Annexure: 2 Technical Specifications Mobile Boltless System- Modular Type

Transcription

1 Annexure: 2 Technical Specifications Mobile Boltless System- Modular Type Design The following standards, as applicable for design of its Boltless Mobile Shelving System. SEMA - Code of practice for the design of Mobile Shelving Systems BS: 5950 (V): 1998 Code of practice for design of cold formed thin gauge sections FEM Code of practice for design of hand loaded static steel shelving system. Raw Material Load bearing members & accessories are made up of relevant high strength steel & the different types of materials used are: Steel Type Minimum guaranteed yield strength Galvanized 210 Mpa IS:277 D Galvanized HR 255 Mpa 255 Mpa Applicable standards ASTM A 653M SS GRADE 37 (CLASS 1) IS: Fe 410 / Equivalent (or) IS: E 250/ Equivalent JIS 3101: SS 400 EN : S 235 Component Usage G50 Upright, Shelf Panel, G50 inner cladding, Shelf Clip, Cladding clamp Undercarriage C Channels CR 210 Mpa IS:513 D JIS ; G3141 Peripheral Claddings, Top panel SG Mpa IS 1865: 1991 Stepped wheel, Plain wheel In addition to high strength, the raw material used for structural load bearing members posses adequate ductility to ensure toughness. The material also has the necessary impact strength for cold room applications up to -30 deg C. Fasteners Boltless superstructure uses NO bolts for assembly of panels, back tie.fasteners are used in understructure assembly & cladding assembly. All these fasteners of Grade 8.8. All fasteners are with galvanized finish to suit industrial atmosphere. 1

2 Surface All components are given a thorough anti-rust treatment. The dry film thickness (DFT) after powder coating would be average 35 microns(minimum). All powder coated components are subjected to an elaborate 4 step, six zone anti corrosion treatment, viz. De-greasing as per IS 6005:1970, rinsing, phospating as per IS 3618:1966 and RO water rinsing. Assembly & Installation Rails are installed initially then understructures are installed over the rails. Then boltless superstructure is installed on the undercarriages. Following this, periphery claddings are installed. Since, boltless superstructure is used, assembly of the system takes very minimal time compared to bolted superstructure. No welding will be carried out at site. Understructure, Rails & Drive unit specification Undercarriage - Movable Movable undercarriage is provided with high strength, high precision cast iron wheels which runs on the rails. Drive unit is connected to the undercarriage via sprocket & chain assembly. Undercarriage is made up of C Profiles which are assembled together to provide rigid base for the system. Anti-tipping elements are incorporated in the undercarriage, to provide redundant safety to the operator. Profile Size Height of Height of from ground Usage Guiding of trolley Lipped C Channel 1.Front C Channel:120x66x66mm 2. C Lip beam end: 114x66x60 3. C Lip beam mid: 114x66x60 120mm 165mm To hold superstructure & to provide rolling By stepped wheels at extreme rails Number of guide (step) 5 Mfg Process 2

3 Undercarriage - Fixed Fixed undercarriage is made up of C Profiles which are assembled together to provide rigid base for the system. Anti-tipping elements are incorporated in the undercarriage, to provide redundant safety to the operator. Profile Size Height of undercarriage Height of undercarriage from ground Usage Mfg Process Lipped C Channel 1. Front C Channel: 120x66x66mm 2. C Lip beam end: 114x66x60 3. C Lip beam mid: 114x66x60 120mm 165mm To hold superstructure & to support moving units Rail Assembly Rails made up of 25x16mm rectangular bars, which enable the undercarriage to move in a guided path & anti-tilt assembly also takes support from rail assembly. Rails are leveled using shims to maintain uniform level throughout the length. Rails are grouted with the ground using shell expansion anchor bolts. There are 12 bolts per meter length of rail. It is provided with slope plates at both sides to avoid hindrance to people who are walking at the system. Profile Size of bar 25 x 16 Material IS 2062 Bottom width of rail Slope plate Thickness Usage Mfg Process Colour Rectangular Bar 100mm 2mm Trolley path and Welding Power Coated. (Top surface of the rails are without powder coating) Graphite Gray (RAL 7024) 3

