iron fist - hans schourup a/s · 3 iron fist rosss national and international rules cnr uni...

I

Iron F

ist ROSSS1) PALLET RACKING DESCRIPTION

-Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1-National and international Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3-Overview and details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4-Capacity revision criteria in case of a change of the original lay-out . . . Page 7-Capacities instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9

2) TRANSPORT, HANDLING AND STORAGE-Transport and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10-Beams package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10-Uprights package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10-Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11

3) ASSEMBLY INSTRUCTIONS-Preparations for the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12-Component quantity for frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15-Types of Iron Fist uprights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 18-Iron Fist frames configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 19-Iron Fist frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Foot Plate and Beams assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 30-Spacers assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 31-Types of Iron Fist connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 32-Levelling/Fixing of Foot Plate and shimming . . . . . . . . . . . . . . . . . . . . . Page 33-Assembly of Iron Fist shelf panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 34-Assembly of pallet back stop tubular element . . . . . . . . . . . . . . . . . . . . Page 35-Assembly of cross bracings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 36-Assembly of back protection wire meshes . . . . . . . . . . . . . . . . . . . . . . Page 38-Assembly tollerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 40-Capacity charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 41-Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 42-Testing report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 43

4) RACKING UTILIZATION-General warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 44-Pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 45-Shape and positioning of the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 46

-Pallets loading and unloading sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 47-Weights and deflections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 48

-Uniformly distributed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 49-Position of beams on frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 50-Load positioning on beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 51-Positioning of pallets on beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 52-Storage of loose materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 53-Warning for fork lift truck drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 54-Obligations and prohibitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 56

GENERAL INDEX

ROSSS

II

Iron F

ist ROSSS5) PERIODICAL CONTROLS AND MAINTENANCE

-Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 57-Maintenance and control procedures . . . . . . . . . . . . . . . . . . . . . . . . . . Page 58-Foot Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 59-Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 60-Maximum permanent deformation of the upright . . . . . . . . . . . . . . . . . . Page 61-Beam connector locks and beams integrity . . . . . . . . . . . . . . . . . . . . . . Page 62-Perpendicularity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 63-Check and maintenance form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 64-Record of maintenance interventions . . . . . . . . . . . . . . . . . . . . . . . . . . Page 65

ROSSS

1

Iron F

ist ROSSSPresentation of the Company

Our company, thanks to a wide experience in the engineering industry and to atechnologically modern production, is able to offer safe and rational solutions forany storage requirements. Our modular structures meet the strongest loadingrequirements but, at the same time, they present the maximum assembly practi-cality and an extraordinary functional agility. ROSSS is the first Italian companyto have obtained the certification of its own Quality System in field of the desi-gning and manufacturing of metal shelving and racking systems; preciselyROSSS obtained the following certification:

-Certification of quality sytem N. 087-A, issued the 12/04/1996 by CERMET according to the UNI EN ISO 9001

- Certification of the Environmental system N. 087-E , issued the 28/06/2002 by CERMET according to UNI EN ISO 14001-96

- Certification of EMAS Registration N° I-000258 issued the 10/11/2004

- Certification for the system of Social Responsabilità Management SA8000:2001 number BE04/3368SA issued the 30/12/2004.

The certifications above have been issued for the following activities:

Research, Designing, Manufacturing and installation of metallic structures inorder to manage industrial and commercial spaces: light shelving systems (pain-ted and galvanized),Pallet racks, Drive-in, Gravity systems, mobile bases forarchiving, mezzanine floors, automatic warehouses and checkouts.

From several years we take part of "A.C.A.I." (Associazione Costruttori AcciaioItaliani) Racking and Shelving system Section which produces a series of rulesfor a safe designing.ROSSS S.p.A. is one of the companies whose passed the examination to get"CISI Qualità Sicurezza" (Costruttori Italiani Scaffalature Industriali) brand.For the designing and manufacturing of our products we follow technical specifi-cations produced by "A.C.A.I." sezione "Scaffalature Industriali". The technicalspecifications above are reffered to the norms listed below.

-·D.M. 9 gennaio 1996 "Norme tecniche per il calcolo, l'esecuzione ed il collado delle strutture in cemento armato, normale e precompresso e perle strutture metalliche"

·CNR 10011/97. Costruzioni di acciaio. Istruzioni per il calcolo, l'esecuzione, il collaudo e la manutenzione.

·CNR 10022/84. Profilati formati a freddo. Istruzione per l'impiego nelle costruzioni.

·UNI EN 10204/92. Prodotti metallici. Tipi di documenti di controllo.

PALLET RACKING TYPE IRON FIST

2

Iron F

ist ROSSS·D. Lgs. 19 settembre 1994, n. 626, relativo al miglioramento della sicu-rezza e della salute dei lavoratori sul luogo di lavoro.

·D. Lgs. 21 maggio 2004, n. 172, relativo alla "Attuazione della direttiva 2001/95/CE sicurezza generale dei prodotti".

·D.P.R. 27 aprile 1955 n. 547

F.E.M. 10.2.02 "The design of static steel pallet racking"

Moreover we refer also to F.E.M. codes ( Federation Europeenne de laManutention-Section X) :

UNI ENV 1993 1-1 (EUROCODICE3) "Progettazione di strutture in acciaio"

F.E.M. 10.2.03 "Guidelines for the safe provision of static steel racking and shelving"

Pallet racking type IRON FIST

The structure is obtained by assembling two main elements, frames and beams,by means of a simple dap-joint and without using any bolts, joints or other com-ponents. Frames are the vertical elements composed by uprights and bracingmembers (diagonals and cross bars); beams are the horizontal load carryingmembers with a closed rectangular section. Currently the system includes fiveseries of frames: 70/150, 90/150, 90/200, 110/200, 130/250, supporting from4.500 up to 35.000 kg per frame, and various types of beams with a range ofcapacities from 930 up to 4.500 kg per pair of beams.It is possible to study particular solutions in case of capacities higher than 30.000kg per frame. All the uprights are made of steel certified 3.1.B UNI EN 10204 ofhigh resistance type. Frames are supplied dismantled, made of galvanized mate-rial, except for those cases differently agreed with the company in the supplycontract.

