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TECHNICAL INFORMATION OF BOLTLESS SHELVING SYSTEMS

The BS5000 Boltless Racking System was designed to offer flexibility and ease of installation. It is to replace the age old slotted angle shelving system, which uses bolts and nuts to fasten the shelves and beams to the uprights.
The standard colour is gloss beige (RAL 1013) for uprights and beams. However, special colours can be supplied subject to quantity, colour code and additional powder coating downtime costs. The uprights, beams and center supports uses steel grade of JIS G3101 SS400.

BS5000 Uprights – B5U
The L-section profile of the B5U upright is 40mm x 40mm x 1.5mmt and it is roll-formed for higher load capacity. Most of our competitors are bending these uprights. Depending on the shelving loads and mezzanine floor capacity, it can be used to support a 2-tier racking system. However, in this case, we will use a thicker upright profile 40mm x 40mm x 2.0mmt. The upright’s standard stocking lengths are 1200mm, 1500mm, 1800mm, 2100mm, 2400mm, 2700mm, 3000mm and 3500mm. However, longer
lengths can be rolled if required. The upright’s `key-hole’ lug holes are punched at 30mm pitch, allowing greater adjustability of shelf levels.

The frame load capacities depend very much on the number of DLB and SLB used, as well as the beam centres. Wider frame depths affect the frame load capacities as well.

BS5000 Foot Plates
BS5000 uprights come with a specially designed plastic foot plate, PF40. No fixings are required. These plastic footplates are provided to prevent the base of the upright from scratching or denting the floor surface, especially if the floor is wooden or carpet.

For 2-tier BS5000 mezzanine system, steel foot plates, B5SFP of 48mm x 48mm x 2mmt are used. 1 set of M6x20 Bolt and Nut is used to tie to the upright. The footplate has a `dimple’ to accommodate shim plates. As required for 2-tier BS5000 racking system, 1 no. of mechanical expansion bolt of M8x60 per foot plate must be used.

BS5000 Shim Plates – B5SP2
Designed to the same dimension of the steel foot plate, the 2mm thick galvanised shim plate’s `dimple’ fit into the corresponding dimple of the foot plates so that when installed, the shim plates are still held in place even when the rack is accidentally knocked or shifted.

Standard Frame Depths
The standard stocking frame depths are 400mm and 600mm. Other depths are available such as 300mm, 450mm, 600mm, 900mm, and 1200mm.

Upright Spacers – B5STB
Commonly called Square Type Brackets (STB) these are upright spacers which are used to tie and space 2 uprights together on a bay, width to width orientation, as well as bay depth to depth orientation. With these ties/spacers, rows of BS5000 shelving bays will be aligned straight. In addition to this function, the spacers are used to strengthen
uprights in BS5000 2-tier systems as well as `access under’ bays.

UPRIGHT HEIGHT NO. OF UPRIGHT SPACERS B5STB
1200 2
1500 2
1800 2
2100 2
2400 3
2700 3
3000 3

More upright spaces are required in the case of 2-tier BS5000 racking system.

Beams – B5DB and B5SB
There are 2 type of beams, namely, Double Lug Beam, B5DB and Single Lug Beam, B5SB and they are available for different shelf load capacities and applications.

B5DB – 66mm x 17mm x 1.5mmt Double Lug Beam
B5SB – 40mm x 20mm 1.5mmt Single Lug Beam

Beam load capacities are based on S.E.M.A Standard Beam Deflection of Span/200.

Center Supports – B5LD
BS5000 center supports of 40mm x 20mm x 1.5mmt are used to support the centers of both fibreboard and steel shelves on a front to back direction. All Double Lug Beams have 2 pressed out lugs on each side for ease in hooking on to BS4000 uprights.

Depending on load capacities of the entire shelving system, BS4000 has the capability to support a two tier system with shelves on the ground and first levels. BS4000 beams and shelves are designed with a guaranteed safety factor of 1:1.65 and beam deflection ratio is limited to Span/200.

PAINT FINISH
Prestar Storage System Sdn Bhd’s epoxy powder-coating line is capable of painting up to 11 meters in length in its Rawang manufacturing facility. All its racking and shelving components are subject to anti-rust pre-phosphate treatment before epoxy powder is oven baked and coated hard on to the steel surface.

The entire coating process gives a glossy, hard finish to all our Racking and Shelving components. During a multi-stage pre-treatment process, the surface of the racking components is chemically coated with an adherent layer of iron phosphate crystals. This phosphate crystalline layer provides an excellent base for the epoxy paint finish as well as preventing galvanic corrosion should the finish coat be scratched and peeled.

The racking components are then automatically conveyed to the heating oven and the temperature of these components are raised to 150 degrees Celsius ensuring all moisture trapped in grooves and bends is completely evaporated before the application of the epoxy powder coat.

