TSH202- App A- Push Back Rack.pdf

APPENDIX A

FOR

PUSH BACK RACKS

AT

SHAW AIR FORCE BASE, SOUTH CAROLINA

BUILDING 1518

CSN: TSH202

DATE: 12 JANUARY 2023

PREPARED BY:

James F. Rowland

JAMES F. ROWLAND

PROJECT ENGINEER

AFLCMC/EZPAE

Brad Thompson Brad Thompson

REVIEWER

AFLCMC/EZPAE

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Table of Contents

1. 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. PUSH BACK RACKS

3.2.5.1. PUSH BACK RAILS

3.2.5.2. PUSH BACK CARTS

3.2.6. LEVELING SHIMS

3.2.7. ANCHORING THE STRUCTURE

3.2.8. ASSEMBLY

3.2.9. DECKING

3.2.10. COLUMN PROTECTORS

3.2.11. END PANELS

3.2.12. ROW MARKERS

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTION

4.2. TESTS

4.3. CERTIFICATIONS

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1. SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for push back racks in Building 1518 at Shaw Air Force Base (AFB), South Carolina. The work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and Air Force (AF) Drawing TSH202-01. This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

1.1. 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. The positions on the floor are considered bays even though there is no bottom shelf beam.

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;

plus pallet supports, decking, or tire supports.

Tire support - 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 as well as RMI/ANSI MH16.1-2012 and RMI/ANSI

MH26.2-2007.

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

The push back racks will be used to store palletized and small, medium and large sized loads, loose items, FA860423RB005 ATTACHMENT 2 3 containers, boxed items, and tri-wall containers (e.g. Uni-Pak containers) in such a manner to permit placement and removal of any individual load without disturbing any other load. The push back racks shall be provided as shown on AF Drawing TSH202-01.

The racks shall be capable of supporting a minimum uniformly distributed load of 6,000 pounds (two 3,000-pound pallets) per bay. The racks shall be designed for use in the seismic zone specified in the Cover PD. The racks shall conform to the requirements of the Rack Manufacturers Institute (RMI) Specification for the Design, Testing, and Utilization of Industrial Steel Storage Racks. The racks shall interface with Government-furnished forklifts and all trucks/forklifts specified in the Cover PD. Column protectors at the main aisles and end-of-aisles shall be provided to protect upright frames from possible forklift impacts.

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. CONFIGURATION REQUIREMENTS

The rack units shall be located as shown on AF Drawing TSH202-01. 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.

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. Upright frames shall meet the following requirements, as a minimum.

Capacity: 24,000 pounds Safety factor: 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’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

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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.

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 1/2-inch anchor bolts in accordance with 3.2.7.

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

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 shall provide a bay width as shown on AF Drawing TSH202-01. 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. If cross-ties are used they shall be the drop-in

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type, the use of mechanical fasteners or welding is unacceptable.

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. 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 or in accordance with AF Drawing TSH202-01 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 three row

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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. PUSH BACK RACKS

The 2-deep push back racks shall be located as shown on AF Drawing TSH202-01. Each bay shall store 4 pallet loads (2 front and 2 back).

3.2.5.1. PUSH BACK RAILS

Push back rails shall be provided to sufficiently support and transfer a 3,000 pound load. Four push back rails shall be provided per bay. Push back rails shall be sloped from back to front. Push back rails shall provide support for the push back carts containing a 3,000 pound pallet load. The push back rails shall prevent the cart from being pushed off the back and shall stop the cart from running off the front. Push back rails shall have a bumper to cushion the impact in the front. Attachment method between the push back rails and the shelf beams shall be approved by the Contracting Officers Technical Representative (COTR). Push back rails and cart shall be similar to the rails and push back cart shown in Picture 1.

3.2.5.2. PUSH BACK CARTS

Two push back carts similar to the push back carts shown in Picture 1 shall be provided per bay. Each push back cart shall support a container with a 48 by 40 inch base with the 48-inch side facing the aisle. The push back cart shall support a minimum 3,000 pound load. The push back cart shall have a 1-inch lip along the sides and the front of the push back cart.

The push back cart shall have a minimum of four wheels with non-precision, dust-tight, lightly-oil lubricated, zinc-plated, anti-friction bearings.

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Picture 1 – Push Back Rack

3.2.6. 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.

3.2.7. ANCHORING THE STRUCTURE

The rack units shall be anchored to resist all design shears 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.