SYSTEM N. _________________ YEAR OF CONSTRUCTION ______________(Please quote the number of delivery note/year)

3

Iron F

ist ROSSSNational and International Rules

CNR UNI 10011/97 “ Costruzioni di acciaio - Istruzioni per il calcolo, l’esecu-zione, il collaudo e la manutenzione”;

CNR 10022/84 “ Profilati formati a freddo – Istruzioni per l’impiego nellecostruzioni”;

UNI ENV 10204/91 “Prodotti metallici. Tipi di documenti di controllo”;

D.P.R. 27 aprile 1955 n. 547; (in generale: anche per segnaletica e cartelloni-stica)

D. Lgs. 19 settembre 1994 n. 626; (in generale: sicurezza nei luoghi di lavoro)

D. Lgs. 17 marzo 1995 n. 115; (sicurezza generale dei prodotti)

La normativa europea per quanto riguarda la progettazione e l’uso del prodotto:

UNI ENV 1993 1-3 (EUROCODICE 3) “Design of steel structures” – Part 1-3 “General rules – Supplementary rules for cold formed thin gaugemembers and sheeting”;

FEM 10.2.02 “The design of steel static pallet raking and shelving”;

FEM 10.2.03 “Recomendation for the safe provision of static steel raking andshelving – Specifier’s code”

FEM 10.3.01 “ Adjustable beam pallet raking (APR) – Tollerances, deforma-tions, e clearances”

RAL/RG 6145 Deutch

ZH/428 Deutch

4

Iron F

ist

OVERVIEW AND DETAILS

ROSSSROSSS

5b

212014

13b13a

5

Iron F

ist ROSSS

1) Upright2) Diagonal3) Cross bar4) Beam5) Spacers:

a) run spacerb) wall tie

6) Drum: a) weldedb) simple

7) Foot plate8) Pallet guide rail9) Curved pallet guide rail10) Screw anchor11) Secondary beam:

a) pressed; b) welded c) longitudinal secondary beam

12) Containers holder: a) single; b) double

13) Frame protection: a) frontal; b) normal

14) Safety Pin15) Shelves type P and type G16) Pallet back stop tubular element17) Wire meshes18) Capacity chart19) Assembled frame20) Upright protection21) C250 protection22) Vertical cross brace23) Ground bracket for cross brace24) Single/Double front diagonal joint stop25) Beam for horizontal braces26) Horizontal cross brace27) Security beam28) Tie rod

26

22

23

24

25

27

28

28

6

Iron F

ist

UTILIZATION LIMITS OF THE RACKING

WARNING

It is not allowed to position on the racking neither horizontal loads nor dynamic loadsboth vertical and/or horizontal.

It is not allowed to bump against or to lean to the racking with fork lift trucks or whate-ver equipment.

It is not allowed to use the racking in a different way from the one described in thismanual.

The racking is designed for a specific use. Possible changes of the geometry may beproduced only under authorization of our Technical Department.

The instructions contained in this manual are significant for some details.

Such instructions are exhaustive for the aims of the present manual: correct assembly,use and maintenance.

The exact dimensional features can be deduced from the delivery note.

The drawings listed in this manual are produced for a commercial didactic purpose.

In case of customer takes care of assembling, ROSSS declines any responsabilityfor damages to things and person caused by this activity.

7

Iron F

ist ROSSSREVISON CRITERIA IN CASE OF A CHANGE OF THE

ORIGINAL LAY-OUT

Frame with beam on the floor Frame without beam on the floor

The first choice of the types of structures is normally made by ROSSs with the sup-plying; these instructions are especially given to be used in case of revision of thelay-out from the user. Once the type of upright has been determined, the maximumcapacity of the racking depends on the position of beams along the frames, the-refore if a change of the position and/or of the number of the original beams is needed, it is important to re-calculate the frame capacity.The definition of the new capacity must be carried out by expert and qualified peo-ple.In case of a change of the capacity values, all the capacity charts related to beamsmust be updated, according to the procedures of page 8.Hereby we present two examples of calculation of the load capacity with steadypitch between beams.

ROSSS

8

Iron F

ist ROSSSROSSS1ST EXAMPLECALCULATION WITH UNIFORM PITCH BETWEEN BEAMS

Initial data: frame type S110/200 without beam on the floor, uniform pitch of 900 mmbetween beams, n. 7 loading levels, loading per level of 3.000 kg, therefore the totalcapacity on the frame is 21.000 kg.Such capacity can be accepted as we can see from the capacity chart related to theframe S110/200 (at the end of this manual).Let us suppose to remove the lowest beam, the height of the 1st beam from the floor isnow 1.800 mm and the load brought by the upper levels is 18.000 kg. From the capa-city chart related to the frame S110/200, we can observe that this one has a maximumcapacity of 18.500 kg with a pitch of 1.800 mm, which is higher than the value we haveobtained by removing the beam, so that this operation is possible. If the capacity of theframe would not be sufficient to satisfy the new condition, it is not possible to remove thebeam and keep 3.000 kg per loading levels.In order to remove the beam, you have to reduce the load on the other level

