RACKING AND STORAGE TECHNOLOGY

RACKING AND STORAGE TECHNOLOGY OMEGA PALLET RACKING

STORAGE TECHNOLOGY FOR EUROPE GALLER can trace its origins back to 1917 and played an active role from the very start in the development of storage technology in Europe. The GALLER works in Kulmbach As one of our valued customers you have made GALLER one of the major companies in Europe in racking and storage technology. We are very grateful to you and feel, at the same time, that we have also been strengthened in our efforts to provide products of the best quality, the best possible customer orientation and the best possible price. From our very first rack, made of wood, to the utilisation of steel components for small racks and to the best racking technology in Europe. GALLER has always had the interests of their customers first and always been to the forefront in the development of storage technology. At our works in the Bavarian town of Kulmbach we manufacture our products utilising computer-controlled systems on a large number of shape rolling mills and machines operating with welding robots, supported by interlinked automatic handling devices: these methods ensure the greatest precision, efficiency and quality. A particular guarantee of our quality is the cathodic dip-coating process followed by powder coating that adds the final touch to the top finish. We are looking forward to being of service to you and can assure you that we will always do our very best for you at all times. Coil storage Rack: profile plant Powder coating plant in operation

THE OMEGA SYSTEM: AN OVERVIEW 1 2 5 6 4 3 1 OMEGA racking 2 Racking vertical beam 3 Cross-member, horizontal and diagonal 4 Foot plate with floor anchoring 5 IPG beam with hooks 6 Spacer The illustrations and pictures do not indicate the actual colours, sizes or finish. We reserve the right to make changes rendered necessary by technical improvements. 4

Contents Omega system overview and specifications 4-5 Omega systems 6-7 Omega multi-position system 8-13 Omega single-position system 14-17 Omega drive-in and drive-through racking 18-21 Standard parts and sizes 22-23 System accessories 24-27 Specifications The best possible statics to optimise profile stability: OMEGA standard profile and SIGMA beams or IPG beams ( I denotes the shape, P denotes profile and G denotes Galler). Welded standard frame constructions for heavy loads with lowest tolerances for automated storage and in racking silo construction. Bolted rack designs provide the alternative for standard racking up to a construction height of 12000 mm. Correctly dimensioned accessories, e.g. corner protector and strips, wire mesh with frames and precision-made guide rails. A finishing unit with a cathodic dip coating plant: this finish provides adequate capacity since it measures 12000 (length) by 2200 mm (depth) by 600 mm (width). The OMEGA racking is finished in light grey (RAL 7035) after a thorough preparatory treatment and final treatment (degreasing, cleaning, activating, zinc phosphate treatment, dip coating and baking). Powder coating is offered as an option for customized colouring after pre-treatment Storage planning design and statics completed by in-house experts. Competent advice from our sales office staff. 5

OMEGA SYSTEMS The multi-position system In each bay there will normally be 2, 3 or 4 pallets (or lattice boxes, steel boxes, etc.) on one IPG pair of beams. With this system there is direct access to each pallet. This is the standard system for storage using fork-lift trucks or high-rise trucks. Thus this system ensures that space will be well utilised with fewer racks, particularly for lengthways storage (X access). The single-position system In each bay there will be only one pallet (or lattice box Mesh box, steel box, etc.) on one pair of deep beams for crossways inserted pallets. The height in each pallet bay can be adjusted separately, if the storage units are of different heights. The available space can be best used to accommodate these heights: of course there is direct access to each bay. The drive-in and drive-through system These two systems stand out in providing an excellent use of space, because 15 pallets or more can be stored at each level in the channels. The drive in system operates from one side only (First-in Last-out), but in the case of drive-through system goods are inserted on one side and removed from the other (First-in Firstout). 6

Aisle widths and equipment In this planning draft, we have shown different types of equipment, aisle widths and heights. When a silo is being constructed or when high pallet racking systems in a warehouse are planned ( 12000 mm), the planning module must be rised in height by at least 200 mm to allow for bracing and, normally a sprinkler system. Up to a construction height of 10000 mm a conventional warehouse is recommended with separately built-in racking. With a construction height between 10000 and 15000 mm a check must be made in each case to establish whether it would be better to plan a separate building or a roof and wall bearing racking system (silo). With a construction height of more than 15000 mm we generally recommend a rack cladded building. 7

THE OMEGA MULTI-POSITION SYSTEM High-rise storage with a high-rise truck Forwarding company storage with drive-in high-rise truck 8 Furniture storage with inductively controlled high-rise truck

Example OMEGA three-bay system with high-rise truck with guide rails for flat, wooden Euro-pallets (1200 mm) deep stored. Longitudinal section Ground plan 9