4 Drive unit Assembly Drive unit assembly is a chain mechanism by proper reduction that will reduce the efforts of the operator. Drive unit is provided with innovative handle mechanism which will always in downwards position, to improve the overall aesthetics of the system & hassle free operation. Hand wheel type Effort Reduction Ratio Locking mechanism Drive force transfer Chain pitch Reverse movement Material of handle of handle Single Handle 1:2.29 (34Teeth : 14Teeth) Lock handle (Kept horizontal means locked & vertically downward means free to move) Through chain (RS40) ½ (12.7mm) Yes ABS (Acrylonitrile Butadiene Styrene) Plastic. Molded Mat finish Boltless Superstructure Components specification Upright Upright is roll-formed construction made up of single piece having slots at 25mm pitch. Uprights are inserted & bolted to the undercarriage. The manufacturing process of punching and forming is in one flow and a synchronized operation, thereby providing dimensional accuracy and contour uniformity consistently. Profile width 50 mm Profile depth 37 mm No of pieces Single Panel adjustability 25 mm Material quality Min Ys=210 Mpa Mfg process Roll forming Colour Light Grey (RAL 7035) Thickness 1.0mm (Min) 4

5 Bracing Bracing type is battened type. Bracing is a formed single piece section which connects two vertical uprights & makes a frame. These are hooked into upright & two plastic rivet pins used for fastening. Section Material thickness Mfg process Connectivity No of fasteners Flat with edge bend and middle rib 1.2mm Hooking & Pin assembly 2 nos of M6x10 plastic rivet pin Colour Light Grey (RAL 7035) Shelf Panel Shelf panels are the load carrying members which are hooked into the uprights via shelf clips. 4 nos of clips are used per panel. Panel levels can be adjusted in the pitch of 25mm. It is a roll-formed section with 14 bends. There are slots for mounting dividers at the pitch of 50mm. No of bend 14 Mfg Process Press forming Usage Decking surface Fasteners No Mounting Using 4 nos of shelf clips Colour Light Grey (RAL 7035) Shelf Panel Depth Side Cross Section 5 Width side Cross Section

6 Shelf Clip Shelf panels are mounted on the upright using this clip. While changing the levels of panels, these clips can be shifted into the next slot in upright without any additional tools. Profile section Material thickness Mfg process 17 x 74 x 2.3mm 1.6mm No of bend 2 Connectivity Insertion Galvanized Back tie Back tie rod cleat (RH) is inserted into upright & then turn buckle is hooked to it. Then back tie rod is hooked to turn buckle & back tie rod cleat (LH). Usage Dia of tie rod Size of turn buckle Connectivity tie rod cleat Fasteners Mfg process tie rod Stability 5mm 90mm Hooking 1 no of plastic rivet pin / cleat Galvanized 6

7 Upright Connector This component used to connect two Uprights back to back when configured as a DF system. Default gap to maintained between two SF system is 1 mm. Profile Material thickness Mfg process Connectivity Fastener Hat Section 1.2 mm Bolting 2 Nos of M6x15 Hex bolt & Nut / pair of connector Galvanized Front Box Cladding (FBC) Assembly It is an assembly of either single / 3 pieces / 6 pieces together to form a front fascia. Mfg Process Fixity Material Material thickness Fastener Colour Bolted to frame via cladding connector CR 1 mm 1. M6x15 Hex Bolt, Nut & Washer with cladding connector 2. M8x20 Hex Bolt, Nut & Washer For inter bolting Middle piece: Graphite Grey (RAL 7024) Edge pieces: Light Grey (RAL 7035) Rear Box Cladding (RBC) Assembly It comprises either single / 3 pieces / 6 pieces together to form a rear fascia. Mfg Process Fixity Material Material thickness Fastener Colour Bolted to frame via cladding connector CR 1 mm 1. M6x15 Hex Bolt, Nut & Washer with cladding connector 2. M8x20 Hex Bolt, Nut & Washer For inter bolting Middle piece: Graphite Grey (RAL 7024) Edge pieces: Light Grey (RAL 7035) 7