Starting configuration

Changed configuration

9

Iron F

ist ROSSS2ND EXAMPLECALCULATION WITH VARIABLE PITCH BETWEEN BEAMS

If the pitch between beams is not uniform, each single pitch should be verified.Let us suppose to verify a system with frames type 110/200, as in the below sketch.Starting from the floor, for a pitch of 1.250 mm, we have a total load by the upper levelsof 18.000 kg (3.000x6), smaller than the frame capacity which is 20.200 kg, as we canobserve from the capacity chart related to the frame S110/200 with a pitch of 1.250 mm,therefore we can accept the load per level.With a pitch of 2.400 mm we have a total load from the upper levels of 15.000 kg(3.000x5), smaller than the capacity of the frame, which is 16.250 kg with a pitch of2.400 mm, therefore the configuration is acceptable. If the capacity of the frame wouldnot be sufficient, you must reduce the load per level or, alternatively, you can reduce thepitch until you can stay within the values indicated in the chart.For the upper levels, if they have a pitch previously checked, as they have a smallerload, they are verified.

CAPACITIES INSTRUCTIONS

According to the features of the system, we supply a capacity chart for frames and acapacity chart for pair of beams to apply to the system according to the conditions ofpage 32.The indications of the capacity per loading level should be carried out by using prepa-red charts, furnishable on request.The values to be indicated are written in kg per pair of beams and refer to uniformlydistributed loads per pallet place.If the material to be stored has specific weights which determine overloading risks accor-ding to the loading level volume, the user should give additional information in order toremove these risks.

The load capacities of the frames are available for pitch between beams up to mm.2000 and at least two couples of beans in height. In case of we don’t respect theconditions above please contact the technical office of ROSSS S.p.A.

ROSSS

10

Iron F

ist ROSSS

L = Beams total length

P = Package depth

H = Package height

1 = forks referring points to lift packages

Kg = in the order specify the maximum load the customer can unload

L = Uprights total length

P = Package depth

H = Package height

TRANSPORT, HANDLING AND STORAGE

Frames are supplied dismantled and packed, while the components are wrapped upwith strips.It is not allowed to use crane or bridge cranes with flexible slings for the transport orthe handling of packages or bundles.

ROSSS

11

Iron F

ist ROSSS

If necessary, according to the specific operation, adopt technical measures to eliminateaccident risks linked to loads handling.

If the material has to wait a long time before being assembled, arrange the elements ofthe racking on a flat surface and avoid to overload them, because they could be dama-ged.

The components of the racking must not be stored in an open environment.

HANDLING

For the handling of the material it is important to use a fork lift truck with suitable capa-city. The forks of the machine should have an APPROPRIATE width as regards as to thelength of the packages and an adequate length to lift the package in a completely safemanner.

ROSSS

12

Iron F

ist ROSSSASSEMBLY INSTRUCTIONS

PREPARATIONS FOR THE ASSEMBLY

1) Verify the capacity of the supporting floor and the capacity to endure

concentrated loads

2) Check the levelling of the floor

3) Verify possible interferences of the racking with existing systems

4) Verify the adequacy of the available spaces as to carry out the

assembly in a safe manner

5) The flooring and lighting of the premises should be studied in order to

allow the staff to work in optimum conditions

ROSSS

13

Iron F

ist ROSSSASSEMBLY TOOLS

Set of spanners LevelScrewdriver JemmyGum-hammer Plumb linePliers Optical levelPower drill Safety belts

WARNING

The assembly team must be provided with all the equipments required to prevent jobaccidents, according to the specific assembly operations(helmet, gloves, accident prevention shoes, safety belts, etc.)

ROSSS

14

Iron F

ist ROSSSFor the handling of frames, during the assembly, we suggest to use suitable mechanicalequipments, such as small cranes, winches and so on.The handling of quite short frames can be carried out manually with a certain number ofpeople.For the shifting of materials of any height, it is necessary to use a fork lift truck of suita-ble capacity and lifting height, while for the assembly a platform with appropriate capa-city and lifting height is required.However it is possible to use, only for heights up to 6.000 mm, transpallets of appro-priate capacity for the shifting of materials and a scaffold over wheels of appropriatecapacity and stability for the racking assembly.

The assembly of the structure starts by lifting vertically the head frame, putting it in itsfinal position.Then the second frame is lifted vertically and beams are installed starting from the bot-tom towards the top, or from the top to the bottom, if the assembly is carried out bymeans of a platform. The remaining frames are assembled in the same way, taking careto the perpendicularity of the system as regards as to the floor (see also page 22).

ROSSS

15

Iron F

ist ROSSSH

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1800 2 4 2 2 7 7 7 4 4 4 22100 2 4 3 2 8 8 8 4 4 4 22400 2 5 3 2 9 9 9 4 4 4 22700 2 4 4 2 9 9 9 4 4 4 23000 2 5 4 2 10 10 10 4 4 4 23300 2 4 5 2 10 10 10 4 4 4 23600 2 5 5 2 11 11 11 4 4 4 23900 2 4 6 2 11 11 11 4 4 4 24200 2 5 6 2 12 12 12 4 4 4 24500 2 4 7 2 12 12 12 4 4 4 24800 2 5 7 2 13 13 13 4 4 4 25100 2 4 8 2 13 13 13 4 4 4 25400 2 5 8 2 14 14 14 4 4 4 25700 2 4 9 2 14 14 14 4 4 4 26000 2 5 9 2 15 15 15 4 4 4 26300 2 4 10 2 15 15 15 4 4 4 26600 2 5 10 2 16 16 16 4 4 4 26900 2 4 11 2 16 16 16 4 4 4 27200 2 5 11 2 17 17 17 4 4 4 27500 2 4 12 2 17 17 17 4 4 4 27800 2 5 12 2 18 18 18 4 4 4 28100 2 4 13 2 18 18 18 4 4 4 28400 2 5 13 2 19 19 19 4 4 4 28700 2 4 14 2 19 19 19 4 4 4 29000 2 5 14 2 20 20 20 4 4 4 29300 2 4 15 2 20 20 20 4 4 4 29600 2 5 15 2 21 21 21 4 4 4 29900 2 4 16 2 21 21 21 4 4 4 210200 2 5 16 2 22 22 22 4 4 4 210500 2 4 17 2 22 22 22 4 4 4 210800 2 5 17 2 23 23 23 4 4 4 211100 2 4 18 2 23 23 23 4 4 4 211400 2 5 18 2 24 24 24 4 4 4 211700 2 4 19 2 24 24 24 4 4 4 212000 2 5 19 2 25 25 25 4 4 4 2

