 inches deep and of dimensions shown in Fig.(1). Tire rack inserts will be in place on two levels. See Fig.(1).

Fig. 1: Pallet Rack Type A

Pallet Rack Type B shall be no more than 168 inches tall with bays of specified dimensions in Fig. (2). Tire rack inserts shall be placed on the first two levels with decking on all levels above second level. See Fig. (2).

LUKE AFB - App A - Page 3

Fig. 2: Pallet Rack Type B

Pallet Rack Type shall be no more than 168 inches tall with bays of specificed dimensions in Fig. (3). Single tire rack inserts on level 1 and 2, with wire decking on all levels above second level. See Fig. (3).

Fig 3: Pallet Rack Type C

Pallet Rack Type D shall be no more than 168 inches tall with bays of specified dimensions in Fig. (4). Wire decking on all levels. See Fig. (4).

LUKE AFB - App A - Page 4

Fig. 4: Pallet Rack Type D

Pallet Rack Type E shall be no more than 168 inches tall with bays of specified dimensions in Fig. (5). Tire rack inserts shall be placed on the first two levels with wire decking on all levels above second level. See Fig. (5).

Fig. 5: Pallet Rack Type E

Pallet Rack Type F shall be no more than 168 inches tall with bays of specified dimensions in Fig. 6. Tire rack inserts shall be placed on the first two levels with wire decking on all levels above second level. See Fig. (6).

LUKE AFB - App A - Page 5

Fig. 6: Pallet Rack Type F no tire rack inserts,

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. CONFIGURATION REQUIREMENTS

The pallet rack units shall be located as shown on AF Drawing

ALK906-01. The racks shall be capable of being assembled side-by-side, in a row, using common uprights to support the shelf beams.

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 upright frame shall be capable of supporting fully loaded bays without permanent deformation. The upright frames of like racks shall be interchangeable. Pallet

Rack Type A shall have an upright capacity of 2200 pounds.

Pallet Rack Type B, C, E, and F shall have an upright capacity of 5500 pounds. Pallet Rack type D shall have an upright capacity of 4400 pounds. All types shall have a safety factor of

1.92 to 1.

3.2.2.1. COLUMNS

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

Contracting Officer or designated representative (CODR). Each

LUKE AFB - App A - Page 6 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 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.

3.2.2.3. 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.

3.2.3. SHELF BEAMS (REV 1)

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 6000lb 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.

3.2.3.1. CONNECTORS

LUKE AFB - App A - Page 7

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.

3.2.4. ROW SPACERS (REV 1)

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. The remaining row spacers shall be installed equidistant from each other.

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

LUKE AFB - App A - Page 8

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.

3.2.7. 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.

3.2.8. DECKING

Wire mesh decking shall be installed in all bays between all parallel shelf beams as shown of AF Drawing ALK906-01. The decking shall be heavy duty welded steel wire with integral support channels capable of supporting a uniformly distributed load of 1100 pounds per bay. 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. Decking shall be R-Mark compliant. 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.

3.2.9. TIRE SUPPORTS

Two tire support beams per bay shall be used to support the tires as shown on AF Drawing ALK906-01. The supports shall be angle iron and shall be adjustable to accommodate a variety of tire diameters.

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.

LUKE AFB - App A - Page 9

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 pallet bays, picked at random, shall each be loaded with two 1100-pound pallets (total

2200 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

3,000-pound pallets 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.

LUKE AFB - App A - Page 10

2. 3.2.8. BAYS FROM EACH PALLET TYPE WILL BE TESTED,to ensure the decking is set in place. The loads shall then be removed. The distance from the top of the deck to the top of the deck above it shall be measured and recorded as M1. The 1100 pound pallets shall then be put back into the designated decking bays. The loads shall be left for a minimum of four continuous hours.

The distance from the designated decking to the top of the decking above it 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.

4.3. 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) June

1990 Specification for the Design, Testing, and

Utilization of Industrial Steel Storage Racks.

2. 3.2.2. Pallet Rack type A shall have an upright capacity of 2200 pounds. Pallet Rack Type B, C, E, and F shall have an upright capacity of 5500 pounds. Pallet Rack type D shall have an upright capacity of 4400 pounds. All types shall have 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.

LUKE AFB - App A - Page 11

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

5. 3.2.8. Certify the wire deck is R-Mark compliant.

TECHNICAL PROPOSAL QUESTIONNAIRE

FOR

LUKE AFB - App A - Page 1 of 3

APPENDIX A, PALLET RACK

Solicitation Number: FA8640- -R-

Project Title: Receiving, Storage and Distribution System

Base: LUKE AFB AZ CSN: ALK906

Appendix A, Pallet Rack, 17th March 2022.

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

Pallet Rack Manufacturer: _______________________________

Paragraph Characteristics

3.2.2.

Upright frame part numbers: ________________________

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

Safety factor of: ___________________________ to 1

3.2.2.1.

Width of column facing the aisle: __________ inches

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

3.2.2.2.

Number of punched holes per bearing plate:________

3.2.3.

Shelf beam part numbers: __________________________

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

3.2.5. Will leveling shims be provided as specified:

YES NO

Offeror:

Solicitation Number: FA8604- -R-

LUKE AFB - App A - Page 2 of 3

3.2.8. Will wire decking be provided as specified:

Capacity of decking: ___________ pounds

Offeror:

Solicitation Number: FA8604- -R-

LUKE AFB - App A - Page 3 of 3

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: ____________________________________