Mobile Pallet Racking - Technical specifications

Design
Godrej uses the following standards, as applicable for design.
BS: 5950 (V): 1998 - Building design using cold formed steel sections
FEM 10.2.02 Code of practice for design of steel pallet racking
FEM 10.3.01 Adjustable beam pallet racking, tolerances, deformations and clearances
SEMA code of practice for the design of static racking.

Raw material
Load bearing members of the system are made out of high strength HR steel having properties
equivalent to grades specified by IS 5986:2002 / IS 2062:2006
The different types of material used for load bearing members such as uprights and beams are:
Steel type
IS: 5986 - Fe 510 /
Equivalent
(or)
IS:2062 - E 350 / Equivalent

Minimum
Equivalent
guaranteed
international standard
yield strength
355 MPa

IS: 5986 - Fe 410 /

Equivalent
(or)
IS:2062 - E 250 / Equivalent

255 MPa

IS:3601 2006 / Equivalent

210 Mpa

JIS 3101: SS 490

EN 10025 : S 355 JR
DIN 17100 : St 52

JIS 3101: SS 400

EN 10025 : S 235 JR
DIN 17100 : St 42

IS:4923 1997 / Equivalent

In addition to high strength, the raw material used for structural load bearing members posses
adequate ductility to ensure toughness. The material also has the necessary impact strength for cold
room applications up to -30 deg C.

Fasteners
All fasteners used are of grade 8.8.These are with galvanized finish to suit industrial
atmosphere.

Surface finish
For long life and protection from corrosion, All Powder coated components are given a
thorough anti-rust treatment. The dry film thickness (DFT) after powder coating would be average 35
microns.

All powder coated components are subjected to an elaborate 4 step, six zone anti corrosion
treatment, viz. De-greasing as per IS 6005:1970, rinsing, phospating as per IS 3618:1966 and Demineralized water rinsing.
Furthermore, the testing of paint for various physical and chemical properties is done as per IS
101: 1964.

Assembly & Installation

The pallet racking system is completely knockdown construction. The racks are grouted on to
the floor using expansion bolts. No welding will be carried out at site.

Racking component specification Super structure

Uprights
Upright is roll formed construction made in single piece without welding. Upright has slots at 50
mm. It enables the warehouse manager to utilize the rack optimally to suit the changing SKU sizes.
Uprights are multi bend profiles, designed to offer maximum load bearing capacity with
optimum surface utilization ensuring high standards of stability and safety. Uprights are bolted with
Base Plates to transfer the load to ground.
The manufacturing process of punching and forming is in one flow and a synchronized
operation, thereby providing dimensional accuracy and contour uniformity consistently.

Upright type

GMH

Profile

Omega

Profile width

80mm

Profile depth

80mm

Number of bend

No of pieces

Single

Beam adjustability

50mm

Material Quality

Min Ys= 355 Mpa

Mfg process

Roll forming

Finish

Powder coated

Colour

Oxford Blue

Stiffener (Option-2)

Stiffeners are the channel, helps to increase the load carrying capacity of upright.

Type of profile

Channel

Profile section

28 x 29 x 28mm

No of bends

2nos

Mfg process

Press forming

Connectivity

Bolted

No of fasteners

4 no of M8x50

Surface finish

Powder coated

Colour

Oxford Blue

Base plate 128mm

It is welded construction bolted to upright. They are anchored to ground using M12 x 100
Torque type mechanical anchor bolts. Floor level variation shall be adjusted with shims.

Width

150 mm

Depth

125 mm

No of grouting bolts

2 no of M12x100

No of fasteners to
connect Upright
Connectivity

4 no of M10x25
Grouting

Mfg Process

Welding & press forming

Finish

Powder coated

Colour

Orange

Bracing
Diagonal and horizontal bracings are lipped channel sections. These are to connect uprights to
make frames. These bracing channels are also made through roll forming technology.