Component quantity for frame assembling Series 70

16

Iron F

ist ROSSSH

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Component quantity for frame assembling Series 90 - 110

17

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pla

te

1800 2 6 4 7 7 7 7 4 4 4 22100 2 8 6 8 8 8 8 4 4 4 22400 2 8 6 9 9 9 9 4 4 4 22700 2 8 8 9 9 9 9 4 4 4 23000 2 8 8 10 10 10 10 4 4 4 23300 2 8 10 10 10 10 10 4 4 4 23600 2 8 10 11 11 11 11 4 4 4 23900 2 8 12 11 11 11 11 4 4 4 24200 2 8 12 12 12 12 12 4 4 4 24500 2 8 14 12 12 12 12 4 4 4 24800 2 8 14 13 13 13 13 4 4 4 25100 2 8 16 13 13 13 13 4 4 4 25400 2 8 16 14 14 14 14 4 4 4 25700 2 8 18 14 14 14 14 4 4 4 26000 2 8 18 15 15 15 15 4 4 4 26300 2 8 20 15 15 15 15 4 4 4 26600 2 8 20 16 16 16 16 4 4 4 26900 2 8 22 16 16 16 16 4 4 4 27200 2 8 22 17 17 17 17 4 4 4 27500 2 8 24 17 17 17 17 4 4 4 27800 2 8 24 18 18 18 18 4 4 4 28100 2 8 26 18 18 18 18 4 4 4 28400 2 8 26 19 19 19 19 4 4 4 28700 2 8 28 19 19 19 19 4 4 4 29000 2 8 28 20 20 20 20 4 4 4 29300 2 8 30 20 20 20 20 4 4 4 29600 2 8 30 21 21 21 21 4 4 4 29900 2 8 32 21 21 21 21 4 4 4 210200 2 8 32 22 22 22 22 4 4 4 210500 2 8 34 22 22 22 22 4 4 4 210800 2 8 34 23 23 23 23 4 4 4 211100 2 8 36 23 23 23 23 4 4 4 211400 2 8 36 24 24 24 24 4 4 4 211700 2 8 38 24 24 24 24 4 4 4 212000 2 8 38 25 25 25 25 4 4 4 2

Component quantity for frame assembling Series 130

18

Iron F

ist ROSSSSERIES 70 / 150Thickness 15/10

SERIES 90 / 150Thickness 15/10

SERIES 90 / 200Thickness 20/10

SERIES 110 / 200

Thickness 20/10

SERIES 130 / 200

Thickness 20/10

SERIES 130 / 250

Thickness 25/10

TYPES OF IRON FIST UPRIGHTS

ROSSS

19

Iron F

ist ROSSSIRON FIST FRAMES CONFIGURATION

The first cross bar is always positioned at 150 mm starting from the floor to the middleof the hole. The distance middle hole - middle hole of the pitches is always 600 mm.In the configuration type B, n. 1 cross bar and two PVC thickness must be installed ali-gned at the top of the uprights.

H= 1800Conf. B

H= 2100Conf. A

H= 2400Conf. B

H= 2700Conf. A

H= 3000Conf. B

H= 3300Conf. A

H= 3600Conf. B

H= 3900Conf. A

H= 4200Conf. B

H= 4500Conf. A

H= 4800Conf. B

H= 5100Conf. A

H= 5400Conf. B

ROSSS

20

Iron F


H= 5700Conf. A

H= 6000Conf. B

H= 6300Conf. A

H= 6600Conf. B

H= 6900Conf. A

H= 7200Conf. B

H= 7500Conf. A

H= 7800Conf. B

ROSSS

21

Iron F


H= 8100Conf. A

H= 8400Conf. B

H= 8700Conf. A

H= 9000Conf. B

H= 9300Conf. A

ROSSS

22

Iron F


H= 9600Conf. B

H= 9900Conf. A

H= 10200Conf. B

H= 10500Conf. A

H= 10800Conf. B

ROSSS

23

Iron F


H= 11100Conf. A

H= 11400Conf. B

H= 11700Conf. A

H= 12000Conf. B

ROSSS

24

Iron F

ist ROSSSROSSSIRON FIST FRAME ASSEMBLY

CONFIGURATION ASERIES 70

UPRIGHTDIAGONAL

SCREW

NUT ANDWHASHER

CROSS-BAR

UPRIGHT

SCREW

NUT ANDWHASHER

CROSS-BAR

PVC-THICKNESS

Loading side

Assembly of diagonals and cross-bar (or another diagonal)with screw through the hole which blocks the two elementsplace one on the other.

Assembly of cross bars and PVC thickness with screw, nutand bolt to the upright.

