Protectors technical manual final draft · Technical Manual English Issue: 01.01.2015 . Issue:...

A Member of the Constructor Group

PROTECTORS

Technical Manual

English Issue: 01.01.2015

Issue: 01.01.2015

Protectors | 2

Foreword:

This manual describes the standard range of protectors used in pallet racking applications, like frame protectors, upright protectors and guards, pallet stop, as well as general protectors used to protect building columns, machines and other equipment in a warehouse or manufacturing environment.

The majority of protectors are designed for the P90 pallet Racking, but can in most cases be used with any type of pallet racking. If used with other types of pallet racking, or with older versions of P90 Pallet Racking, special attention is needed to ensure the products fits together, e.g. with regards to size of base plates, frame widths and so on.

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Table of content:

1 P90 Frame Protector ................................................................................................................ 4

2 Tubular Rack Protection........................................................................................................... 9

3 C Rail Frame Protector .......................................................................................................... 10

4 Protex Barrier Rail.................................................................................................................. 14

5 P90 Column Guard ................................................................................................................ 20

6 Protec-it Column Guard ......................................................................................................... 21

7 P90 Upright Guard ................................................................................................................. 22

8 Shock Absorbing Column Guard ............................................................................................ 24

9 P90 Deepstor Column Guard ................................................................................................. 26

10 Safety Bollard ........................................................................................................................ 27

11 Asphalt Floor Channel with Column Guard ............................................................................ 28

12 Horisontal pallet stop ............................................................................................................. 29

13 Anti-Collapse Mesh ................................................................................................................ 31

14 Tunnel Guards ....................................................................................................................... 32

15 Special pallet stop - fixed to the rear beams........................................................................... 33

16 Special Ram and Side Protection for Pallet racking frames .................................................... 34

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1 P90 Frame Protector

Positioned to guard exposed end frames of single and double entry racks, these protectors provide resistance to impact damage from fork lift trucks operating in transfer aisles. The frame protector consists of 2 protective guards and a beam section. With double entry racks, an additional support is fitted at mid-span to further strengthen the beam section enabling it to be positioned closer to the frames. With special frame depths, 2 beam sections can be spliced together with a Beam Connector.

When using a frame protector with a length of 2350 mm, the maximum distance between the outer edges of the baseplates is 2600 mm.

The P90 Frame Protectors are available in 400mm height.

For the P90 Frame Protector we have the following kits:

Part code Description Height

190223005 P90 FRAME PROT. 400X 900 R1004CPL 400mm

190223006 P90 FRAME PROT. 400X1100 R1004CPL 400mm

190223007 P90 FRAME PROT. 400X2000 R1004CPL 400mm *

190223008 P90 FRAME PROT. 400X2400 R1004CPL 400mm *

The kit contains : Left and right Frame Protector Guard, Frame protector Beam, and for 2000mm and 2400mm length also the protector Beam Support, in addition to all required fixings. The required number of concrete screws are included: 3 No. CONCRETE SCREW TSMB-ST 10X100 PG for each Frame Protector Guard and 2 No. for each Protector Beam support.

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P90 Frame Protector Guard

To form a complete P90 Frame Protector you need a left and a right hand side Frame Protector Guard, in addition to the beam and support for the beam. The frame Protector Guards are made of 5mm steel, painted in yellow, RAL 1004.

Each of the Protector Guards must be bolted to the floor using 3 No. of CONCRETE SCREWS


190123001 P90 FRAME PROT. GUARD 400 LH R1004 400mm

190123002 P90 FRAME PROT. GUARD 400 RH R1004 400mm

* Not FEM/EN compliant. These standards require a minimum height of 400mm.

Fixings

Part code Description No/Each

891100420 CONCRETE SCREW TSMB-ST 10X100 PG 3

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P90 Frame Protector Beam

The Frame Protector Beams are available in lengths suitable for the most common single and double frame widths. Please note that frame protector is FEM10.2.02/EN15512 compliant.

The beam section is inserted between the outer and inner legs of the guards.

This facilitates replacement and enables the use of other materials with similar dimensions and strength, i.e. wood.

The Protector Beam is painted Yellow RAL 1004.