THE OMEGA MULTI-POSITION SYSTEM The system in detail The pallet station The station is for pallets hooked in the first upright positioning. Upper guide rail for high-rise trucks The upper guide rail with low tolerances at the aisle bridges and at the cross-over areas mounted on a cantilever designed racking. The sprinkler line Here the sprinkler line is shown running in the shadow of the beams (horizontally) and of the supporting members (vertically). Racking in a furniture store: a positioning station The first section is the receiving station for roller containers. The racking vertical members are separated by a T-frame from the front so that pallets can be moved easily. 10

System accessories Special deep beams for crossways inserted wooden, flat Euro-pallets Special deep beams that are flat are inserted at a 52 mm support width to hold the wooden flat Euro-pallets stored crosswise. These beams are deep drawn from one piece and can be adjusted at the sides if necessary. Z deep beams These deep beams have rised edges at the sides to facilitate positioning and to preventing pallets from sliding off. These beams are fixed by clamped joints. They can be adjusted at the sides to accept different widths. Cross Beam Support When the beam-span is wide, each compartment has a device to prevent tipping. The device is bolted between the front and the rear beams. It prevents the beam from twisting. Drum support This is welded on. It lies on the pallet beams and is held firmly by angled profiles. The drum is centred by means of angle profiles welded on in the direction of the depth. 11

THE OMEGA MULTI-POSITION SYSTEM System accessories Frame Spacer For fixing the frame distance between double-sided racking. Anti-slip protection beam A continuous anti-slip protection beam made of C profile steel. When double-sided pallet racking is being used (as shown here), this device is fixed by supports in the middle between the racking. This will prevent the pallets from slipping off at the rear. When a sprinkler system is being used, two such anti-slip devices can be fixed parallel to each other, separated by a clear distance of at least 100 mm. With single sided racking the antislip device can be fixed with a support bolted at the back. Support member joint, inside, U, bolted Beams can also be utilised at upright connections. At this connection the load for the extra member must not exceed 6000 kg. Support member joint Members can be joined to increase height by means of welded joint plates using a central friction grip bolted joint. The load can be in excess of 6000 kg. 12

System accessories IPG beams With chipboard floor and Z steel locking device. IPG beams With grid floor and bolt fixing. Walk-through aisle with ceiling GF beams With laid-in wooden or chipboard decking. As an option flush-fitting with beam top edge. GF beams With laid-in steel panels and flush-fitting with beam top edge. Drive-through with cross-over walkway 13

THE OMEGA SINGLE-POSITION SYSTEM pharmaceutical industry motor vehicle industry motor vehicle industry 14

Example For steel box pallets, storage depth 1000 mm high-rise trucks wire guided (inductive). Longitudinal section Ground plan 15

THE OMEGA SINGLE-POSITION SYSTEM System components Deep beam G hook G hook with welded on deep beam (front view). Deep beam G hook The deep beam is hooked into the elongated holes at the side of the vertical member bracing by means of two welded hooks. The pitch of the holes is 50:50 mm and so the beam can be adjusted. The side edging is at an angle of about 170 and stops the pallet when it is positioned and stored. There is a push-through safety device fixed at the rear to a bracket. Deep beam G hook / DS As above, but with a welded-on push-through safety device. 16

System components Deep support beams on longitudinal beams To ensure stability the OMEGA single-position must be supported top and bottom, depending on construction height, at one or more levels by longitudinal beams. Here the deep beam is bolted to the longitudinal beams. There are, in addition, continuous push-through safety devices at the rear. Deep support beams on longitudinal beams / DS As above, but with welded pushthrough safety device. Deep support beams bolted at the side Deep support beam, angle profile, bolted from the side directly on the racking. The pitch of the holes is 50:50 mm so that the beam can be adjusted. 17

OMEGA DRIVE-IN AND DRIVE-THROUGH RACKING Industrial storage for recycling materials Forwarding agent storage Packaging storage 18

Example Drive-in racking for flat, wooden Euro-pallets using a counter balance truck or a fork-lift reach truck. Front view Ground plan 19

OMEGA DRIVE-IN AND DRIVE-THROUGH RACKING System components Pallet beam with positioning device Special profile guide rail (modified Z profile), beam width 100 mm, total profile height approx 165 mm. Fixed at the sides so that the bolt heads do not obstruct the surface of the beam. Guard A flat steel guard at the same level as the pallet beam fitted to the brackets. The guard serves as a deflector rail and guide rail. Pallet guard A pallet guard fixed above the pallet beam. This prevents damage to the upright by the pallets that are being stored. 20