(3rd hole from the floor)

FRAME SERIES 70

Screw M 8 x 50Nut M 8 Self-blocking

Grower washerIf screws are not supplied by Rosss,use the type 8.8

25

Iron F


CONFIGURATION B SERIES 70

UPRIGHT

SCREW

NUT ANDWHASHER

CROSS-BAR

PVC-THICKNESS

UPRIGHT

SCREW

NUT ANDWHASHER

CROSS-BARS

FRAME SERIES 70


Grower washer

If screws are not supplied by Rosss,use the type 8.8

Loadingside

UPRIGHT DIAGONAL

SCREW

NUT ANDWHASHER

CROSS-BAR(3rd hole from the floor)

Assembly of diagonals and cross-bar (or another diagonal)with screw through the hole which blocks the two elementsplace one on the other.

Assembly of cross bar and PVC thickness on the uprightwith screw, nut and washer.

Assembly of upper double cross bar on the upright withscrew, nut and washer.

26

Iron F

ist ROSSSIRON FIST FRAME ASSEMBLY

CONFIGURATION ASERIES 90-110

FRAME SERIES 90-110



Loading side


DIAGONAL

SCREW

NUT ANDWHASHER

CROSS-BAR

PVC-THICKNESS

UPRIGHT

SCREW

NUT ANDWHASHER

CROSS-BAR

PVC-THICKNESS

Assembly of diagonals and cross-bar (or another diagonal)with screw through the hole which blocks the two elementsthanks a PVC thickness placed one on the other.


UPRIGHT

27

Iron F

ist ROSSSIRON FIST FRAME ASSEMBLY

CONFIGURATION B SERIES 90-110

Loading side

FRAME SERIES 90-110




UPRIGHT

DIAGONAL

SCREW

NUT ANDWHASHER

CROSS-BAR

PVC-THICKNESS

UPRIGHT

SCREW

NUT ANDWHASHER

CROSS-BAR

PVC-THICKNESS

Assembly of diagonals and cross-bar (or another diagonal)with screw through the hole which blocks the two elementsthanks a PVC thickness placed one on the other.


28

Iron F


CONFIGURATION ASERIES 130

1 2

(2nd hole from the floor)

FRAME SERIES 130Screw M 10 x 110

Nut M 10 Self-blockingGrower washer


Assembly of diagonals and cross-bars (or another diago-nals) with screw through the hole which blocks the two ele-ments thanks a PVC thickness placed one on the other.


Loading side

UPRIGHT DIAGONAL

SCREW

NUT ANDWHASHER

PVC-THICKNESS

UPRIGHT

SCREW

NUT ANDWHASHER

CROSS-BAR

PVC-THICKNESS

CROSS-BAR CROSS-BAR

29

Iron F


CONFIGURATION BSERIES 130

1 2

(2nd hole from the floor)

FRAME SERIES 130Screw M 10 x 110

Nut M 10 Self-blockingGrower washer



Loading side

UPRIGHT DIAGONAL

SCREW

NUT ANDWHASHER

PVC-THICKNESS

UPRIGHT

SCREW

NUT ANDWHASHER

CROSS-BAR

PVC-THICKNESS

CROSS-BAR

CROSS-BAR CROSS-BAR

Assembly of diagonals and cross-bars (or another diago-nals) with screw through the hole which blocks the two ele-ments thanks a PVC thickness placed one on the other.

30

Iron F

ist ROSSSROSSSFOOT PLATES AND BEAMS ASSEMBLY

Assembly of additional blocking element ofupright to Foot Plate (only for series 90/110)

Series 70 Series 90

Series 110 Series 130

Beam assembly

HOLES FOR SCREW ANCHORS MM 10 HOLES FOR SCREW ANCHORS ´ 12

HOLES FOR SCREW ANCHORS ´ 12 HOLES FOR SCREW ANCHORS ´ 12

1) Upright 4) Screw 8 x 702) Foot Plate 5) Screw 12 x 503) Blocking element 6) Nut + square washer

7) Nut + washer

HOLES FOR SCREW ANCHORS MM 10

HOLES FOR SCREW ANCHORS MM 10 HOLES FOR SCREW ANCHORS MM 10

45

67

1

23

31

Iron F

ist ROSSS“C" - shaped run spacerThe run spacers must be installed with apitch of 2.500 mm starting from the floor,with a minimum of two run spacers in hei-ght.Tighten the run spacer profile with twoscrews M8 x 20, washers and nuts M8from the upright inside.

Serie 70 - 90 - 110Block spacer profile with 2 screws M 8 x20, washere and nuts M 8 from the internalpart of the uprightsSerie 130Block spacer profile with 2 screws M 10 x20, washere and nuts M 10 from the inter-nal part of the uprights.

Run spacer made of pressed tubularelementThe run spacers must be installed with apitch of 2.500 mm starting from the floor,with a minimum of two run spacers in hei-ght.Tighten the run spacer profile with fourscrews M8 x 20, washers and nuts M8from the upright inside.

Serie 70 - 90 - 110Block spacer profile with 2 screws M 8 x20, washere and nuts M 8 from the inter-nal part of the uprightsSerie 130Block spacer profile with 2 screws M 10 x20, washere and nuts M 10 from the inter-nal part of the uprights.

Wall tieThe wall ties must be installed with a pitchof 2.500 mm starting from the floor, with aminimum of two wall ties in height.Fix with two screws M8 x 20, washers andnuts M8 from the upright inside.

Serie 70 - 90 - 110Block spacer profile with 2 screws M 8 x20, washere and nuts M 8 from the inter-nal part of the uprightsSerie 130Block spacer profile with 2 screws M 10 x20, washere and nuts M 10 from the inter-nal part of the uprights.