190123005 P90 FRAME PROT. BEAM 400X 850 R1004 400mm

190123006 P90 FRAME PROT. BEAM 400X1050 R1004 400mm



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P90 Frame Protector Beam Support

The Frame Protector Beam Supports must be used to support the mid span of Frame Protectors for doubly entry racks and for other situations where the protector beam has a length 2000mm, or longer.

The Protector Beam Support is painted Yellow RAL 1004.

The Protector Beam Support is bolted to the floor using two Concrete Screws, and to the Protector beam using 2 M8 Hexagonal Bolts and Nyloc Nuts.


190123003 P90 FRAME PROT. BEAM SUPP 400 R1004 400mm

Fixings



890100305 BOLT HEX FULL DIN933 88 M 8X 25 BZP 2

890174300 NUT HEX NYLOC DIN985 8 M 8 BZP 2

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P90 Frame Protector Beam Connection

The Beam connection is used to connect 2 beam sections in cases where special frames are used or when the length of the protector beam require two beams to be spliced.

The Frame Protector Beam Connection is painted Yellow RAL 1004.

The Beam Connection is fixed to the concrete floor with 2 no. of concrete screws.

Part codes

Part code Description

190123004 P90 FRAME PROT. BEAM CONNECTION R1004

Part codes for floor fixings



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2 Tubular Rack Protection

Positioned to guard exposed end frames of single and double entry racks, these protectors provide resistance to impact damage from fork lift trucks. The Tubular Rack Protections are made of ø88.9 x 3mm tubular pipe, and are painted Yellow RAL 1004. The floor fixings are not included in the part codes, and must be ordered separately. The required No. of floor fixings is 8 no. per each Protector.


190127000 TUBULAR RACK PROTECTION 900 R1004 500mm





190127005 TUBULAR RACK PROTECTION 2500 R1004 500mm Floor fixings



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3 C Rail Frame Protector

The C-Rail Frame Protector consists of a left and right hand side C Rail Weld Post, one or two C Rail Channels and fixings.

The C Rail weld Post is available in two different heights, 460mm and 760mm. For the 460mm height one C Rail Channel is used, whilst for the 760mm height two Channels are used.

The C Rail Channel is available in 4 different lengths 690mm to 2190mm. The actual width of the complete Frame Protector is 210mm longer than the C Rail Channel - see table underneath

The C Rail posts are fixed to the floor using 4 No of Concrete Screws, and the C Rail Channel are fixed to the posts using one M12 Hexagonal bolt and Nyloc Nut in each end. (Totally two per Channel)

The different sizes are available as kits – see table underneath:


190228004 C RAIL FRAME PROT 460X900 R1004 CPL 460mm








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C Rail Weld Post

The C Rail Weld Post is made of Square Tube SHS Section 100x100x5mm, and is painted Yellow RAL 1004.

The Posts are available as left and right hand side, as well as an intermediate post to be used for longer Protectors.


190128007 C RAIL WELD POST RH 460 R1004 460mm

190128008 C RAIL WELD POST LH 460 R1004 460mm

190128009 C RAIL WELD POST MD 460 R1004 460mm

190128004 C RAIL WELD POST RH 760 R1004 760mm

190128005 C RAIL WELD POST LH 760 R1004 760mm

190128006 C RAIL WELD POST MD 760 R1004 760mm Floor fixings



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C Rail Channel

The C Rail Channel is made as a C channel 100x50mm n mm thick. The Channel is painted Yellow RAL1004.

The Channel is bolted to the post using one M12 Hexagonal bolt and Nyloc nut in each end.


190128000 C RAIL CHANNEL 900 (690) R1004

190128001 C RAIL CHANNEL 1100 (890) R1004

190128002 C RAIL CHANNEL 2000 (1790) R1004

190128003 C RAIL CHANNEL 2400 (2190) R1004

Fixings


890100508 BOLT HEX FULL DIN933 88 M12X 40 BZP 2

890174500 NUT HEX NYLOC DIN985 8 M12 BZP 2

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Plastic Cap

The plastic caps are used to close the top of the posts,


190128010 PLASTIC CAP SHS 100X100X5 1

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4 Protex Barrier Rail

This PROTEX Safety System designed in compliance with all generally applicable safety guidelines and with regard to the safe operation of storage and operating systems.