Bracing

Type of profile

Lipped channel

Profile section

30 x 30 x 6mm

Mfg process

Roll forming

No of bend

4nos

Connectivity

Bolted

No of fasteners

2 no of M8x50

Surface finish

Galvanized

Beam GBH(Option-2)
Beams are of box type construction. Better strength for beams, since it is box profile, unlike
open profiles which tend to buckle for heavy loads or for longer beam lengths. Beam top is 50mm
width to provide larger surface area for resting decking surface.
Beam locks by locking pins ensure that beams are engaged with uprights precisely and prevent
any accidental beam dislodgement due to handling equipments.
Type of Profile

Box

Usage
Height

Middle
100 & 135mm

Width

50

No of Lip connector

4 Lip

Mfg process

Roll Forming & Welding

Locking mechanism

L shape locking pin

Dia of Locking Pin

Dia 6mm

Surface Finish

Powder Coated

Colour

Orange

Beam GHEM(Option-1)
Beams are of box type construction. Better strength for beams, since it is box profile, unlike
open profiles which tend to buckle for heavy loads or for longer beam lengths. Beam top is 50mm
width to provide larger surface area for resting decking surface.
Beam locks by locking pins ensure that beams are engaged with uprights precisely and prevent
any accidental beam dislodgement due to handling equipments.
Type of Profile

Box

Usage
Height

Middle
100mm

Width

50

No of Lip connector

4 Lip

Mfg process

Roll Forming & Welding

Locking mechanism

L shape locking pin

Dia of Locking Pin

Dia 6mm

Surface Finish

Powder Coated

Colour

Orange

Pallet stopper
Pallet back stoppers are provided at the rear side of the racks to limit the overhang of the pallet
on back side. The stoppers can be used as common for back to back racks. This is designed with
adequate strength though the purpose is only to act as a feeler for the MHE operator to decide when
to place the pallet.
Type of profile

Pipe

Diameter

48 mm

Length

Length of bay in mm

Connectivity

With clamp & U-bolt

Overhang permitting

100mm (max)

Mfg process

Bolted with clamp

Surface finish

Powder coated

Colour

Yellow

Mobile Pallet Racking - Under Structure

Under Carriage

Movement speed
Time delay between bases
Noise level
Control

4.5m/min.
3 seconds max.
Less than 70 dB
PLCs

Understructure consists of front channels and skid channels (wheel carriages)

It is modular in construction (absolutely no welding at site)
Floor guidance is with a set of plain and flanged wheels
There will be a set of skid channels below every upright so that the load is distributed directly
to the rail and the floor

Rails

For new warehouses the rails can be embedded while constructing the floor itself.

Motors

0.37 kW(1/2 HP), 3 phase motors are used, mostly manufactured by Nord
The motors are enclosed within the height of the understructure.
The motor is covered for preventing from damage.

Front Safety Sensor

The access is controlled by a light beam barrier along the front of plant
This provokes immediate stop of the bases if a person enters the aisle during the movement.

Lateral Photoelectric cells

Placed laterally at the base of the initial and terminal slide of each trolley, the photoelectric
cells, composed of a projector and a receiver
They emit an invisible ray which creates a real barrier.
When the continuous flow of the ray is interrupted by unexpected presence of person or object
in the aisle, the plant immediately stops to prevent accidents or damages.

Emergency Pushbutton

Red mushroom-shaped emergency pushbuttons are placed on the control boards of the trolleys
as well as on the main control board.
When these pushbuttons are pressed the system immediately stops safely

Pre-start button

The pres-tart pushbutton is placed on the shelving inside the aisle. This pushbutton shall be
pressed before the system is started.
The position of the pre-start pushbutton is such that the operator before moving the plant is
obliged to check that the corridor is free from any material left or from any obstruction, and
that there is no one in the dangerous area. All these operations can be made in radio mode
from forklift truck.

Acoustic Signal & Blinking lights

When the trolleys are moving, a yellow blinking signal and acoustic signal are automatically
activated, as a warning sign for the operators. Blinking lights are on each base.
The acoustic signal starts on pressing the prestart button itself, thus allowing people to move or
to press the emergency stop button in case of danger

Optional Accessories

Remote Control

Remote control device enable to run the system automatically

The remote system has 128 channels and can be also connected to other electrical devices such
as doors, lights, etc.

Picking Mode

The aisle of the plant is divided in two or three smaller corridors (according to the width of the corridor
itself), so to allow the access to various corridors for manual picking.

Ventilation Mode & Automatic lights device

Ventilation Mode (Night-time position)

This is particularly useful for the installation in cold-storage rooms, since it allows equal space
between trolleys, creating small corridors between one trolley and the other. This allows a
better aeration of the products stored during the standstill of the plant

Automatic lights

This device allows switch-on the lights only over the open aisle, switching off the unused ones
or closed aisles. There by reducing the energy consumption.

Anti blackout device

Using this device wired to an external alternative power supply (such as a portable generator)
its possible to move one trolley for time in case of blackout condition.