Assembly specification These instructions are to assemble Dexion Speedlock Pallet Racking which conforms with the specifications below. Frame heights not more than 4800mm Frame depths 840mm Not less than two bays long (1 x starter and 1 x extension bay) Not less than two storage s in a bay Height to first beam and beam spacing as prescribed in these instructions Uniformly distributed load per pair of beams Maximum 2 tonne per pair of beams Designed for 1165mm x 1165mm pallet size Refer to your Dexion Supply Centre for assembly of pallet racking outside these specifications. Site requirements Floor Should generally be of a solid CONCRETE construction designed to accept the point loads imposed by the rack legs. Installations on other types of floor, such as timber, bitumen and tarmac, should be avoided. Dry conditions Components and load data are based on dry internal applications. Temperature range +3 C to +40 C. Applications in chill and cold stores with operating temperatures below +3 C, and where moisture is likely to be present, may require components with additional corrosion protection. PAGE 1 of 10 REV 1 OCT 2012
Components required The following is a schedule of the components you require to safely assemble Speedlock Pallet Racking. The number of starters and extension Pallet Racking units purchased will determine the final quantities of each component. Frames x 3 Beams x 8 Beam safety locks x 8 Levelling plates 0.9 x 6 Levelling plates 2.9 x 6 Safe Working Load Sign x 1 M10 x 16 Hex head bolts and nuts x 2 Sleeve anchors x 12 PAGE 2 of 10 REV 1 OCT 2012
Ensure a safe work environment prior to assembly Risk assessment Prior to assembly, a risk assessment should be undertaken which considers all tasks necessary to complete the assembly of the Rack. This includes the equipment being used and any hazardous substances being handled. This will highlight associated risks and ensure necessary steps taken to reduce the risk to acceptable s. From this risk assessment a Safe Working Method Statement (SWMS) should be produced. Safe work method statement An SWMS is developed for activities undertaken by workers, which identify the hazards associated with a work activity. They assess the risks of these hazards occurring and outline the preventative controls to be put in place. It is a requirement of Work Health and Safety Legislation that an SWMS be prepared for high risk work, prior to the work commencing For further information regarding SWMS refer to Government fact sheet Guidance for producing Safe Work Method Statements http://www.fsc.gov.au/sites/fsc/resources/az/pages/factsheet-guidanceforproducingsafeworkmethodstatements.aspx Site Survey A site survey should be undertaken prior to the supply of material to site and an assembly layout prepared. This layout should include but limited to: Location of doorways Location of building columns Floor type, flatness and any joint locations Headroom clearance and any obstructions Equipment The following is a guide only, on the equipment required to facilitate the safe assembly of the structure. Equipment may include, but limited to: Hand pallet trucks Surveying equipment Access tower Fork lift trucks Hand tools Trolleys Power tools Scissor lifts Personal protective equipment Personal protective equipment should be worn to ensure personal safety during assembly. Personal protective equipment may include but not limited to: Hard hat Safety boots or shoes Rigger gloves High visibility vest Ear defenders Work wear Safety harness Safety goggles PAGE 3 of 10 REV 1 OCT 2012
Height to first beam and beam spacing The assembly of your pallet racking MUST adhere to the measurements depicted in the diagrams below: Height to first beam Beam spacings Configurations outside these parameters will affect the racks load carrying capacity. Note: The clearance between the load and the beam is 100mm. 4625mm 4725mm 4125mm 3475mm 2325mm 3125mm 2725mm 1175mm 1525mm 1325mm Upright Length 4800mm Beam s 4 Upright Length 4800mm Beam s 3 Upright Length 4200mm Beam s 3 3525mm 2325mm 2925mm 2325mm 1125mm 1425mm 1125mm Upright Length 3600mm Beam s 3 Upright Length 3000mm Beam s 2 Upright Length 2400mm Beam s 2 PAGE 4 of 10 REV 1 OCT 2012