The system is in compliance with the German regulation BGR 234.

PROTEX components can be used as impact protection for industrial offices and conveyor components, and as a barrier to separate different areas.

The system consists of uprights in 3 different heights, barrier rails, handrails, brackets, plastic caps and fixings.

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Protex Upright

The Protex uprights are available in heights 425mm, 800mm and 1050mm. The uprights are made of tube sections RHS 100x50x4mm, welded to a 120x185x10mm base plate. The uprights are painted Yellow RAL1004.

The uprights are fixed to the concrete floor using 3 No. of concrete screws.


190170004 PROTEX UPRIGHT 425 R1004

190170005 PROTEX UPRIGHT 800 R1004

190170006 PROTEX UPRIGHT 1050 R1004 Floor fixings



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Protex E-Barrier Rail

The Protex E-Barriere rail is made of 2mm thick steel bent to form the shape shown on the illustration above. The total height of the section is 186mm.

The rails are painted Yellow RAL 1004.

The rails are fixed to the uprights using Hexagonal bolts, adjusting washers, normal washer and nuts.


190170003 PROTEX E-BARRIER RAIL 3000 R1004





Fixings

Part code Description No per connection

point.*

890103416 BOLT HEX PART ISO4014 88 M10X 80BZP 1

190170013 M10DOME WASHER (LINDAPTER) 1

890180400 WASHER FLAT DIN125A 10.5 BZP 1

890170400 NUT HEX DIN934 8 M10 BZP 1

*1 of each is needed for each rail to upright connection. E.g. for two rails in height – 2 of each are needed for each upright.

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Protex Hand Rail

The hand rail can be used in combination with the upright height of 1050m. The hand rail is made of square tube SHS 50x50x2mm and is painted Yellow RAL 1004, and is available in lengths 2000mm, 2500mm and 3000mm.


190170009 PROTEX HANDRAIL 3000 R1004



The hand rail is fixed to the uprights with special mounting brackets, and socket button head screws, washers, nuts and self-drilling screws.

Fixings

Part code Description No per connection

point.*

890110305 BOLT BUTT ISO7380/1 109 M 8X25 BZP 2

890180300 WASHER FLAT DIN125A 8.4 BZP 2

890170300 NUT HEX DIN934 8 M 8 BZP 2

890140603 bolts ZEBRA PIAS 6.3X16VZ DIN7504K 2

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Protex Corner Cleat

The Corner Cleat is used to connect and secure corner connections.

The Cleat is made is L-shaped with the dimensions 170x45mm, and is made of 4mm thick steel. The Cleat is painted Yellow RAL1004.


190170010 PROTEX CORNER CLEAT UPR./BARR. R1004



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Protex Hand Rail Mounting Bracket

Center Left Right

The brackets are used to fix the hand railing to the uprights, and are available in left, right and center versions.


190270010 PROTEX CORNR CLEAT UPR/BARR.CPL

190270012 PROTEX BRACKET HANDRAIL LEFT CPL

190270013 PROTEX BRACKET HANDRAIL RIGHT CPL

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5 P90 Column Guard

The P90 Column Guards are designed to protect a single P90 upright, and are available in two different widths.

The Column Guards are made of 4mm steel and painted Yellow RAL1004.

The Column Guard is FEM10.2.02/EN15512 compliant.

Please observe that the lowest possible beam level for the pallet racking will depend on the choice of column guard, and will be 580mm.

The Column Guards are fixed to the floor using 4 No. of Concrete screws.

Part code Description Height Upright type

190120002 P90 COLUMN GUARD 75-100 400 R1004 400mm 75-90-100

190120003 P90 COLUMN GUARD 120/140 400 R1004 400mm 120-140

Floor fixings



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6 Protec-it Column Guard

Protect-it™ is a column guard clipped directly to the various uprights, and no addition fixings are needed.

The guard is designed to absorb the energy ion case of being hit by a forklift truck. The Protect-it is tested and approved to FEM/EN.