SPACERS ASSEMBLY

ROSSS

ALL KINDS OF SPACERS HAVE NEVER TO BE FIXED TO THE WALL

32

Iron F

ist ROSSSTYPE M

Connector for welded beam(from 4 to 6 hooks)

TYPE S

Pressed connector with 2 hooksTubular element 642

TYPE S


TYPE S

Pressed connector with 4 hooksTubular element 1042 - 1242 - 1252

TYPE S


TYPE S


TYPES OF IRON FIST CONNECTORS

ROSSS

33

Iron F

ist ROSSS

A = Maximum shimming with levelling plates of 0.5-3 mm

B = Acceptable tolerances

If the value of A is less than 10 mm, use the levelling plates listed in our price list,otherwise use specific levelling plates furnishable on request.

We suggest to use a power drill with drills suitable for the used screw anchor. Drill thefloor by the hole on the Foot Plate, remove the dust from the hole, insert the screwanchor completely and tighten it lightly. You should use two screw anchors for the frontupright and one screw anchor for the back upright.Before fixing the screw anchors to the floor, carry out a final check of the racking.

LEVELLING

FIXING OF FOOT PLATE AND SHIMMING

B= ± 1mm

A= ± 0 10mm

WARNING:BEFORE INSERTING THE 2ND SCREW ANCHOR BE SURE THAT THE

REQUIRED LEVELLING HAS BEEN ALREADY CARRIED OUT

1) Lift the frame and insert the levellingplate

2) Fix the frame to the floor through screwanchors

ROSSS

SCREW ANCHOR 12x90

34

Iron F

ist ROSSSASSEMBLY OF IRON FIST SHELF PANELS

ASSEMBLY OF CENTRAL SHELF PANELS TYPE P WITHANTI-CRUSHING PROFILE

ASSEMBLY OF FINAL SHELF PANELS TYPE P FOR BEAMS

a) Shelf panel

b) Anti-crushing profile

c) Pressed beam type S

d) Welded beam type M

1) Position the anti-crushing profile upon the beam

2) Hook the shelf to the profile and the beam

3) It is important that the anti-crushing profile is positioned on the beam at least on theloading side of the frame

WARNING: THE CENTRAL SHELF PANELS TYPE P CANNOT BE APPLIED ON THEPRESSED CONNECTORS OF BEAMS TYPE S.

IN ORDER TO COMPLETE THE LOADING LEVEL USE THE FINAL SHELF PANELS TYPE P.

WARNING:WE SUGGEST TO PAY ATTENTION INIDENTIFYING THE TYPE OF BEAM (MM40 OR 50), WHERE THE SHELF PANELSHAVE TO BE POSITIONED, BECAUSETHIS IS A VARIABLE WHICH AFFECTSTHE DIMENSION OF THE SHELF PANELITSELF

A) Final shelf panel type P

B) Anti-crushing profile

C) Beam type S

A

B

C

A

B

D

ROSSS

35

Iron F

ist ROSSSPALLET BACK STOP TUBU-LAR ELEMENT FOR SINGLEBAY

The connector must be inserted in theupright in order to have a distance ofabout 130 mm between the upper part ofthe beam and the top of the pallet stoptubular element.In order to avoid the slipping of the palletstop tubular element, insert n. 2 screwsM8 x 70 in the holes at the extremities ofthe same.

PALLET BACK STOPTUBULAR ELEMENT FORDOUBLE BAY (SINGLETUBULAR ELEMENT)

If the pallet stop tubular element includestwo bays, a further connector should beapplied on the central upright.In order to avoid the slipping of the palletstop tubular element, insert n. 2 screws M8x 70 in the holes at the extremities of thesame.

PALLET BACK STOP TUBU-LAR ELEMENT FOR DOUBLE BAY (DOUBLETUBULAR ELEMENT)

If the pallet stop tubular element includestwo bays, whose length obstructs the useof a single piece, you should assemble 4connectors.In order to avoid the slipping of the palletstop tubular element, insert n. 2 screwsM8 x 70 in the holes at the extremities ofthe same.

ASSEMBLY OF PALLET BACK STOP TUBULAR ELEMENT

ROSSS

36

Iron F

ist ROSSSASSEMBLY OF HORIZONTAL CROSS BRACING

If horizontal cross bracing is compoused by only one element, the tie-rod must be fixedat the cross braceand at the welded bracket of the beam (upper illustration).If horizontal cross bracing is compoused by two elements (lower illustration), the tie-rodmust be interposed between the two elements.

A) Beam with welded bracketB) Horizontal cross bracingC) Tie-rod M 8D) Screw M6 x 16 + Nut + Washer

B

A

D

C

B

AD

C

D

B

D

37

Iron F

ist ROSSSASSEMBLY OF VERTICAL CROSS BRACING

A

F

L

I

M

D

C

B

E

A

E

E

E

E

E

E

F

G

G

G

G

H

H

IL

A) Vertical cross bracingB) Ground bracketC) Security beamD) Diagonal joint stop

E) S.70 - Screw M8x20 + Nut + WasherS.90/110 - Screw M10x20 + N + W

F) Screw M10x20 + Nut + WasherG) Screw M10x30 + Nut + WasherH) Increased Washer D10I) Internal protection for tie-rodL) Galvanized dowelM) Tie-rod M16

If vertical cross-brace is compoused by two elements (like in this illustration), the tie-rodmust be interposed between the two elements.If vertical cross-brace is compoused by only one element, the tie-rod must be interpo-sed between the element and the diagonal joint stop.