Assembly instructions 1. Measure and mark out the location of the pallet racking, prior to the assembly of the rack, making sure that the bays of racking will end up square and running in a straight line; this can be achieved by marking out a simple 3; 4; 5 right angled triangle on the ground. 3 90 4 5 Each upright location should be clearly marked on the floor, and its taken to find the highest point under the rack. The remainder of the assembly will have their uprights packed with ing plates to match this highest point. Ensure aisles or access to emergency escape routes are not blocked by the assembly of the rack. 2. Stand two frames for the starter bay and fit the first beam at the specified height for your racking configuration. NOTE: The free end of the bottom horizontal always points into the operating aisle. PAGE 5 of 10 REV 1 OCT 2012
3. Secure beam safety locks to either end of the beam. Locking pins MUST be fully engaged in the upright slots when installing beams. SPRING STEEL CLIP FORGED STEEL PIN 4. Fit remaining front and rear beam s. Repeat steps for adjoining bays, not forgetting to secure the beam in position with beam safety locks. PAGE 6 of 10 REV 1 OCT 2012
5. Stand the extension frame and fit beams at the identical of the starter bay. Ensure beams are secured in position with beam safety locks. PAGE 7 of 10 REV 1 OCT 2012
6. To the rack, fit the appropriate number of ling plates under each base plate which is attached to the upright. As a check to make sure the racks are true & plumb to the vertical, a spirit should be used to measure the out of plumb, on the front face of the frame upright, adding or subtracting plates as required. UPRIGHT M10x16 HEX HEAD NUT & BOLT (2) BASEPLATE 2.9mm LEVELLING PLATE 0.9mm LEVELLING PLATE 7. All base plates attached to uprights must be anchored to the floor to resist any lateral movement or uplift of the rack. Secure the base plate using 2 x Floor fixings through 14mm dia. front right and left hole with 12 x 75mm or 12 x 100mm approved Sleeve Anchors as shown below. SLEEVE ANCHOR PAGE 8 of 10 REV 1 OCT 2012
8. To comply with AS4084:2012, fix Safe Working Load Sign to one conspicuous location in the racking area at approx 2m above the floor. It is recommended that the Safe Working Load Sign is fixed to the end of the rack using 2 x M10 x 16 Hex head bolts and nuts. PAGE 9 of 10 REV 1 OCT 2012
Important safety information General care Little or no maintenance is required other than cleaning. Wipe with a damp cloth, using a mild detergent (only if required). Do not use a hose to spray the racking Do not use abrasive or caustic cleaning agents Inspections Periodic inspections should be carried out to identify any damage or issues due to incorrect use. Check for the following: Frame fixings are secure Beams are free from damage Beams are not overloaded Beams are fully engaged in the frame slots All safety locks are correctly engaged If the vertical beam deflection is more than span/180 the beam is overloaded. Remove the load and check against permissible load data. If the unloaded beam has set more than span /900, it must be replaced. Rack out-of-plumb should not exceed height/350 in both directions IMPORTANT If the racking is damaged it should be reported immediately to ensure the necessary precautionary actions are taken. It is not recommended to repair damaged components. Any part no longer fit for use should be replaced on a like for like basis. Never cut and splice in a small piece of upright or apply heat in an attempt to straighten bent components. It is recommended that owners of pallet racking are familiar The WorkSafe Guidance note Pallet racking operation and maintenance http://www.worksafe.vic.gov.au/ Whilst the utmost care is taken to ensure the accuracy of the data and design details shown within, Dexion (Australia) Pty Limited cannot, under any circumstances, be held liable for any injuries, expenses or loss which may, in any degree, be attributed to the use or adoption of such data and design details. Any modification, repair, or alteration of Dexion products by a third party without written approval from Dexion voids Dexion s obligations under the Lifetime Warranty. This document remains the sole property of Dexion (Australia) Pty Limited. Copyright: Dexion (Australia) Pty Limited. PAGE 10 of 10 REV 1 OCT 2012