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3.2.8. ASSEMBLY

The assembled pallet and push back rack system shall be rigid, stable, and without deformation or skewing when each bay is loaded to the capacity of the design loads. The 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.

3.2.9. DECKING

Wire mesh decking shall be installed in all bays between all parallel shelf beams for non push back rack sections. 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. 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. Where building columns are located within the pallet racks and where decking is required, the Contractor shall provide a useful decking bay by cutting the decking to fit around the building column.

3.2.10. COLUMN PROTECTORS

Column protectors shall be installed at each column located at the main aisles and end-of-aisles. The column protectors shall be designed to protect the column leg against forktruck, pallet, or other vehicular/object impacts. The column protector shall protect all exposed sides of the column and shall be anchored to the floor. Protectors that weld to the columns are not acceptable. The column protectors shall be minimum 12 inches high, minimum 9 gauge, heavy-duty steel construction.

3.2.11. END PANELS

End panels shall be installed on the end upright of each rack section. The end panel shall be made of plywood panels securely attached to the upright. The end panels shall fully cover the upright section.

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3.2.12. 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. The Contractor shall provide a blank card for each card holder.

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

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1. 3.1. and 3.2.3.

Three pallet bays, 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. 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) / BEAM WIDTH] * 100

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

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.

3. 3.1. Test to ensure that the pallet racks is capable of interfacing with forklifts. While using the vehicles, verify that they interface with the racks by loading and unloading the rack. Check the interface between the pallet rack, the forklift, and the operator. If normal operations are impeded in any way due to the rack configuration or the rack interferes with the storage and retrieval operations then the system fails the test.

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4. 3.2.9. Three decking bays, picked at random, shall each be loaded with two 3,000-pound pallets (total 6,000 pounds) 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 3,000-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) / BEAM WIDTH] * 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 Cover PD.

No. Paragraph Certifications

1. 3.1. The pallet racks conforms to the requirements the Rack Manufacturers Institute (RMI) Specification for the Design, Testing, and Utilization of Industrial Steel Storage Racks.

2. 3.2.2. Each upright frame shall have a minimum safe load capacity of 18,000 pounds as specified and 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

5. 3.2.9. The wire decking is R-Mark compliant.

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6. 3.2.12.1 All shelf frames are designed for, constructed to, and capable of sustaining the minimum safe load with a safety factor of at least 1.65 to 1.

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TECHNICAL PROPOSAL QUESTIONNAIRE

FOR

PALLET AND PUSH BACK RACKS

Solicitation Number: FA8604- -R- Project Title: Storage Aid System Base: Shaw AFB, SC CSN: TSH202 Appendix A, Push Back Racks, 12 January 2023

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 and Push Back Rack Manufacturer: _______________________ Model Numbers: ________________________________________________

Paragraph Characteristics

3.2.1. Dimensions:

Width of pallet rack unit:___________ inches Depth of pallet rack unit:___________ inches

Height of pallet rack unit:__________ inches

3.2.2. Upright frame part number(s):

Minimum capacity of upright frame(s):

_____________________________________________ 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 number(s):

Type of shelf beam(s):

Bay width provided by shelf beam: _________ inches Minimum capacity per bay: _________________ pounds

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Solicitation Number: FA8604- -R-

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Safety factor of: ___________________________ to 1 Will shelf deflection meet the requirements as specified? YES NO

3.2.3.2. Will shelf beam-to-column safety locks be provided

as specified? YES NO

3.2.4. Will row spacers be provided as specified?

YES NO

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

3.2.5.

3.2.5.1.

3.2.5.2.

Will push back racks be provided as specified?

YES NO

Number of rails provided per bay: __________________ Number of carts provided per bay: __________________ Cart load capacity: _______________________________ Rails/Carts part number(s): _______________________

3.2.6. Will leveling shims be provided as specified:

YES NO

3.2.7. Diameter of anchors to be provided:________ inches

Length of anchors to be provided: _________ inches Number of anchors per bearing plate: _____________

3.2.9. Will wire decking be provided as specified:

YES NO

Part number of decking: __________________________ Capacity of decking: _____________________________

3.1 Will existing pallet racks in Building 5160 be

modified, anchored and assembled, in addition to providing column protectors and row spacer, as specified:

YES NO

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Solicitation Number: FA8604- -R-

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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: ____________________________________

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