38

Iron F

ist ROSSS

A) Bracket

B) Screws M8 x 20

C) Wire mesh

D) Stiffening profile

E) Stop element

F) Screws M10 x 30

G) Plates

H) Washers

I) Nuts

1)Install the bracket on the upright with screws M8 x 20, nuts and washers

2)Position the wire meshes upon the bracket, placing the stiffening profile between them

3)Fix the plates on the wire meshes and on the bracket with screws M10 x 30

4)Block the wire mesh by inserting the stop element in the holes of the stiffening profile

ASSEMBLY OF BACK PROTECTION WIRE MESHES

ASSEMBLY OF BASIC WIRE MESH WITH STIFFENING PROFILE

ROSSS

39

Iron F

ist ROSSS

A) Bracket

B) Screws M8 x 20

C) Wire mesh

D) Screws M10 x 30

E) Plates

F) Washers

G) Nuts

A) Wire mesh

B) Screws M8 x 50

C) Nuts

D) Washers

ASSEMBLY OF BACK PROTECTION WIRE MESHES

ASSEMBLY OF BASIC WIRE MESH

ASSEMBLY OF WIRE MESH WITH "L" - SHAPED FRAME

1)Assemble the bracket on the upright with screws M8 x 20, nuts and washers

2)Position the wire meshes with screws M10 x 30, nuts and washers

3)Fix the plate on the wire meshes with screws M10 x 30, nuts and washers.

1) Position the wire mesh by hitting the screws M8 x 50 on the external hole of the upright

2) Tighten the wire mesh with nuts and washers

ROSSS

40

Iron F

ist ROSSSASSEMBLY TOLERANCES

Before fixing definitively the frame to the floor, check the verticality, lining and levellingof the structure by inserting some levelling plates under the Foot Plates, where neces-sary.

VERTICALITY

ALIGNMENT

ROSSS

L1 H 500

L2 H 500

VI

VI

41

Iron F

ist ROSSSCAPACITY CHARTS

Position the frame capacity chart on the head of the row at a suitable height in order itcould be well visible.The capacity charts related to the loading levels must be applied to each loading levelor to identical groups of loading levels.We can supply, on demand, the capacity beam labels.

ROSSS

42

Iron F

ist ROSSSTESTING

The testing of the pallet rack or drive-in must be carried out by experienced andqualified people.

If the testing is carried out directly by ROSSs, the employed staff will be trained for thespecific case.

For the purposes of the testing and by following the information of this manual, the nextpoints should be verified:

1) Lay-out of the system according to ROSSs drawing (if existent)

2) Check the integrity of frames and beams (see page referred to periodical checks andmaintenance)

3) Check the verticality, lining and levelling of the systems (see pages 22 and 26 installation instructions)

4) Check the positioning of beams (the positioning must be the one indicated)

5) Check the correct assembly of beam connector locks on all the beams

6) Check the correct assembly of frames (see page 14 installation instructions)

7) Check the correct assembly and fixing of Foot Plates (see page 16 installation instructions)

8) Check the correct assembly of the supplied fittings

9) Check the correct positioning of the capacity charts (see pages 8 and 35 installationinstructions)

ROSSS

43

Iron F

ist ROSSSTESTING REPORT

If the assembly has been carried out by ROSSs, at the end of the testing, the inspectorshould draw up the above form in each part. The form should be signed both by theassembly responsible and by the customer.

ROSSS

44

Iron F

ist ROSSSRACKING UTILIZATION

GENERAL WARNINGS

We suggest the use of convenient protections for the uprights and for the extremities ofthe system in those areas, where the risk to bump against the system with fork lift trucksis very high.

PEOPLE ARE NOT ALLOWED TO GO UP THE SYSTEM

ROSSS

45

Iron F

ist ROSSSPALLETS

Do not use damaged pallets or pallets in bad conditions.

Pallet in bad conditions

Pallet in good conditions

ROSSS

46

Iron F

ist ROSSSSHAPE AND POSITIONING OF THE LOAD

Correct shape and positioning of the load

Load unevenly distributed

If the shape and positioning of the load upon the pallet is uneven, discharge the rackingand re-position the load.

ROSSS

47

Iron F

ist ROSSSPALLETS LOADING AND UNLOADING SEQUENCE

We suggest to load the racking starting from the bottom to the top, positioningthe central load at the end of the whole operation.

Recommended loading sequence

Not recommended loading sequence

ROSSS

48

Iron F

ist ROSSSWEIGHTS AND DEFLECTIONS

Do not store higher loads than the ones indicated in the capacity charts.In case of excessive weights, reduce the load.

Beam deflection m L/200 In the event of a higher deflection reduce the load/weight.

600 kg

800 kg

1200 kg

1600 kg

Portata 1200 kg

Capacity of 1.200 kg

ROSSS

49

Iron F

ist ROSSSTHE MAXIMUM LOAD MUST BE UNIFORMLY DISTRIBUTED

kg. 1000

kg. 500

kg. 1500

kg. 3000

kg. 1000

kg. 1000

kg. 3000

kg. 1000

ROSSS

50

Iron F

ist ROSSSPOSITION OF BEAMS ON FRAMES

Do not change the position and number of beams initially set.This change is allowed only following the instructions of this manual

The pitch between beams mustnot be modified

Beams must not be removed

Fixed position of beams

ROSSS

51

Iron F

ist ROSSSLOAD POSITIONING ON BEAMS

Position the pallet in a balanced way between the two beams.

In order to distribute theload correctly and guaran-tee the security of the ope-rators, it is compulsory torespect the distances indi-cated between pallet andpallet and between uprightand pallet according to therule F.E.M. 10.3.01.

ROSSS

52

Iron F

ist ROSSSPOSITIONING OF PALLETS ON BEAMS

Use the dimensions and positioning indicated below.Do not change the dimensions of the pallet.