8 End Cladding (EBC) Assembly End cladding is provided at the extreme sides ( i.e. Sides of the SFF (Single Faced Fixed) unit & SFM (Single Faced Movable) Unit) of the block. Mfg Process Fixity Material Bolted to frame via EBC Locking Beam CR Material thickness Fastener 1 mm M8x20 Hex Bolt, Nut & Washer for connecting with EBC locking beam & for inter bolting Colour Light Grey (RAL 7035) Manual Locking Stiffener Locking stiffener is a mechanism used to lock the overall block. Once the aisle is closed & locking stiffener is locked, the system becomes a block and no access to material is possible. This gives access control to the material in the system. Lock comes with 2 keys. This is over and above the Electronic Pin Lock. Usage Lock type Stiffener Body thickness Rod diameter Mfg Process Centralized Locking of the system Recess Handle Lock 1mm 9mm & welding Colour Light Grey (RAL 7035) 8

9 Anti-Toppling Assembly. Usage Dia of the tube Material thickness Mfg Process of pipe of housing Stability 38mm 2mm & welding Galvanized Colour of housing Light Grey (RAL 7035) Label Holder Label shall be inserted from top of the holder. One label holder is provided to SF / DF unit. Paper Size A4 Label holder size 315x250x6 Connectivity Fastener Type Material Bolted 3 nos of M4x16 Slotted round head screw & Nut Acrylic Inner side Plain Cladding Inner side plain claddings are most common cladding type & assembled in between two units. Type of profile Plain sheet Thickness 0.6 mm Mfg process Fixity Bolted to upright Fasteners 4 nos of M6x15 Fastener type Hex. Bolt & nut Colour Light Grey (RAL 7035) 9

10 End back plain Cladding End back plain claddings are located at the back of the unit. Type of profile Plain Thickness Mfg process Fixity Fasteners Fastener type 0.8 mm Using 4 nos of back cladding clip & Bolting 4 nos of M5x15 & 1 no of M5x10 pan head self tap screw Slotted round head screw Colour Light Grey (RAL 7035) Back cladding clip This clip is used to connect end back cladding with G50 upright. This clip is common for end back plain & end back mesh claddings. Size Thickness Mfg process Surface finish 30 x 27 x 25mm 1.2 mm Galvanized 10

11 Electronic pin Lock Electronic pin lock Electronic pin lock is a mechanism used to lock the overall system (Block). Electronic pin Lock will be locked automatically, while closing the aisle. The lock can be opened with preset pin numbers for accessing the material. Usage Lock type Total no of user codes Possible lock code combinations Power source Centralized Locking of the system Electronic pin Lock 9 (One master code and eight user codes) One million Battery No of batteries 2 Battery type 9V,Alkaline battery Electronic pin Lock integration with Mobistack Neo Battery make Low power indication Battery operating cycle Type of mechanism Mechanical override Pin lock Certifications Electronic pin lock Colour Assembly Body thickness Duracell sound beeps New batteries will power lock for approximately 8000 openings when used without the time delay feature Motor drive In case of maintenance, a Unique mechanical bypass key can be used. UL Bright Chrome 1.25mm Assembly Mfg Process & welding Assembly Assembly Colour RAL 7035 Electronic pin lock assembly Keypad Lock 11