Moving on to the paint booth, nozzle guns mounted from both sides of the conveyor automatically apply the epoxy powder electrostatically on to the surface of the anti-rust treated steel components.

Over a period of ten minutes, the powder coated racking components are subjected to a steeltemperature of 190 to 200 degrees Celsius. These racking components then go through a process of cooling before it is finally packed for storage and delivery. The completed coating is a maximum thickness of 80 microns, average being 65 microns.

The above powder coating process gives the products a hard, tough and glossy paint finish.

TABLE OF WEIGHT

TABLE OF WEIGHT
Product Code Bay Dimensions No. of Levels Shelf Material Shelf Load Capacity (Kg) UDL per level
Width (mm) Depth (mm) Height (mm)
1830094 900 300 1800 4 Level 3 Compartment Steel / Plywood 350
1830124 1200 300 1800 4 Level 3 Compartment Steel / Plywood 350
1840094 900 400 1800 4 Level 3 Compartment Steel / Plywood 350
1840124 1200 400 1800 4 Level 3 Compartment Steel / Plywood 350
1845094 900 450 1800 4 Level 3 Compartment Steel / Plywood 350
1845124 1200 450 1800 4 Level 3 Compartment Steel / Plywood 350
1860094 900 600 1800 4 Level 3 Compartment Steel / Plywood 350
1860124 1200 600 1800 4 Level 3 Compartment Steel / Plywood 350
2130095 900 300 2100 5 Level 4 Compartment Steel / Plywood 280
2130125 1200 300 2100 5 Level 4 Compartment Steel / Plywood 280
2140095 900 400 2100 5 Level 4 Compartment Steel / Plywood 280
2140125 1200 400 2100 5 Level 4 Compartment Steel / Plywood 280
2145095 900 450 2100 5 Level 4 Compartment Steel / Plywood 280
2145125 1200 450 2100 5 Level 4 Compartment Steel / Plywood 280
2160095 900 600 2100 5 Level 4 Compartment Steel / Plywood 280
2160125 1200 600 2100 5 Level 4 Compartment Steel / Plywood 280
2430096 900 300 2400 6 Level 5 Compartment Steel / Plywood 230
2430126 1200 300 2400 6 Level 5 Compartment Steel / Plywood 230
2440096 900 400 2400 6 Level 5 Compartment Steel / Plywood 230
2440126 1200 400 2400 6 Level 5 Compartment Steel / Plywood 230
2445096 900 450 2400 6 Level 5 Compartment Steel / Plywood 230
2445126 1200 450 2400 6 Level 5 Compartment Steel / Plywood 230
2460096 900 600 2400 6 Level 5 Compartment Steel / Plywood 230
2460126 1200 600 2400 6 Level 5 Compartment Steel / Plywood 230
2730097 900 300 2700 7 Level 6 Compartment Steel / Plywood 200
2730127 1200 300 2700 7 Level 6 Compartment Steel / Plywood 200
2740097 900 400 2700 7 Level 6 Compartment Steel / Plywood 200
2740127 1200 400 2700 7 Level 6 Compartment Steel / Plywood 200
2745097 900 450 2700 7 Level 6 Compartment Steel / Plywood 200
2745127 1200 450 2700 7 Level 6 Compartment Steel / Plywood 200
2760097 900 600 2700 7 Level 6 Compartment Steel / Plywood 200
2760127 1200 600 2700 7 Level 6 Compartment Steel / Plywood 200
3130098 900 300 3100 8 Level 7 Compartment Steel / Plywood 170
3130128 1200 300 3100 8 Level 7 Compartment Steel / Plywood 170
3140098 900 400 3100 8 Level 7 Compartment Steel / Plywood 170
3140128 1200 400 3100 8 Level 7 Compartment Steel / Plywood 170
3145098 900 450 3100 8 Level 7 Compartment Steel / Plywood 170
3145128 1200 450 3100 8 Level 7 Compartment Steel / Plywood 170
3160098 900 600 3100 8 Level 7 Compartment Steel / Plywood 170
3160128 1200 600 3100 8 Level 7 Compartment Steel / Plywood 170
3530099 900 300 3500 9 Level 8 Compartment Steel / Plywood 150
3530129 1200 300 3500 9 Level 8 Compartment Steel / Plywood 150
3540099 900 400 3500 9 Level 8 Compartment Steel / Plywood 150
3540129 1200 400 3500 9 Level 8 Compartment Steel / Plywood 150
3545099 900 450 3500 9 Level 8 Compartment Steel / Plywood 150
3545129 1200 450 3500 9 Level 8 Compartment Steel / Plywood 150
3560099 900 600 3500 9 Level 8 Compartment Steel / Plywood 150
3560129 1200 600 3500 9 Level 8 Compartment Steel / Plywood 150

COMPONENTS