Brochure in PDF - Pallet racking

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
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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
55
254
100
120
150
55
S 100
S 125
S 150
(=profile height 100 mm)
(=profile height 125 mm)
(=profile height 150 mm)
254
100
125
150
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