System accessories Top longitudinal beam Required to maintain stability of drive-in racking and drive-through racking. In each case it is hung for each channel using an OMEGA claw into the vertical member profiles above the top most pallet compartment and is secured by bolts. The system is extremely variable because it can be extended, modified or dismantled, because the claws are fixed separately for each channel. Guide rail Set into a C profile fixed to the floor. The rail runs the entire depth of the channel. At the front there is a positioning opening to ensure that the channel can be entered easily. Anti-slip protection beam A straight beam for normal usage. Anti-slip protection beam A beam bent at a right angle for joining elements 21

STANDARD PARTS AND SIZES OMEGA AND OMEGA M OMEGA Welded vertical upright OMEGA M Bolted vertical member Each OMEGA vertical upright as a standard part will be welded into its position with low tolerances and then finished completely by cathodic dip coating. The OMEGA M vertical member is an assembly system that is bolted together on site. The vertical member needs little space for storage and so transport costs are low. The struts and the horizontal bracing are galvanized, and the base plates are cathodic dip coated. Standard base plates bolted-on foot Standard base plate and standard connection for bolted vertical member frame. 22

Standard profiles and components for the Omega systems OMEGA vertical member profiles Standard profile Standard profile with slotes Standard profile with round hole IPG beam clearance 66 IPG 100 (=profile height 100 mm) IPG 120 (=profile height 120 mm) IPG 150 (=profile height 150 mm) S beam clearance 254 100 125 150 55 254 100 120 150 55 S 100 S 125 S 150 (=profile height 100 mm) (=profile height 125 mm) (=profile height 150 mm) Depending on the type of beam and the different load capacity requirements, the IPG beams and S beams are produced with a sheet thickness from 1.75 mm to 2.50 mm. 23

SYSTEM ACCESSORIES Special U guide rail The special U guide rail (U35/110/55/ 4 mm) is used for automatically guiding high-rise trucks or commissioning vehicles. The rail is set and levelled on raw concrete, and the space between the rails where the racking is to stand is filled with concrete. The upper edge of the U profile will prevent the concrete from cracking at later stages, when the racking is being used! U guide rail, levelled The aisle between the rails is filled as required with screed. If the floor has been levelled (with screed) the guide rail will be laid flush. The standard procedure is for the guide rail to be finished with cathodic dip coating RAL 7035. If the screed is bound with magnesium oxychloride cement, additional protection will be provided by powder coating. U guide rail, not levelled Opening (not illustrated) At the entrance to the aisle for the high-rise trucks the opening for the guide rails is inclined at 15 at the front. L guide rail The L guide rail (L100/65/9 mm., DIN 1029) is also used for automatically guiding high-rise trucks or commissioning vehicles. But this rail is not levelled on the prepared screed (or concrete). The ground must, however, already lie on the floor side within the tolerances required for operation. In the case of guide rails 50 mm the beam is not required. L guide rail When the sections that are approximately 6000 mm are being fixed, 2x2 welded bolts have to be used at the joints and a steel plate bolted on top. 24

Corner protector Height 400 mm, made of 4 mm steel plate anchored to the floor with pegs (shear connector). Painted with black/yellow stripes as required by safety regulations. Vertical protector Made of 4 mm steel plate for the vertical member and 8 mm steel plate anchored to the floor with pegs (shear connector). Surface painted with black/yellow stripes. The 400 mm upright strips are provided with corner upright protector and are connected at the centre with bolts. By using adapters in the middle the upright protector strips can be made to fit the racking depths. Anti-collision frame protector This is for strengthening the vertical member and is slid over the racking support and bolted on. U111/45/5 mm, 800 mm high (or reaching to lower pallet beam) Light grey RAL 7035. 25

GENERAL ACCESSORIES Rear protectiv mesh This is a framed grid that is fixed with special bolts to the racking. Storage divider This is a framed mesh that is fixed with a foot plate plugged to the floor. The gates can be either opening or sliding (also available with a grid). 26

Capacity label (type, year built, order number, load/compartment, max. stand load, max. compartment height). Location description bar code Adhesive foil for the location bar code. Alphanumeric location description Adhesive foil for the alphanumeric location bar code. Main plate (order number, stand type, level spacing, field load, beam type, compartment width, compartment load, and year). Aisle indicators Aisle indicators made of strong plastic with the aisle numbers glued on. 27

Our Production Programme: Pallet racks High-bay silos Dynamic live storage Tray and drawer storage Wide span and compartment racks Mobile racking systems Cantilever racking Drive-Through racking Drive-In racking Storage platforms sales office UA: Firma LagerService 12/3 Mate Zalky St, apt. 61, 04211 Kiev, Ukraine, Tel/Fax: +38(044)5036560 or 5036419, E-mail: office@lagerservice.com.ua, www.lagerservice.com.ua Subject to technical changes or printing errors 12/2006 www.kaiser - fotografie.de