P = Beams projection

L = Pallets depth

L < P + 50

L > P + 200

The F.E.M. rule suggests: L - P ± 100

P = Beams projection

L = Pallets depth

ROSSS

53

Iron F

ist ROSSS

Fork lift truck drivers must be well trained and use the maximum caution.At the end of the shift, the driver must remove the starting key from the fork lift truck.Adjust the speed of the fork lift truck according to the features of the route, the type ofload and the braking distance of the fork lift truck.During the operation take all the required measures as to guarantee the stability of thefork lift truck and of the load. It is not allowed and very dangerous to carry people on the fork lift truck.Pallets must be positioned very slowly upon the beams as to reduce the impact on theracking, following the instructions of this manual (see the next pages).It is necessary to use a fork lift truck which must be suitable for the loads to be liftedand for the operations inside the system.

STORAGE OF LOOSE MATERIALS

WARNINGS FOR FORK LIFT TRUCK DRIVERS

For the storage of loose materials use only containers with 4 side walls.In case of pallets with foot plates use the specific fittings.

In case of pallets with loose load, we suggest the use of protections on the back sideand at the extremities of the racking.

ROSSS

54

Iron F

ist ROSSS

Do not circulate with the forks lifted

WARNINGS FOR FORK LIFT TRUCK DRIVERS

Circulate with the forks lowered

ROSSS

55

Iron F

ist ROSSSWARNINGS FOR FORK LIFT TRUCK DRIVERS

The pallet must be inserted inthe loading level of about mm 50as regards as to the beams sur-face.

Do not drag the pallet on the beams

ROSSS

56

Iron F

ist ROSSSOBLIGATIONS AND PROHIBITIONS

Do not stay between the fork lifttruck and the racking

Do not bump against the racking

People should maintain a sufficient safety distance from fork lift trucks and during loadspositioning.

ROSSS

CONTROLS PROCEDURES

57

Iron F

ist ROSSSINSPECTIONS

Inspections should be carried out in order to identify possible anomalies not discoveredduring the normal use of the racking.By carrying out a planned maintenance of the system, it is possible to avoid dangeroussituations which can cause accidents. Moreover it is possible to prevent interruptions ofthe activity, optimising the utilization of the system.

Planned inspections allow to avoid:

1) Accidents to people2) Damages to materials3) Interruption of the production activity4) Loss of functionality and following economical losses5) Criminal proceedings against the buyer if an uncorrected maintenance has been

carried out

PERIODICAL CONTROLS AND MAINTENENCE

Type of control Interval Evaluation criteriaPallets conditions six-monthly see figures p. 39Fixing of Foot Plate to upright six-monthly see figures p. 26Frames integrity six-monthly see figures p. 54Beams integrity six-monthly see figures p. 55System verticality annual see figures p. 22System levelling annual see figures p. 26Beam connector locks six-monthly see figures p. 55Beams positioning six-monthly as from the projectOverloads six-monthly see figures p. 42-43Loads shape six-monthly see figures p. 40Loads placing six-monthly see fig. p. 40-43-45-46Capacity charts six-monthly see figures p. 35Pallet back stop tubular element six-monthly see figures p. 28Painting annual as from the contract

ROSSS

58

Iron F

ist ROSSSMAINTENANCE AND CONTROL PROCEDURES

If there is an immediate dangerous situation in the system, we suggest to unload thematerial from the interested area of the racking as to avoid accidents to the assignedstaff.The technicians of Rosss will proceed, on request, to check the problem determining thecorrective intervention in order to restore the system in a short time.For the maintenance and repair jobs only original spare parts must be used.It is possible, on request, to draw up a maintenance contract, therefore the inspectionsare carried out by trained and qualified people of Rosss. This situation can guaranteethe maximum utilization of the warranty period and an optimal use of the system, avoi-ding the dangers due to interventions carried out by unqualified people.

ROSSS

Our production is under guarantee byASSICURAZIONI GENERALI

with Insurance policy n. 989455770“Risk products policy” e “Civil liability”

with coverage up to € 1.549.370.

59

Iron F

ist ROSSSFOOT PLATES

In case of an incorrect fixing of the Foot Plates, unload the racking and fix the Foot Platecorrectly.

Upright and Foot Plate correctly assembled

Levelling plates not centred Screw anchor not completelyinserted

ROSSS

60

Iron F

ist ROSSSFRAMES

In case of damaged upright and bracing members (diagonals and cross bras), unloadthe racking and replace the damaged parts.

Frame in optimal conditions

Damaged frame or upright

ROSSS

61

Iron F

ist ROSSSMAXIMUM PERMANENT DEFORMATION OF THE UPRIGHT

Frame side view

Frame front view

For a maximum length of mm 1.000 it is possible to have a max. deformation of theupright of mm 5 or mm 3

ROSSS

62

Iron F

ist ROSSSBEAM CONNECTOR LOCKS FOR BEAMS INTEGRITY

Verify the presence of beam connector locks and re-insert them if missed.

With beam connector lock

Without beam connector lock

Beam in optimal condition

Damaged beam

Maximum permanent deformation of beam

ROSSS

63

Iron F

ist ROSSSPERPENDICULARITY

In case of a perpendicularity out of tolerance as regards as to the supporting surface(see p. 21), unload the racking and restore it within the tolerance limits.

Correct situation

Uncorrected situation

ROSSS

64

Iron F

ist ROSSSCHECK AND MAINTENANCE FORM

Technician Name/Surname Controls form DepartmenN° of Racking

Type of Regular Not Notes about (on)chek regular suggested intervention

Fax-simile of the check form

ROSSS

65

Iron F

ist ROSSSRECORD OF MAINTENANCE INTERVENTIONS

N° Date Internal Intervention Data of interventionintervention description documents

Fax-simile of the check form

ROSSS

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