Protect-it is available in a number of sizes, and in the table underneath you will see part codes and descriptions for those fitting P90 uprights. Some of the Protect-it elements are 100mm high and require 4 No. to form a 400mm high protector as the FEM/EN norms require, and some are 134mm high and do only require 3 No.

Part code Description Colour Height per pcs.

Upright

190124011 P90 PROTECT-IT GUARD 75/90 BLACK Black 134mm P75+/P90+

190124012 P90 PROTECT-IT GUARD 75/90 YELLOW Yellow 134mm P75+/P90+

190124005 P90 PROTECT-IT GUARD 100 BLACK Black 100mm P100+

190124006 P90 PROTECT-IT GUARD 100 YELLOW Yellow 100mm P100+

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7 P90 Upright Guard

Intermediate Corner

The Upright Guards are fixed directly to the uprights. Foam inserts must be fixed inside the guards to provide a shock absorbing function. The guards are fixed to the upright using 4 No. bolts and nuts.

The Upright Guards are made of 3mm steel, and are painted Yellow RAL1004.

Part codes for the Upright Guards kits: Please note that the foam must be inserted (self-adhesive) before assembly.

Part code Description Type Upright type

190222001 P90 UPRIGHT GUARD 75 INT R1004 CPL Intermediate 75mm

190222002 P90 UPRIGHT GUARD 75 CRN R1004 CPL Corner 75mm









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Required fixings for the Upright Guards


890110408 BOLT BUTT ISO7380/1 109 M10X40 BZP 4

890174400 NUT HEX NYLOC DIN985 8 M10 BZP 4

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8 Shock Absorbing Column Guard

Please note that the guard is painted yellow, and equipped with black stripes as shown on the photo on the right hand side.

The Shock Absorbing Column Guard is designed to absorb the impact energy in case of being hit by the fork lift truck. The Guard is FEM/EN compliant.

The Shock Absorbing Column Guard is made of 5mm thick steel and is painted Yellow, with black stripes.

The Guard is supplied as a pre-packed kit containing guard, base plates, rubber bush and fixings.

Part code for the kit:


190221001 P90 SHOCK ABS COLUMN GUARD R1004CPL 418mm

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Part codes for the components:


190121001 Shock absorbing column guard RAL1004

190121002 Shock absorbing rubber buffer Ø80/Ø 21x63

190121003 Shock absorbing rubber ring Ø20/ Ø12,5

190121004 Shock absorbing rubber ring Ø40/ Ø12,5

190121005 Shock absorbing washer Ø55x5

Floor fixings:

Part code Description No. / each


891121526 CHEM ANCH BOLT W-VD-A/S M12X160 BZP 1

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9 P90 Deepstor Column Guard

The P90 Deepstor Column Guard is designed to protect the front upright in a Deepstor upright wall. The guard can be used to attach guide rails to the front upright.

The guard is 400mm high and is available for 90-100-120-130-140 and 150mm wide uprights.

The column guards are fixed to the concrete floor using 4 No. of Concrete screws.

Part codes>


190120012 P90 D/STOR COLUMN GUARD 90 400R1004









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10 Safety Bollard

Painted Yellow RAL 1004 Hot Dip Galvanised HDG

The Safety Bollard is designed to protect columns and other installations in the warehouse or manufacturing area from being hit by fork lift trucks or other vehicles.

The Safety Bollards are made of tube CHS 168.3x4mm.

The Safety Bollards are available I 3 different heights, 850mm, 1000mm and 1200mm, and are either painted Yellow RAL 1004 or in Hot Dip Galvanized versions.

The Safety Bollards are fixing to the concrete floor using 4 No. of Concrete Screws.

Part codes>


190125000 SAFETY BOLLARD 850 R1004 850mm



190125003 SAFETY BOLLARD 850 HDG 850mm






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11 Asphalt Floor Channel with Column Guard

This is a special solution for use on asphalt floor. The column guard offer protection of the upright in case of collision between the fork lift truck and the pallet racking frame.

Please note that the pull out and shear performance of the asphalt anchors are limited and even with this type of protection there are a significant risk of pulling out the floor anchors and/or displacement of the frames.

Please follow the guidelines for load and frame dimensions in the P90 Technical manual. This solution can only be used for 90mm uprights with standard duty base plates and 1037mm or 1100mm frame widths.