12 S.NO TECHNICAL SPECIFICATIONS BIDDER COMPLIANCE BIDDER REMARKS 1 Mobile Boltless system- Modular Type Block A-LD5 Module With over all dimensions 6830mm(W) X 2966mm(H)(System Height) X 466mm(D) for SFF, 868mm (D) for DFMD & 466(D) for SFMD Each module of 1300mm W (Inner to Inner) Loading Level 7 nos. with 70Kgs UDL / Level SFF- 1no, DFMD- 4nos, and SFMD- 1no, No. of Blocks: 3nos Block B: LD4A Module With over all dimensions 6430mm(W) X 2966mm(H)(System Height) X 466mm(D) for SFF, 868mm(D) for DFMD & 466(D) for SFMD With 4modules of 1300mm W (Inner to Inner) & 1 Module of 900mm W (Inner to Inner) Loading Level 7 nos. with 70Kgs UDL / Level SFF- 1no, DFMD- 4nos, and SFMD- 1no, No. of Blocks: 1no Block C-LD5 Module With over all dimensions 6830mm(W) X 2966mm(H)(System Height) X 466mm(D) for SFF, 868mm (D) for DFMD & 466(D) for SFMD Each module of 1300mm W (Inner to Inner) Loading Level 7 nos. with 70Kgs UDL / Level SFF- 1no, DFMD- 6nos, and SFMD- 1no, No. of Blocks: 2nos Block D-LD5 Module With over all dimensions 6830mm(W) X 2966mm(H)(System Height) X 466mm(D) for SFF, 868mm (D) for DFMD & 466(D) for SFMD Each module of 1300mm W (Inner to Inner) Loading Level 7 nos. with 70Kgs UDL / Level SFF- 1no, DFMD- 5nos, and SFMD- 1no, No. of Blocks: 1no 12

13 Block E-LD5 Module With over all dimensions 6830mm(W) X 2966mm(H)(System Height) X 466mm(D) for SFF, 868mm (D) for DFMD & 466(D) for SFMD Each module of 1300mm W (Inner to Inner) Loading Level 7 nos. with 70Kgs UDL / Level SFF- 1no, DFMD- 5nos, and SFMD- 1no, No. of Blocks: 1nos The Working Aisle of Minimum 800mm to maintain in Design Load per level carrying capacity = 70kgs minimum (Uniformly distributed load). The Mobile Shelving system is completely knock down construction. No welding will be carried out at site. Please confirm the Mobile shelving can be dismantled component wise for future relocation Requirements. The Mobile Shelving system should be provided with totally boltless superstructure assembly. Superstructure:- Superstructure of the system is the integrated storage units having multiple loading levels on each unit with boltless assembly. Assembled superstructure has to be mounted on the modular undercarriage with a typical base plate. Upright (Verticals Member):- Upright used in the system as main vertical members are of T profile only where loading shelves/panels are mounted and should be of section 50mm(W)x37mm(D) of 1.0mmThickness (Min). Slotted L Angle constructions not acceptable Upright must have holes at a minimum pitch of ¾ to an inch maximum to an inch for flexible readjustment of the load levels height as and when required. Upright used must be of single piece of required length without joint. Materials of construction: IS:277 D. Minimum yield strength 210 Mpa. Process of manufacturing: Roll formed. : Epoxy powder coated 13

14 Colour: Light Grey(RAL 7035). Shelf Panels :- Panels are hooked into uprights with '4' Shelf clips per panel. Size of the Panels shall be 1300mm W X 400mm D and should be as per Drawing. No of Bend : 14 Bends with construction as shown in Technical Specifications. Material of construction conform CR ; IS 277 D,Minimum yield strength 210Mpa. Mounting : Using '4' Shelf Clips for Easy Adjustability whenever required. Process of manufactured: press forming. : Epoxy powder coated. Colour: Light Grey(RAL 7035). Bracing : Section : Flat with Edge Bend without sharp edges and middle Rib. Size & Thickness of Bracings shall be minimum 399mm(L)x 139(H)x1.2mm Thick. Manufacturing Process : Connectivity : Hooked & Pin Assembly : Epoxy powder coated Colour: Light Grey(RAL 7035). Back Tie : Dia of Tie Rod : 5 mm' Size of Turn Buckle : 90mm Connectivity : Hooking Manufacturing : : Galvanized Fastners:- Modular Boltless system uses NO Nut & Bolts for Panel assembly,back tie.fastners are used in Understructure assembly and cladding assembly are of grade 8.8 and Galvanized. 14