Part codes:

Part code Description Frame width

118146001 P90 ASPHALT FLOOR CHANNEL 1280 R9002 1037mm and 1100mm

190120006 P90 COLUMN GUARD 90 H400 R1004

For asphalt floor anchors, please see the P90 Technical manual.

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12 Horisontal pallet stop

The Horisontal Pallet stop is to stop pallets from falling through the back end of the rack, and it is not designed to be a pallet positioning device! It is designed for use in racking where the standard pallet overhang is 50 mm front and rear. The profile is positioned 50 mm behind the back side of the pallet. The pallet only touches the profile if the fork lift pushes the pallet so far into the rack that the front edge of the pallet is pushed behind the front edge of the front beam. The back stop profile is positioned within the height of the pallet; it is designed to accept damage without affecting the main supporting structure. Part codes for kits (contain bracket, clamps and fixings, but not the horizontal back stop 50x40x2.0)


118245011 P90 HORI BS FIX.KIT SB 90/100 800

118245012 P90 HORI BS FIX.KIT EB 90/100 800





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Part codes for the individual components


118145003 P90 HORI BACKSTOP 90/100 BRACKET1050 1

118145002 P90 HORI BACKSTOP 90/100 BRACKET1100 1

118145008 P90 HORI BACKSTOP CLAMP 3

118145009 P90 HORI BACKSTOP FIXING CHANNEL 4

118145010 P90 HORI BACKSTOP 50x40x2.0 1885PG 4







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13 Anti-Collapse Mesh

Mesh panels are fixed to the back of a rack to protect the area behind it, if is accessible to persons, from products accidentally falling from a pallet on the rack.

Mesh panels can be fixed either at floor level or at the first beam level.

Mesh panels can also be used to clad the end frames of the rack.

Dimensions:

Grid sizes: 50/30 mm and 50/60 mm

Elements consist of wire mesh welded to a surrounding tubular framework.

Anti-collapse mesh is always sourced from sub-.suppliers and there are several possible suppliers as e.g. Axelent, Garantell, Troax, and more.

Constructor Group will normally have a supply agreement with one or more suppliers within this category. Please contact your local purchase responsible for further information about the suppliers available.

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14 Tunnel Guards

Half Pallet Support / Tunnel Guard

Mesh shelf Grating shelf

The photos above are examples of different types of tunnel guards available.

Tunnel guards are a component (or set of components) placed between the beams and stored goods over an access aisle or fire escape positioned behind pallet racking.

A number of different components can be used as tunnel guards: 1. Tunnel Guards without falling product protection

• Half Pallet Supports – These provide additional support to pallets, but do not offer any protection from falling goods.

• Half Pallet Supports (Welded) – These provide additional support to pallets, but do not offer any protection from falling goods.

2. Tunnel Guards with falling product protection

Chipboard Decking – Generally used for lighter weight boxed products these DO protect against falling goods.

• Galvanized steel shelf panels – These can provide a greater load capacity over chipboard decking and DO protect against falling goods.

• Wire Mesh Decking – These provide additional support to pallets and DO protect against falling goods.

• Wooden Decking – These provide additional support to pallets and DO protect against falling goods.

• Grating Modules – These provide additional support to pallets and DO protect against falling goods.

The load capacity and finish is dependent upon the type of tunnel guard used. They can also be manufactured to suit your application.

For more details – please see the P90 Technical manual.

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15 Special pallet stop - fixed to the rear beams

This is a special pallet stop designed to sit between the rear beams in a double rack run. The device is fixed to the rear beams and there are to be used one for each pallet location. The stopper will function from both sides and be a common stopper for the pallets in both rows.

This solution is designed and used in UK.

No Group part codes exists for the moment.

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16 Special Ram and Side Protection for Pallet racking frames

The special Ram and Side Protection are used for customers in UK. This is an extremely rigid design suitable to be used in tough environments, and if replacement are required new Rams van be installed using the same holes in the concrete floor as the damaged one.

The frame protector consists of two column guards where 32mm diameter steel bolts are welded on. These bolts go into holes drilled in the concrete floor.

The protector is 300mm high.

The lengths of the bolts that go into the floor are xxx mm.

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