15 Inner /Mid /End Claddings Inner cladding to be provided at the inner common sides to separate the bodies and mix up of storage materials Plain Mid claddings are to be provided at the inner common backs of Double Faced to separate the bodies and of minimum 0.65mm End cladding to be Provided at the Ends and of Minimum 0.8mm Material of construction confirming to CR ; IS: 513 grade D,JIS;G3141 Process of Manufactured: press forming : All the inner/mid/end cladding has to be epoxy powder coated Colour :Light grey (RAL 7035). Front/Rear Box Cladding : Peripheries of the system have to be covered with claddings, which must be of Box Type Claddings of suitable & required combination at the front and Rear. No plain claddings are acceptable at front/end peripheries of the system. Connectivity : Bolted to frame via cladding connector. Riveting not acceptable as due to future relocation possibility Material : Cold Rolled Steel with 1mm Thickness : Epoxy Powder Coated Colour: Middle piece- Graphite Grey (RAL 7024) & Edge Pieces- Light Grey (RAL 7035) Manual Lock Stiffener to be provided for access control with 2keys with powder coated of Light Grey ( RAL 7035) and in addition to the Electronic Pin Lock Anti-Toppling Assembly to be provided for Stability purpose. Undercarriage : Understructure should comprised three varieties of undercarriages as Single faced Fixed/Single Faced Mobile/Double Faced Mobile 15

16 Understructures used in the system are required be completely modular knockdown frame with bolted assembly of multiple sections of Lipped C channels of required section without welding and to be dismantled for future relocation Requirements Size : 1)Front "C" channel 120x66x66 mm. 2)'C' Lip Beam Mid &End 114x66x60 mm. Height of Undercarriage from ground 165mm Max, as due to civil clear height availability and storage capacity achievement. Understructures for Movable Units has to be fitted with stepped & flat cast wheels for noiseless movement of undercarriages, assembled with suitable teeth sprockets at required dia of shaft for necessary load bearing. Chain construction on rails not acceptable Materials of construction has to confirm HR ; IS 2062 : Epoxy powder coated. Rails :- Sides of the rails must be made with slanted sloped surface allowing movement of trolley inside as well as to ensure smooth walk through Profile : Rectangular Bar. Size 25x16. Bottom Width :100mm. Slope plate Thickness : 2mm. Material of construction has to confirm to IS 2062 : Epoxy powder coated Drive Mechanism:- Single Handle Type Drive force Transfer : Through Chain with Chain pitch Effort Reduction Ratio :1:2.29 Reverse Movement: Yes. of Handle: Molded Mat. 16

17 20 Electronic Pin Lock : Locking Type : Centralized Locking of System No of User Codes : 9 nos with One Million combinations Power Sources : Battery (2 nos) with 9 v Alkaline Battery Low Power Indication : Sound Beeps Battery Openning Cycle : Minimum 8000 openings without the Time Delay Feature Mechanism Type : Motor Drive Colour : Bright Chrome Safety Locking arrangement: Safety locking arrangement must be provided along with hand wheel drive assembly in order to provide safety during operation inside the system. Safety & stability arrangement:- In order to provide safety & stability to the system necessary stability arrangement both on the superstructure as well as in the undercarriage must be provided to the system Pretreatment and Final of the System:- For long life and protection from corrosion, All components are given a thorough anti-rust treatment. The dry film thickness (DFT) after powder coating would be average 35 microns. All powder coated components are subjected to an elaborate 4 step, six zone anti corrosion treatment, viz. De-greasing as per IS 6005:1970, rinsing, phospating as per IS 3618:1966 and De-mineralized water rinsing. Furthermore, the testing of paint for various physical and chemical properties is done as per IS 101: The paint used in the system shall be of Lead free composition For Super Structure part - Load design calculation to be submitted along with the Bid as a proof that materials are offered as per the Codes specified in Tender specifications Raw material proof from major Steel Suppilers like Tata/Jindal,used in production,to be submitted 17

18 If the Bidder submit any counter condition or deviation from the Technical specification mentioned in the Tender, it shall be summarily rejected. Responsive Tenders will be evaluated on the Basis of the Basic prices of Supply & Installation, excluding Taxes Delivery & Installation: Within 30Days 18